Pulling the Components for the Shop Order

Once a shop order has been saved and the system has allocated component quantities to the shop order, you can Process a Pull Ticket for the shop order. A Pull Ticket is used to physically retrieve the components for the shop order out of your inventory and to transfer them into work in process (the shop floor system).   

A Pull Ticket is normally processed only after all components have been allocated to the shop order.  This allows you to pull only components that are needed for the shop orders that can actually be built.  However, the system does NOT require all components to be available in order for a pull ticket to be processed.  You can process a pull ticket for any quantities that have been allocated to the shop order.  This allows you to handle situations where you need to complete a partial shop order quantity or to handle situations where it makes sense to partially pull and work on the components while you are waiting for the remaining parts.

The Allocated and the Pulled quantities that are stored in the Shop Order Header can be used to quickly determine which orders should be pulled  (the orders with an allocated quantity) or completed  (the open orders that have a pulled quantity) based on the component status.  The Header Allocated and Pulled quantities display the number of top level items that components that have been completely allocated for, and the number of top level items that components have been completely pulled for.  These quantities are automatically updated by the system when the shop order is processed and when inventory transactions result in additional inventory being allocated to the order.

The following steps can be used to print and process a pull ticket.

1.  Verify that the shop order is open and inventory is allocated to the order.  You can view the amount of inventory allocated to each component line in the Shop Lines Panel or you can use the allocated quantity in the shop order header to determine whether or not enough components have been allocated to build the top level item.  The header allocated amount indicates the amount of top level items that all components have been allocated for.  You may pull a shop order that is partially or fully allocated.

2.  Print a Pull Ticket for the Shop Order.  The Print (normally F4) key can be used to display the print options available in the Shop Order program.  Select the Pull Ticket option to print a pull ticket for the order.  At this point, the system does the following.

•      The system flags the shop order as printed.  While the shop order is printed, the system does not allocate any additional component quantities to the order, and the system blocks you from printing a pull ticket for the order.  Only one pull ticket may be processed for each shop order at one time.

•      The system commits the allocated inventory quantities to the shop order.  As the Pull Ticket is created, the system identifies the bins that each component quantity should be pulled from, and it commits or reserves this portion of the bin quantity to the shop order.

•      The system loads the allocated quantity from each of the shop order lines being printed into another field that is used when the Pull Ticket is processed.  This field is used to default the quantity that was actually pulled from stock.

3.  Physically pull the component items listed on the Pull Ticket from Inventory.  If any of the items or quantities on the Pull Ticket are not found, the actual amount pulled from inventory should be recorded on the pull ticket.

4.  Process the Pull Ticket.  Once a pull ticket has been created for the shop order and the components have been pulled from inventory, The Process Pull Ticket option in the Shop Order program is used to process the Pull Ticket.  When the Process Pull Ticket option is selected, the system displays the Process Pull Ticket program and it loads the program with the component information from the shop order.  The Process Pull Ticket displays several different quantity fields for each component line.  These include Needed (the total quantity of the component required for the shop order), Pulled (the amount of the component already pulled out of inventory for this shop order), Alloc (the quantity of the component allocated to the shop line – which should be the same as the amount from the pull ticket), and the Pull Now quantity.  The Pull Now Quantity is the quantity that is actually being pulled from inventory.  This quantity defaults to the same value as the allocated quantity but can be changed as required. 

5.  Verify or change the pull now quantity to match the quantity actually pulled for each component.  You can modify the Pull Now quantity for a component by selecting the appropriate component and pressing the Enter key.  This action displays the Edit Picker Item program which displays the details (item, bins and quantities) for each component line that was printed on the Pull ticket.  You can modify the bins and quantities shown in this panel to match the bins and quantities that you actually found in inventory.  Note:  If you do not find the components in the bins specified by the Pull Ticket, it is likely that the Bin or Inventory quantity for the item is incorrect and you should research and resolve this issue once the pull ticket has been processed.  This may require you to de-allocate inventory and then adjust inventory.  These procedures are discussed in the documentation for the Warehouse Management system.

6.  Press the Save Key to finish processing the pull ticket.  At this point the system.

•      Updates the inventory and work in process sub ledgers for the items that were moved into work in process.  The inventory on hand and allocated quantities for each component are reduced and the pulled quantity and the cost of each component is moved into the appropriate shop order line.  The open shop order lines with a pulled quantity are used by the system when producing a “valuation” report for the work in process sub-ledger.

•      Updates the bins that the components were pulled from.  The bin on hand and committed quantities are reduced by the quantity pulled for each component.

•      Updates the pulled quantity in the Shop Order header to indicate the number of top level items that components have been completely pulled for.  This number is a convenient means for determining which orders can be assembled and completed based on the component availability.

More:

Serializing the Shop Order