Re: Shop Orders (within a Shop Order)

One thing to watch out for when rescheduling orders, then rerunning MRP.
MRP cannot reschedule when it would make the due dates past due, with
respect to your planning date.
MRP cannot reschedule when the parts involved have effectivity dates that
are invalid in some date range.

The query I described earlier is called MATAVAIL = material availability
with respect to readiness to do next step.

We have another query called ENGRESCH meaning engineering collection ...
need to reschedule production.

It shows
shop order # & item #
Due date from original creation or last change to the order
The constant '-Change to-'
Date recommended by MRP
quantity required
quantity finished

Selection criteria is shop order still open, item type finished product,
date range, facility specified,
SQFIN LT SQREQ (more still to do, ignoring scrap)
MRP date not zero ... when MRP date is zero that means MRP is not suggesting
any change ... when MRP date is all 9's that means MRP thinks the order
should be cancelled

FSO only file needed for on the report, except link to IIM to get item type

In our reality we make to customer orders which can fluctuate rapidly with
date due, quantity due, etc. An order is pulled up, delayed ... this
happens after shop orders launched.

The customer order is the highest level of MRP ... change CO & run MRP, it
reccommends date changes for the SO's but does not actually change those
dates ... we have to change them, either manually, or write some program.

Same deal for lower levels.

But we only change the due date in the FSO, then rerun the MRP.
The dates in the system are now recalculated one level further down.

Main problem is due date on the printed labor tickets.
Changing date in system does not change date originally printed.

We have the added complication that if MRP says do it sooner, we want to do
it sooner, but if MRP says do it later, our people want to decide that
individually, since they may know stuff about raw material availability
where the corrected expected dates have not been keyed into the PO's, or
there may be some temporary shop floor bottleneck.

Because of this we have altered some of the shop floor reportsd that shw the
work still to be done.
In some cases, we are substituting the MRP date for the original due date.

We have thousands of queries. It can sometimes be a challenge ... we
remember we had a query to do X, what did we call it?

I have a CL to copy directory of query definitions to an *OUTFILE for yet
another query to list them by the description we gave.

Don Cavaiani wrote

Al,

Looks like, in my testing, that once a S.O. is created, nothing you
do DATE WISE on any other screens (and followed by MPS and MRP
regenerations) will CHANGE the due dates of the S.O.'s and the Material
Allocations file. It would take a manual intervention on each and every
related S.O. # to change the dates due.

Don

-----Original Message-----
From: bpcs-l-bounces+dcavaiani=amerequip.com@xxxxxxxxxxxx
[mailto:bpcs-l-bounces+dcavaiani=amerequip.com@xxxxxxxxxxxx] On
Behalf Of macwheel99@xxxxxxxxxx Sent: Wednesday, September 24, 2008
2:08 PM To: BPCS ERP System Subject: Re: [BPCS-L] Shop Orders
(within a Shop Order)

We have a similar situation.

The people in Assembly are organized into teams around what we call a
"wheel" where maybe 10 people each doing their thing on a panel that
comes around slowly, combining maybe 20 sub-components into a
combined upper level part.

The person who is setting up a wheel to do some part, that person wants
to be sure that we have everything feady ... they key in the shop order
for the part to be assembled. This links to the FMA file of that
shop order, which lists all the compoenent items going into that
part, for which we can get at the on-hand of those componennts in
the right warehouse, and for the components where the on-hand is
insufficient, access any open shop order to make that component, as
identified by the FSO file, then bring up details on that shop
order. The leader of the assembly operation can then use that to
track down how soon we will be done with those shop orders, or
select some other part to assemble soon.

We have a CL to put queries/400 on a menu ... you do not have to give
people command line authority to run a query/400 definition.

Here's how our query combines files FMA FSO IIM FOD in 405CD

Field Test Field
MPROD EQ IPROD
MORD EQ SORD
MPROD EQ ODPRD

Here's corporate IIM on-hand, but you could go after relevant warehouse
OH iADJ+iRCT+iOPB-iISS

Here's what is still to be made on the lower level parts
NEEDED mqreq- mqiss

Here are the fields selected for the query/400 inquiry The files are
1.FMA 2.FSO 3.IIM 4.FOD

Field
T01.MORD
T02.SPROD
T01.MPROD
T03.IDESC
NEEDED
QP
OH
T04.OORD
T04.OQTY
T04.OOPNO
T04.OOPDS
T04.ODEPT
T04.OQTYP

Selection criteria

AND/OR Field Test Value (Field, Number,
SPROD EQ 'Enter Part Number'
AND SID NE 'SZ'
AND NEEDED GT OH
AND ODID EQ 'OD'

Hope this gets you a chunk of the way to a solution.

As for rescheduling ... when shop orders are released, they get a
planning date based on time of launching. If at a later date, you
change the upper level due date & rerun MRP, it recalculates MRP date
only one level down, so we have reports listing shop orders where the
MRP recalculated date says to do something sooner, later, cancel,
whatever, so that people then have the option of going down one
level & doing maintenance to agree with the MRP advice, or removing
from shop floor those orders that MRP says we do not need any more.

All orders below customer orders, such as purchase orders, have the
original date we planned, or changed to, and the MRP recalculated
date based on other stuff going on in the system. We have date math,
in which we are not interested in MRP changes of only a day or two,
only when the rescheduling is significant.

Al Macintyre
who uses Query/400 a lot because most managers & users want new stuff
setup yesterday & are quite happy to get quick & dirty, irrespective
of performance & other issues

Don Cavaiani wrote

Anyone dealt with this issue:

The system generates a shop order for a Manufactured (welded)
assembly. At the same time, it also generates say 15 other shop
orders for the fabrication of the manufactured components which GO
INTO the this upper level (welded) assembly.

Now, for whatever reason - say a shortage of a purchased component,
the scheduler wants to "back-off" the scheduled due date of the
(welded) assembly.

If this is done via the system, then MAYBE it reschedules all of the
Shop Orders for all of the manufactured components as well??

But, let's say the scheduler just wants to immediately pull that
(welded) Assembly out of the actual production pipeline, along with
all of the shop orders for all of the manufactured parts as well.

Is there anyone who has a developed a query or some other method of
LINKING all of the 15 manufactured parts shop orders to the (welded)
assembly shop order?

Seems like it would not be that difficult?

Thanks,
Don C.

Don F. Cavaiani
IT Manager
Amerequip Corp.
920-894-7063

"It's amazing what you can accomplish if you don't care who gets the
credit." Harry S. Truman

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