Handling By-Products On Shop Orders—Extended Exercises

IMPORTANT
It is extremely important that you set up and work within your own site to maintain your data integrity. If you work within any other site, you will compromise your own exercise data as well as the data of other students. Predictable exercise results require that your data be isolated in your own site.

Basic Data Setup

Discrete Manufacturing Overview Racing Engine

Purpose: The purpose of this exercise is to create the required data that will be used in the discrete manufacturing exercises. This sets up data for your site that only needs to be done once for the discrete manufacturing course exercises.

  1. Set up your site for discrete manufacturing of racing engines.

General exercise for Overview of Discrete Manufacturing Data

Inventory Location

Purpose: The purpose of this exercise is to set up an inventory picking location for running functionality isolated by site.

Windows:
Inventory Locations

  1. If you haven't done so already, create the inventory picking location as shown in the table below.
Site Location No Warehouse Location Name Location Group
Your Site 2C Sub Subassembly inv 30

General exercise for Entering Inventory Locations

Main Exercises

Purpose: The purpose of these exercises is to create, remove and modify by-products in shop orders.

Windows:
Shop Order
Shop Order/By-Product

The oil pan for the racing engine is a manufactured part that is produced from sheet steel and which has a by-product of scrap steel. Sometimes steel disks are stamped from the sheet steel along with the oil pans. You want to create the following shop orders:

After creating the second shop order, you realize that the yield of scrap steel will be reduced when the steel disks are also produced. In addition, you decide to produce only the smaller steel disk. You change the shop order by-products on the second shop order.

Creating a Shop Order Containing a Structure with a By-Product

You want to create a shop order for 20 oil pans and the standard by-product of scrap steel.

  1. Open the Shop Order window and create a new shop order on your site for the 21-313 (Oil Pan) part with a lot size of 20. Save the information.
  2. Record the value that the system automatically generated for the Order No field so that it will be easy for you to later query for your shop order.
  3. Click the By-Product tab and verify that a record exists for the 21-935 (Steel, Scrap) part with a value of 0.5 in the Qty per Unit field, and a value of 10 in the Lot Size field.

Note: The Receiving By-Products on Shop Orders exercise continues the processing of this shop order.

Adding a By-Product to a Shop Order

You want to create a shop order for 20 oil pans, two sizes of steel disks, and the scrap steel.

  1. Open the Shop Order window and create a new shop order in your site for the 21-313 (Oil Pan) part with a lot size of 20. Save the information.
  2. Record the value that the system automatically generated for the Order No field, so that it will be easy for you to later query for your shop order.
  3. Click the By-Product tab and verify that a record exists for the 21-935 (Steel, Scrap) part with a value of 0.5 in the Qty per Unit field, and a value of 10 in the Lot Size field.
  4. In the table, create a new record and enter 21-936 in the Part No field, then enter 4 in the Qty per Unit field. Save the information.
  5. Verify that the Lot Size field contains 80.
  6. In the table, create a new record, and enter 21-937 in the Part No field, then enter 2 in the Qty per Unit field. Save the information.
  7. Verify that the Lot Size field contains 40.

Modifying and Removing a By-Product on a Shop Order

After creating the second shop order, you realize that the yield of scrap steel will be reduced when the steel disks are also produced. Also you decide to produce only the smaller steel disk. You change the shop order by-products on the second shop order.

  1. On the By-Product tab, select the row for 21-937 part number. Delete the record because you will not produce the larger steel disks after all.
  2. Save the change.
  3. On the row for the 21-935 part number, change the value of the Qty per Unit field to 25, which will reduce the yield of scrap steel.
  4. Save the change.
  5. Verify that the value of the Lot Size field has changed to 5. You know that the resulting scrap steel might be as much as 6. Change the value in Lot Size to 6 and Save the change.

Note: The Receiving By-Products on Shop Orders exercise continues the processing of this shop order.