The Packing List Module is used to record the details of shipments to customers.

The Packing List is created when the user has completed assembly, or pulled parts for an order and the order is scheduled to ship. There is also provision for a stand-alone (manual invoice) packing list.

Note:  In order to initiate the packing list, the Sales Order MUST have the Order Acknowledgment box checked, indicating that it is OK to ship the product to the customer.  For further Detail See Article #1150.

Packing List tab field definitions

Detail tab field definitions

Buttons

	If there is a Sales Order associated with the shipment, depressing this button will display the Sales Order line items for the user to select for this shipment.
	Depressing this button will allow the user to add a manual item to the Packing List.
	Highlighting a line item and depressing this button will delete the line.
	This button is depressed to enter Sets of Serial numbers to ship
	For the line item highlighted, this field is for any applicable notes.

Shipping Instructions Tab Detail

This tab is used for special instructions regarding the shipment.  This information defaults in from the Customer Info module.

History tab field definitions

Notes tab field definitions

Enter Inventory Mgt/Packing List Management/Packing List Management

The following screen will appear.  When the screen first opens, the user is limited to only four of the seven action buttons shown: Find an existing Packing List, Add a new Packing List record,  Print a packing list or report, and Exit.

Pressing the Add Button displays the following sequences:

If the user elects to add by Sales Order, a screen appears listing Open Sales Orders in numerical order, along with the Customer Name, Customer PO, and if applicable the  RMA number. The user selects the Sales Order number by either entering it into the red box, or scrolling down the list and clicking on the selected order.
If the user elects to add by Sales Order/Customer, a screen appears listing Customers.  The user selects the customer by either entering it into the red box, or scrolling down the list and clicking on the selected Customer. Decide between Active or Inactive customer by checking the appropriate box. Type in the Customer name or highlight the customer and double click to select.
Then a list of all of the selected Customer Sales orders are shown in numerical order, along with the Customer Name, Customer PO, and RMA number (If applicable). The user selects the Sales Order by either entering it into the red box, or scrolling down the list and clicking on the selected order.
If the user elects to add by Stand Alone, a screen appears listing Customers.  The user selects the customer by either entering it into the red box, or scrolling down the list and clicking on the selected Customer. Decide between Active or Inactive customer by checking the appropriate box. Type in the Customer name or highlight the customer and double click to select. See procedures below to Add a Stand Alone Packing List (Manual Invoice).

Once the Sales Order selection has been made, the Packing List screen is popluated with the appropriate data based on the default shipping destination established for the customer selected:

If Manual is selected for Packing List numbers in Number System Setup user will need to enter P/L No.

Move cursor to the Frt Amt (Freight Amount) field. The user may then enter the amount of the freight charges for the shipment. (These may also be entered during the invoicing, if the freight amounts are not yet known).

After completing the Packing List information screen, the user clicks on the Detail Tab

In this screen, the user defines the material to be shipped.

The user may choose from one of the directive buttons to proceed:

If the user has selected the Add Sales Order Item(s) option, and user receives the following message, it may be due to the status of the line item on the SO.  If the line item Status on the Sales order is "Admin Hold"  or "Mfgr Hold"   you will receive the following message when creating the PL.




If the user has selected the Add Sales Order Item(s) option, (data can automatically be completed in this screen) the following screen will appear:

Highlight the appropriate Sales Order line item.  Depress the OK button and the sales order line item(s) will populate the detail screen.

The user will note that each item defined on the sales order is added to the packing list, and the Quantity is at zero. If the sales order has many lines and only a few are NOT being shipped, then the user can add them all, and delete the lines that do not apply. The user then completes the quantity column with the amount of product shipped for this packing list.

 

The following message will appear if the part requires a certificate and the "Done" box has NOT be checked.  The packing list will NOT be allowed to be saved until checking off the certificate required "Done" box.  

 

 

 

The following message will appear if the user is attempting to ship product out of FGI that was not originally transfered into FGI from a Work order that was associated to that Sales order.  This is just a warning that you will be releaving stock that was transfered into FGI from a Work order that was associated to a different Sales order, and is asking the user if they are sure that is what they want to do?  It does not hurt anything to answer yes, the only thing that might happen later down the road is the product that you had transfered  into FGI from a different sales order has already been shipped against this Sales order or packing list. 

 

Depress the Yes button. 

 If the user attempts to ship a product with no or not enough available inventory, ManEx advises the user and prompts to cancel the transaction.

TIP Users may modify the appearance of the columns on the spread sheet by click and holding on the column header description, and slide the description to the right or left, then releasing the mouse button. The width of the columns may also be modified by click and holding on the right edge of the column header and sliding the border right or left.

As the user completes a quantity shipped, ManEx produces an inventory allocation table displaying the available and reserved inventory on hand for the product being shipped if there is more than one location. If the Sales Order allocated product for this order, the quantity will be shown in the Reserved Qty column.

Enter Ship Qty.

If the product and the work order were identified as requiring serial numbers and there are no products available in inventory with the appropriate serial numbers, the following message will display:

Depress the OK button.  The transaction will be cancelled.

If the product and the work order were identified as requiring serial numbers and there is product available in inventory the following screen will display:

Use the > or >> button to move the Serial Number into the Ship Prepared Serial Number column. Depress the OK button. The serial numbers will display in the Serial Number Entry window. The serial numbers will print on the packing list.

 

 

If user receives the following message when trying to ship out parts:

 

 

The user may return to the SO, depress the Edit button and double click on the Order Qty  field.  The available MFGRs will be listed and the users can make the needed changes.

 

 

Return to the Packing List module and the record can then be processed.  

If the user selects Add manual item, the user will be prompted for the sales type:

Depress the down arrow for Sales Type and the following list will appear:

Highlight and click on the Sales Type of Interest and the following screen will appear:

The Revenue GL number and the Cost GL number will update. Note:  When creating Stand Alone Invoices users should not select the same GL account number that is entered in the Actsetup for the Account Receivables.  IF you do, then the resulting transaction will debit and credit both the sane GL account number.   Depress the OK button.

The user will be prompted for Quantity, Back Order amount, Description and Units of Measure.

The user may enter notes of any length for a line item by highlighting the appropriate line item and then selecting the Item Note.

If the user wishes to establish shipping instructions, then pressing on the screen tab Ship Inst will bring up the following screen.

Tabbing on the History tab will bring up the following:

This will give you the Shipping Historyof the Part highlighted in the Detail screen.

In addition to special notes to the shipping department, tabbing to the Notes screen, there are two additional areas for notes: the Sales Order Notes, and the Packing List Footnotes. The Sales Order Notes will be maintained in the ManEx system for review by other users, and the Packing List Footnotes will be added to the packing list when printed. 

When the user has completed all of the information needed for the packing list, the information must be saved.

Note: The Packing List MUST be printed for the shipping information to advance to Invoice Administration.

If the user has set the system setup to Manual Invoice numbering, then ManEx will prompt for the invoice number to be used for the packing list.

If automatic numbering is used in the setup, then ManEx will supply the invoice number, and close the screen.

Hold for Credit Limit

If the user has elected Enforce Credit Limit at Shipment feature in Accounts Receivable Defaults in Accounting Setup, the following message will appear if a non-supervisor attempts to ship:

 

 

The program gets the total Accounts Receivable (AR Aging) + Not Posted Invoice (invoice not printed out of the Admin/Invoice module) + Open SO Amounts.  Compares it to the Credit Limit setup in the Customer Information module.

This is based on having the "Include Open Orders for Credit Approvals for Shipping" option checked, (within the Print PL/Invoice setup module) (if you do not want to include open Sales Orders you would want to uncheck this option) and the "Enforce Credit Limit at Shipment" option checked, (within the Sales-A/R setup module)(uncheck this option if you do not want to Enforce the Credit Limit at Shipment). 

Make sure that these options are marked properly to get the results you are expecting.

Depress the OK button,  and enter a supervisor password or a password for a user with rights within the Security module, that has the ability to approve the credit limit exceed message. The following warning will appear:

To continue, select "Yes" to abandon select "No".

Add a Stand Alone Packing List  

Add by Stand Alone procedure is the ONLY way that a manual invoice can be created. 

If the user elects to add by Stand Alone, a screen appears listing Customers.  The user selects the customer by either entering it into the red box, or scrolling down the list and clicking on the selected Customer. Decide between Active or Inactive customer by checking the appropriate box. Type in the Customer name or highlight the customer and double click to select. Once the customer is selected, you will be prompted for your password. The following screen will appear:

 

Go to the Detail Tab, and select Add manual item, the user will be prompted for the Credit G/L Number:

Depress the down arrow, select to Find By either Account Type or Account Numbers. 

If you select by Account Type, the GL Type box will be enabled.  Depress the down arrow next to the GL Type box and a list of accounts will appear. Select the desired GL Type.

Once the GL Type is selected the Account number box will be enabled.  Depress the down arrow next to the Account Numbers box, and only the G/L accounts within that range will appear.  Select the desired GL account number.

If you select by Account Numbers, the Account Numbers box will be enabled. Depress the down arrow next to the Account Numbers box, and the list of ALL of the G/L Account numbers will appear. Select the desired G/L account number.

The user will be prompted for Quantity, Back Order amount, Description and Units of Measure.

Finish the process as detailed above.

Note: The user may edit a Packing List up until the time that the Invoice is printed.After that, no edits are allowed.

At the conclusion of the modification process, the user may either press the Save button to save the changes or press the Cancel button to cancel changes.

The user may re-print the Packing List.

After activation, "Sales Order Management" access for each user must be setup in the ManEx System Security module.  Users with “Supervisor Rights” will automatically have access.

Enter Inventory Mgt/Packing List Management/Sales Order Shipping Schedule Module   .

 

The following screen will appear:

 

This is the listing of all open and unshipped Sales Orders.  The user may sort by Ship Date, Sales Order Number, Customer or Part Number by depressing the appropriate button.

Sales Order Shipping Requirements List Field Definitions

Ship Date	The due date of the Sales Order.
Sales Order Number	The number assigned to the Sales Order.
Customer	The name of the customer.
Part Number	The number assigned to the part.
Rev	The number of the revision assigned to the part.
Part Mfgr	The manufacturer name assigned to the part.  (This is only displayed if the "MAKE" item originates from a RMA order, or the item is a "BUY" or "MAKE_BUY")  See Note below.
Mfgr Part Number	The  manufacturer part number assigned to the part.  (This is only displayed if the "MAKE" item originates from a RMA order, or the item is a "BUY" or "MAKE_BUY") See Note below.
Scheduled Quantity	The quantity to be shipped for the Sales Order.
FGI Quantity	The quantity currently in finished goods inventory.

After activation, "RMA Management" access for each user must be setup in the ManEx System Security module.  Users with “Supervisor Rights” will automatically have access.

The Return Material Authorization module notifies receiving to expect a return from a customer.

Once the material is received back from the Customer, this module is used to record the receipt, create the Re-Work Work Order, adds the product into the work order, and the applicable Credit Memo. Once the RMA is received, a Credit Memo automatically forwards to the Accounting Accounts Receivable Credit Memo module, if a dollar amount was entered for the return.

When the re-work/replacement is ready to re-ship, a Packing List and Invoice can be created.

RMA Receiver Tab Field Definitions

Customer	This is the name of the Customer who returned the material.
RMA Receiving Number	This is the unique number assigned to the RMA Receiver.
Ship From	This is the Customer’s address from which the material was returned.
RMA Receiving Date	This is the date the user’s Receiving Department received the returned material.
RMA Order Number	This is the RMA Order Number assigned in the RMA Management module.See above.
Purchase Order	The was the customer’s original purchase order number for the original Sales Order.
Attention	This is the contact name at the Customer.
Ship Via	This is the original carrier for the original Sales Order.
Freight Amount	This is the freight originally charged the customer on the original Sales Order.
RMA Order Acknowledgement	This box is checked in the RMA Management module, as explained above.
Freight	This is the freight arrangement per the original Sales Order.
Waybill	This is the Waybill number pertaining to the original Sales Order.
Credit	This is the Customer’s Credit Status with the user.
FOB	This is the original FOB terms pertaining to the original Sales Order.
Entered By	These are the user’s initials authorizing the material return in the RMA Management module.

RMA Receiver Detail Tab Field Definitions

Customer	This is the name of the Customer who returned the material
RMA Receiving Number	This is the unique number assigned to the RMA Receiver.
Ln	The line number of the Return Material Authorization or the line member of the order to be re-worked/replaced and returned to the customer.
Part Number	The user’s internal number for the part or assembly.
Rev	The revision number pertaining to the Part Number.
Class	The user’s classification covering the Part Number.
Type	The type within the classification covering the Part Number.
Qty	It’s the amount of the original order which the customer is returning. See Article #1240 for more detail on why the system will not allow user to enter in a fraction of a number, and an alternative.
Back Order	The amount of product still expected to be returned by the customer.
Description	The user’s description covering the Part Number.
UOM	The unit of measure pertaining to the product.
	This button allows the user to add items from the RMA Management module.
	This button allows the user to delete the highlighted line.
Packing List Ship Date	The date the Original Packing list was created.
Warranty Expiration	The date the warranty originally extended to the customer expires.
Serial Number Entry	The serial numbers pertaining to the items returned.
	The note pertaining to the Part Number as entered in the Inventory Master.

RMA Receiver Notes Tab Field Definitions

RMA Note	This is the internal note used by the user regarding the Return Material Authorization as entered in the RMA Management module.
RMA Receiver Note	This is a note that will be displayed on the RMA Packing List.
Credit Memo Reason	This is the note created when the Credit Memo was created.

RMA Receiver Work Order List Tab

If the RMA Management module called for a re-work or replacement in addition to authorization of the return of material, the system will have created a Work Order.  Information regarding any such Work Order will appear in this tab.

RMA Receivng Work Order List Tab Field Definitions

Ln	The line number of the Return Material Authorization or the line member of the order to be re-worked/replaced and returned to the customer.
Part Number	The user’s internal number for the part or assembly.
Rev	The revision number pertaining to the Part Number.
Class	The user’s classification covering the Part Number.
Type	The type within the classification covering the Part Number.
Description	The user’s description covering the Part Number.
Work Order Number	The unique number assigned to the Work Order for Re-Work or Replacement
Work Order Due Date	The date the Work Order is scheduled to be completed.
Build Quantity	The number of units to be re-worked or replaced.
Back Order	The number of units still to be shipped.
Work Center	The name of the Work Center where the Work Order is currently.
Quantity	The quantity of the Work Order currently at the Work Center

No Journal Entry is created in the RMA module, however the system was collecting the JE components from that module as follows:

Assume that the original sale was for 10 units @ $100.00 each, with a standard cost of $80.00 each and freight charged the customer of $15.00.

At the time the user selects the original Invoice number in the Return Material Authorization module, the system “remembers” the original accounting entry that was created at the time the original Invoice was printed, which was:

Debit Accounts Receivable – Trade  $1,015.00

Debit Cost of Goods Sold  $800.00

Credit Sales  $1,000.00

Credit Finished Goods Inventory  $800.00

Credit Freight Income  $15.00

When the user enters the “return quantity” (the one entered as a negative quantity), the system will remember that the original cost of sales was $80.00 per unit.

The user then enters the pricing on the item to be returned on the Pricing page of the RMA module.

The pricing entered can be any amount up to the amount of the original pricing of $100.00 per unit. And so the journal entry component for the debit to the sales account is 2X $100.00 = $200.00, in this example.

The user selects the sales and cost of goods general ledger accounts to be used per the Sales Type column:

And so, the sales account number selected will be debited for $200.00 once the journal entry is created, upon the actual receipt of the returned item.And the related Cost of Goods sold account will be credited for the $160.00.

If the return is to be reworked and then returned back to the customer, the user creates a second line item on the RMA using a positive quantity which is in actuality creating the RMA Sales Order and an eventual invoice upon shipment.

The journal entry and the applicable Credit Memo for the returnis created in this Return Material Authorization Receiving module.On this screen, the user indicates the amount of freight to be credited, such as a pro rata 2/10 of $15.00, or $3.00, for example:

After the user types in the quantity received on the Detail page and depresses the Save button, several things happen all at once:

The Journal Entry is created as follows and forwards to the Release to General Ledger module:

Debit Sales  $200.00

Debit WIP  $160.00

Debit Freight  $3.00

Credit Accounts Receivable $203.00

Credit COGS  $160.00

1. The Credit Memo is created for an amount of $203.00 total.  If the original invoice is still open, the amount of the credit memo will net against the original invoice leaving an open balance of $812.00, $1,015.00 minus $203.00.   If the invoice is paid than a credit balance will appear on the A/P Aging for the unapplied amount up to $203.00.
2. The e-mail trigger is activated announcing that a Credit Memo has been created.
3. The ReWork Work Order is created.
4. The returned material is placed into WIP.

Once the Rework Work order is released, the user may opt to go into kitting and add line shortages which will be included in the Material Variance once the Kit is closed.Please refer to the Kitting and Shortage Management manual.

From this point forward, the accounting is the same as for a regular order.

Enter Inventory Mgt/RMA Receiver Module

The following screen will appear:

To find an RMA receiver, depress the Find action button.  The following selection screen will appear:

Find RMA Receiver by RMA Receiving Number If you choose to find an RMA Receiver by the RMA Receiving Number, depress that selection and the following screen will appear: Type the RMA Receiving Number into the red box or highlight your selection and double click.

Find RMA Receiver by Customer If you select to find the RMA Receiver by Customer, a list of customers will appear: Type the Customer Name into the red box or highlight and double click.
A list of RMA receivers for that customer will appear: Type the RMA Receiving Number into the red box or highlight the selection and double click.

Find RMA Receiver by RMA Order Number If you decide to find the RMA Receiver by the RMA Order Number, a list of RMA Orders will appear: Type the RMA Order number into the red box or highlight your selection and double click
A list of RMA receivers will appear: Type the RMA Receiving number into the red box or highlight your selection and double click.

Once the Find operation has been completed, the found RMA Receiver will populate the screen. 

Enter Inventory Mgt/RMA Receiver Module

The following screen will appear:

To add a new RMA Receiver, depress the Add record action button. The following selection list will appear: 

Type the RMA Order Number into the red box or highlight your choice and double click.  Information from the RMA Management module will appear once you enter your password, as shown below:

RMA Receiving Tab

Depress the down arrow to select the appropriate ship from address.

Edit the RMA Receiving Date, if desired.

Depress the down arrow to select the appropriate customer contact, Ship Via, Freight, or FOB.

Enter the amount of freight, if desired.

Enter the number of the Waybill, if desired. 

 All other fields will be defaulted in.

Depress the RMA Receiver Detail Tab.   The following screen will appear:

Depress the Add RMA order item(s) button.  A list of products, etc. pertaining to the RMA selected will appear:

 

Enter the Received Qty and depress the OK button, and the following screen will appear:

Type the Serial Number to be received into the Receiver Serial No box (if it doesn't exist in the system, System will prompt user if they wish to add serial # and the SN will be created). Or, select the Serial Number(s) being returned by highlighting and depressing the > button. For multiple serial numbers, hold the CTRL key down while highlighting.  If you want to include all Serial Numbers, depress the >> button.

Depress the OK button.  The Serial Number Entry box will update.

Rework Work Order Serial Numbers

When a Rework Work order is established for a serialized product, the user may select existing serial numbers that are in inventory (finished goods) that are to be reworked. Rework Work Orders will not accept new serial numbers.  When a serial number is placed in the Rework Work Order, the serial number must exist in finished goods, and the number of serial numbers transferred to the Work Order must equal the quantity of assemblies for the Work Order.  The part number for the serial number that is moved into the Rework Work Order does not need to be the same part number and revision as the Work Order.  Thus, if a user wants to upgrade part number 123 rev A to part number 123 rev B, they can transfer the parts to the Work Order and identify the serial number transferred.  Parts may also be changed to a new part number:  Example:part number 123 rev A can be placed in a Rework Work Order for part number 234 rev C.  The only condition is that the quantity and number of serial numbers must match.

You may enter an item Note, if desired.

The completed screen will look like this:

Depressing the Note tab will bring up the following screen:

The credit memo reason will display as referencing the RMA number.  You may add to the Credit Memo Reason, if you wish.

You may add an RMA note or an RMA Receiver Note, if desired.

When RMA is complete.  Depress the Save record action button to save changes, or depress the Abandon changes button.

If you depress the Save record action button, the following message will appear:

To continue the save, depress the Yes button. 

You may not change anything on this screen.

Note: The user can not kit a Rework Work Order. The user may only pull the shortage. Please refer to the Kitting, Allocating &  Shortage Management article.

Note:  If the RMA line number for the negative (returning) item is placed on administrative hold, then receiving will not be able to receive in the parts until it is cleared. 

Credit Memo

In System setup/Purchasing Setup it gives the user the option to use PO Dock Receiving.  If this box is checked, the purchases are received at the dock requiring the user to complete a PO Dock Receiving record, listing the supplier’s packing list number and the quantities per that packing list.  An inspection report is printed.  The purchases are inspected and counted.  (If this box is left unchecked the user can skip the PO Dock Receiving step and go directly to the PO Receiving and Inspection record.)

Fields & Definitions

The user may edit the Dock Receiving record as long as a related PO Receiving has NOT been done.

1. Find  Dock Receiver.
2. Depress the Edit action button.
3. You’ll be prompted for your password.
4. User may edit the supplier's Packing List Number or the quantity received. The system does allow you to receive more then the PO quantity/Overage.   Note: Users must have special access in order to receive overages,  there is a checkbox to allow overages within Security/User Rights for PO Receiving. 
5. Depress the Save changes action button.

If you try to receive more than the PO quantity, you’ll receive the following warning message:

If you enter YES and depress the Save action button (and if you have exceeded the overage percentage from the Purchase Setup and\or PO line item) you will receive the following warning message.  Note: The overage is applied to the entire PO order qty - it does not go down to the schedule level.  Example:  If you have an order qty of 100 and an allowed overage of 5% the system will allow you to receive in a total overage of 105.  But if you have only scheduled a qty of 25 and go to recieve in qty of 30 the system will allow you to do so, because it has not met the order overage yet.

To obtain the PO Dock Receiving reports, select the Print button from the ManEx action buttons at the top of the screen.     The report screen will appear: Select the appropriate radio for the output format you desire: Screen, Printer, XL File, TXT File, or PDF. Highlight the desired report and then depress the Option tab if applicable.

The following is printed:

If you select the Open PO Dock Receiving Report, the following additional window will display at the bottom of the screen:   Select detail either by PO Number or by Received Date.Depress the OK button.

Receiving is the next step after creating and submitting a Purchase Order.  

In System setup/Purchase Setup it gives the user the option to use PO Dock Receiving.  If this box is checked, the purchases are received at the dock requiring the user to complete a   PO Dock Receiving record, listing the supplier’s packing list number and the quantities per that packing list.  An inspection report is printed.  The purchases are inspected and counted.  (If this box is left unchecked the user can skip the PO Dock Receiving step and go directly to the Purchase Order Receiving & Inspection record.

The user then is required to complete a PO Receiving & Inspection record. This module has a provision for rejected purchases.

For rejected materials, ManEx provides for a PO DMR (Discrepant Materials Receipt) module. The Discrepant Material Receiver is used to receive material which  does not meet the specifications for the purchased part or purchase order.  This module allows for review by the Materials Review Board.  Then, if not acceptable, the material may be returned to the supplier.  The user may reject in the Purchase & Receiving Management module OR may return an item From Inventory.  If an item is returned From Inventory, and the PO has been reconciled, a Debit Memo forwards into Accounting along with the appropriate journal entry. 

For the Highlighted Line Item:

Due Date	The date the item was due to the user’s dock.
Balance	The un-received balance of the order.
Accept Qty	The quantity accepted in Purchase Order Receiving.
Reject Qty	The quantity rejected which will be placed in the Material Review Board warehouse.
Distribute To	This is classification of the distribution of the item when received, either to regular Inventory Receiving or  to Allocate to a specific Work Order or Project.
Requestor	On MRO and Services Purchase Orders, the name of the requestor is indicated.
N/A	For future use.
WO Number	The number of the Work Order for which the item was purchased.
Warehouse	The name of the warehouse where the accepted quantity will be placed.
Location	The specific location within the warehouse.
Note	Schedule notes pertaining to that specific item and scheduled date.
Material Type	The material type listed is at the AVL level
Inspection Required	This will be visible ONLY when selected in the Inventory module.  Check box when complete.  If box is NOT checked user will NOT be able to save record.
Certificate Required	This will be visible ONLY when selected in the Inventory and/or PO module.  Check box when complete.  If box is NOT checked user will NOT be able to save.
First Article Required	This will be visible ONLY when selected in the Inventory module.  Check box when complete.  If box is NOT checked user will NOT be able to save record.
	Enter any special notes pertaining to the 1st article.
Lot Code	Lot Code number assigned to part.
Exp. Date	Expiration date of Lot Code.
Reference	User assigned number or code for reference
Lot Qty	Qty of parts lot includes.
Reject Qty	Qty of parts rejected out of lot.
Serial Number	Serial numbers assigned to parts.
Reject	Check box if that serial number is being rejected.
Insp Exception Note	This information is displayed as reference information for processing the Receipts through the system.
Insp Excep Doc.	This information is displayed as reference information for processing the Receipts through the system.

Directive Buttons:

The Item Inspection Note screen will be editable in the Add/Edit mode within the PO Receiving module (not editable when in view mode).  This button will turn Red when information has been entered.  The information added in the PO Receiving module will also be viewable in the Purchase Order module.

	If this button is displayed in Red related documents have been attached to this item in the ICM module and may be viewed by depressing the "View Inventory Item Related Documentation" button.  For further detail see Article #2396.
	Depress this button to view Item Master Notes for that specific part.  If there are Item Master Notes the button will be Red.
	Depress this button to view PO Item notes entered in the Purchase Order.  If there are PO Item notes the button will be Red.
	Depress this button to view PO notes entered in the Purchase Order.  If there are PO notes the button will be Red.
	Depressing this button will bring up the following screen. If shortages exist for the current line item the button will be Red.  For further detail see Article #105 .

The system shows all the shortages for the part that is received, if:

1. the WO is not closed or cancelled 
2. the WO balance is more than 0
3. the kit line "Ignore Kit" flag is not on
4. the Kit status is "Released"

It is up to the user to decide which receipt has to be applied to which shortage.

Work Order Shortage List field definitions:

Work Order Due Date	The date the Work Order was due to be completed and ready to ship.
Work Order Number	The number of the Work Order.
Customer	The name of the customer listed on the Work Order.
Product Number	The Product number listed on the Work Order.
Revision	The revision listed on the Work Order.
Shortage Quantity	The amount of the Work Order shortage.
Qty Issued	The quantity issued to the Work Order shortage. System does not allow you to issue quantities greater than the shortage quantity.  For more detail see Article #2479.
Balance	The balance of the shortage after issuing parts to WO.
Approved	This will be checked if the AVL that you are receiving is an approved AVL for that shortage.  This will give the users the needed information on screen to make the decision to use or not use a non-approved AVL to fulfill a shortage.

Incoming Receipts field definitions:

PO REC Due Date	The date the Purchase Order Receiving was completed.
Available Qty	The quantity accepted within Purchase Order Receiving.
Warehouse	The name of the warehouse where the accepted quantity will be placed.
Location	The specific location within the warehouse.
Part Mfgr	The manufacturer for the part.
MPN	The manufacturer part number.
Allocated To	If the parts have been allocated to a WO or project when PO was created.
Requestor	On MRO and Services Purchase Orders, the name of the requestor is indicated.
Lot Code	Lot Code number assigned to part.
Exp Date	Expiration date of Lot Code.
Reference	User assigned number or code for reference

Highlight WO Shortage and drag Incoming Receipt here to issue field defintions:

Work Order	The number of the Work Order.
PO Rec Due Date	The date the Purchase Order Receiving was completed.
Warehouse	The name of the warehouse where the accepted quantity will be placed.
Location	The specific location within the warehouse.
Part Mfgr	The manufacturer for the part.
MPN	The manufacturer part number.
Qty Issued	The quantity issued to Work Order Shortage
Lot Code	Lot Code number assigned to part.
Exp Date	Expiration date of Lot Code.
Reference	User assigned number or code for reference

 

Depress the Inventory Mgt/Purchase Order Receiving & DMR/Purchase & Receiving Management module

The following screen will appear:

1. Pressing the Find action button at the top of the main screen displays the following sequences: This allows the user to search by Purchase Order Number, Supplier, or Receiver Number.

2a. If the user selects to find by Purchase Order Number, a screen is presented listing all orders placed. Type the PO number into the red box or highlight the PO Number of choice and double click.The PO information will populate the screen.
2b. If the user selects to find by Supplier, a screen is presented listing all of the suppliers with all orders placed. Type the supplier into the red box or highlight the supplier of choice and double click.The PO information will populate the screen.
2c. If the user selects to find by Receiver Number, a screen is presented listing all of the receiver numbers with all orders placed. Type the receiver number into the red box or highlight the receiver number of choice and double click.The PO information will populate the screen.

3. The found information will populate the screen, as follows:

If system is setup for Dock Receiving follow a.  If system is setup for Inventory receiving ONLY follow b. 

1. 1. Print out the  Purchase Order Receipt Inspection Worksheet.
   2. You will go directly to step 3. 
2. Inspect the shipment received. 
3. Add a record.
4. The user will be prompted for the password. 
5. Find  a Purchase Order 
6. If Supplier Packing List Number is not already entered, enter it now.
7. Select the part to receive.
8. Enter the quantity accepted and/or rejected and reject reasons.  (When using the PO Dock, user has to either accept the entire Dock qty or reject the balance.  User can not accept only a partial PO Dock qty).   Note: Users must have special access in order to receive overages, receive early shipments,and/or receive banned MPNs.  There is a checkbox to allow user to receive overages, receive early shipments, and/or receive banned MPSs, within Security/User Rights for PO Receiving.   

    

   User will receive the following warning if the number of parts received is higher than the qty ordered. The overage is applied to the entire PO order qty - it does NOT go down to the schedule level.  Example:  If you have an order qty of 100 and an allowed overage of 5% the system will allow you to receive in a total overage of 105.  But if you have only scheduled a qty of 25 and go to receive in qty of 30 the system will allow you to do so, because it has not met the order overage yet.  Note:  A negative qty will appear in the balance column on the PO when an overage has been received. Note:  User must have special access in order to receive overages.   There is a checkbox to allow overages within Security/User Rights for PO Receiving.  If user does NOT have these rights, they will NOT be able to continue.

   User will receive the following warning if the receipt is before the PO due date and the early tolerance time allowed in the  Purchase Setup screen.  Note: Users must have special access in order to receive early shipments. There is a checkbox to allow early shipments within Security/User Rights for PO Receiving.  If user does not have these rights, they will NOT be able to continue.

    

    

9. If the “Allow auto creating location at receiving” box is checked in Inventory Control, AVL level & Warehouse Setup, this will allow the user to add or edit the location at time of receipt. User may also select an existing warehouse at receiving instead of having to create one before receiving.   For further information on the "Allow auto creating location at receiving" see Inventory Control & Warehouse setup.  If the Inspection Required, Certificate Required, and/or the First Article Required is setup in the Inventory Control Management module,   these boxes will be displayed in Red and the "DONE" boxes must be checked to continue the receiving process.  

    

10. In the system setup - Purchase Setup user can choose to allow receiver to change AVL at the receipt.   The pull down will display all the Mfgr and Mfgr PN's listed in the AVL screen in the ICM module.

11. Enter Serial Number and/or Lot Information if required.

12. Issue parts directly to Work Order Shortages.

13. Save the record.

Introduction

The users can receive components that require Lot Code Only, Serial Number Only, or both Serial Number and Lot Code, following the instructions listed below.  A part that requires a Lot Coded is setup in the Inventory Part Class set-up module.  A part that requires Serial numbers is set-up in Inventory Control Module.

1. Fill in accepted item quanitity as instructed in the Add a PO Receiving Inspection Record.
2. Depress the Add button next to the Lot Code section.

3. Type in the Lot Code. The expiration date, reference date and quantity will automatically update, (if the part class/type setup is set to auto update expiration date and reference for the lot code).   In order for a Lot Code to be unique, the system looks at four fields for comparison.  They are Lot Code, Reference, and PO Number.  So while a batch may have the same Lot Code as another batch, if it arrives in a different PO, the it will be classified as a different lot.  The expiration date is optional and is not required when creating a new lot.

   

4. Serial numbers will have to be assigned only if a part has the serial number box checked in the inventory module.
   1. Select either single or range.
   2. Enter the serial number in the red box and depress enter.
   3. The serial numbers will automatically update. (Serial numbers may or may not have lot codes).

       

Highlight the line item of interest on the PO Receiving and Inspection screen.

Depress the Work Order Shortage List and Issue button.

Highlight the work order shortage at top of screen. 

Drag Available Qty located in the middle of your screen under Incoming Receipt.

System will not allow user to issue quantities greater than the shortage quantity.  See Article #2479 for further detail.

The following messge will be displayed if user issues a quantity greater than the shortage quantity. 



NOTE:  If a user has the Work Order Checklist feature active and tries to use the PO Receiving shortage and issues feature within the PO Receiving, it will not recognize the shortages until the kit has been flagged as "Kit Complete".  It is designed this way because the user will not know if the parts are short until the kit is completed. 

You may have parts in the inventory and have not pulled them to the kit yet.  If you allow seeing the shortage (which may not be a shortage because parts are not pulled yet) from the PO receiving, the receiver may be trained to automatically issue to the shortages first, but it may not be a shortage because parts have not been pulled from inventory, so how would they know if it is a real shortage or just not pulled from inventory yet.

 

1. Highlight the PO item number located in the middle section of the PO Receiving and Inspection screen.
2. Type in the accepted quantity (if any).
3. Place the cursor in the next box (rej qty) and type in the rejected quantity.
4. Select a reject reason from the pull down in the top section of the screen.
5. If lot coded type in the accepted qty and rejected qty in the lot code screen.
6. If serial numbers are required check the serial numbers that have been rejected.
7. Continue this process until all items are either accepted or rejected.

   

8. Depress the Save button.   
9. If all items on the Purchase Order have been received it will be marked "CLOSED". 

1. If the Purchase Order has been processed through accounting:
   1. Transfer the discrepant material into the MRB (materials review board) warehouse via Inventory Handling.
   2. Enter the PO DMR module (discrepant material return).
   3. Add from Inventory. (This is called an INVENTORY DMR).
2. If the user has already pulled the kit associated with the part to be returned to the supplier.
   1.  Enter the Kitting module.
   2. Find the work order.
   3. Depress the Utility tab and depress the De Kit button.  This process will return the part into the inventory warehouse. (Please refer to the Kitting & Shortage Mgmt module).

Introduction

After the user has accepted all of the items on a Closed Purchase Order and then subsequently it’s discovered that the material received is discrepant, do the following if Accounting hasn’t already processed the Supplier’s Invoice for payment:

1. Enter the Purchase and Receiving Managment Module.
2. Find the closed PO, using the Find a Purchase Order.
3. Depress the Edit button.
4. Type in your password.
5. Highlight the discrepant Part Number Line Item in the top section of the screen.
6. In the middle section of the screen, enter the revised accepted quantity, and the rejected quantity.
7. Go back up to the top section of the screen and select a reject reason.
8. If there is Lot Code Tracking involved, also adjust the Lot accepted quantity and rejected quantity, and check the serial numbers that have been rejected.
9. Depress the Save button.

Select the appropriate radio for the output format you desire: Screen, Printer, XL File, TXT File, or PDF. Highlight the desired report and then depress the Option tab if applicable.

MATERIAL RECEIPT LABELS For the PO Receiving Material Receipt Labels, you can choose between the Avery label #5163 (laser Sheet 4x2) or the Zebra Printer.   Select PO Status - Open or Closed.  Select to pick PO # from List or Enter Single PO #.  Select the PO from the pull down. Depress the GO button.

The information will automatically fill in.  Enter the quantity of labels needed for each item.   Note:  The Mfgr and Mfgr PN info is being pulled from the PO Module and not the Receiving Module. Depress the OK button.

MATERIAL RECEIPT TRAVELER REPORT For the Material Receipt Traveler report, highlight that report. Go  to the Options screen, select the PO Items Type from the pull down screen.  Depress the OK button.

The following is printed.

MATERIAL RECEIPT HISTORY FOR ONE PART REPORT  For the Material Receipt History for One Part report, highlight that report. Go to the Options screen.  Enter the part number.  Enter the desired date range.  To clear the selection, check the Clear Selection box and re-enter the desired date range.   Check the box to Suppress leading "0" when printing serial numbers. Depress the OK button.

The following is printed:

MATERIAL RECEIPT HISTORY REPORT FOR ALL PARTS For the Material Receipt History Report for ALL Parts, highlight that report and make the appropriate selection at the bottom of the screen, By Part Number, By Warehouse or By Supplier. Go to the Options tab.  Enter the desired date range.  To clear the selection, check the Clear Selection box and re-enter the desired date range.   Check the box to Suppress leading "0" when printing serial numbers. Depress the OK button.

The following is printed:

PURCHASE ORDER RECEIPT INSPECTION WORKSHEET or PURCHASE ORDER RECEIPT INSPECTION WORKSHEET with REQUESTER For the Purchase Order Receipt Inspection Work Sheet, or Purchase Order Receipt Inspection Work Sheet with Requester, highlight that report. Go to the Options tab. Highlight the Purchase Order and depress the > button.  If you want all of the Purchase Orders listed, depress the >> button. Depress the OK button.

The following is printed:

Material Receipt History Report for PO For the Material Receipt History Report for PO, highlight that report. Go to the option tab. Choose Single PO or PO received in given Date Range by selecting the radial.  Enter date range.   Check the box to Suppress leading "0" when printing serial numbers.   The Project/Work Order Allocation information will be displayed on the report. NOTE: The report has to pull the allocation information from the Purchase Order Item Schedule, if the item schedule allocation is modified after receipts have already been made against this item, the report will also change to display what is currently assigned for allocation, not what they were received into the system as. Depress the OK button.

The following will print:

Enter Inventory Mgt/Purchase Order Receiving & DMR/Purchase Bar Code Receiving Module

The following screen will appear:

When you first open the Bar code screen your cursor will be located in the “Bar Command” text box.  Use print button to print a bar code for all the commands you can use in this screen.

Discrepant Material Return is used to return material which is different than what was ordered, received late, over shipment, damaged, etc.

There are two ways to return discrepant materials.

1.                    The discrepancy is discovered in PO Inspection/Acceptance Receiving and rejected there.

2.                    The discrepancy is discovered after the Inventory has been placed into stock.  This module allows for review by the Materials Review Board.  Then, if not acceptable, the material may be returned to the supplier.  Once the DMR (discrepant material return) is created, information regarding the return is forwarded into Accounting where a Debit Memo and the accompanying accounting journal entry is created.

Once the Discrepant Material is added, the user may print out a DMR (discrepant material return) Packing List.

In Defect Code Entry we allow users to move product into FGI, when a part is transferred to FGI, the program will compare the total cost of components with the "material cost" of the assembly, then create the configuration variance. In addition to that, the system will create additional 4 records for "Labor", "Overhead", "Other Costs" and "User Defined" costs.

Fields & Definitions

Return Items tab field definitions

Field & Definitions

This procedure is used after accounting has Reconciled the Purchase Order.  If accounting has not yet reconciled the purchase order, see  Rejecting Items if Accounting hasn't Processed the Invoice.

Note that the discrepant material must be transfer into the MRB (materials review board) warehouse via Inventory Handling before you can proceed.

To enter the PO DMR (discrepant material return) module, select Inventory Mgt / Purchase Order Receiving & DMR (discrepant material return) / PO DMR (discrepant material return).

1. Depress the Add button.
2. Type in your password.
3. The following screen will appear;
   
                                                                                                                               
4. Select the From Inventory radial.
5. Type in the Part Number and depress the OK button.  The following screen will appear (If there is more than one Purchase Order involved it will list them all)     
   
   
                                                                                                           

6. Highlight the Purchase Order of choice.

7. Depress the OK button. Information regarding that part number for the Purchase Order selected will display:

8. Type in the returned quantity in the Return From section.
9.  In the DMR List section, type in the RMA number.
10. Type your name in the Confirm By column.
11. Depress the Packing List Tab.

12. Typing in your Packing List number for the return.  Type in the associated waybill number.  

 

If accounting has not yet transferred the reconciled invoice into AP Aging, the following message will appear:

 

Depress the Save button.  The following screen will appear:

 

 

 

Once the DMR (discrepant material return) has been added and saved, a Debit Memo will be created.  If Debit memo numbering is manual, the user will be prompted for the number.  Additionally, the corresponding entry will be created and the balance in the Accounts Payable Aging will adjust as soon as the Debit Memo is printed.

 

If the invoice happens to be in a Saved Check batch the following warning will be displayed:

 

 

 

To enter the PO DMR (discrepant material return) module, select Inventory Mgt / Purchase Order Receiving & DMR (discrepant material return) / PO DMR (discrepant material return).

1. Depress the Add button.
2. Type in your password.The following screen will appear:

   

3. Select the From PO Receiving radial.
   1. If you then mark the radial Purchase Order #, you will need to type in the number of the PO on which material was rejected.
   2. If you mark the radial Supplier, you must then type in the name of the Supplier and then depress the OK button.
   3. A list of Purchase Orders pertaining to that supplier will appear.

      

       
4. Type the PO number of interest in the red box or highlight and double click.

5. Depress the OK button.  (Note there are four additional screens if lot code and serial numbers are involved).

6. Type in the DMR number (if set-up for manual numbering) you are assigning to this return.
7. Type in the RMA number as provided by the supplier.
8. Type your name in the Confirm By space.
9. Highlight the line item containing the rejected quantity. (If returning a part that involves a Lot Code, type in the returned quantity in the Lot Code section and it will automatically update the Return From section. Check the serial numbers being returned).
10. Depress the Packing List tab.
11. Enter the Packing List number you wish to assign to the return. (Note that this number is NOT tied to regular shipping Packing Lists.This is a manually numbered field that is only for reference on the DMR’s.Any alpha-numeric code can be used here.DMR packing list numbers cannot be found in the regular shipping module – Packing List Management.It is suggested that the user manually log these codes or type in some kind of significant code, such as the date followed by the PO#).
12. Type in the Waybill number.
13. Depress the Save button. The View DMR screen will appear: 

     

    

     

To enter the PO DMR (discrepant material return) module, select Inventory Mgt / Purchase Order Receiving & DMR (discrepant material return) / PO DMR (discrepant material return).
1. Depress the Find button. The following screen will appear:  2. Select the appropriate radial – either DMR Number or Receiver Number. 3. Type the appropriate DMR or Receiver number into the Red box. 4. Depress the OK button.

The following screen will appear:

To print out the DMR (discrepant material return) Packing List, depress the Print button. The following screen will appear: Highlight the DMR (discrepant material return) Packing List Form. Depress the Options tab.
The following screen will appear: Select the Output, either Screen, Printer, XL File, TXT File, or PDF.  Select the number of copies by toggling on the arrows.  If you don’t want to print the DMR displayed, click on the Select DMR from the list radial then highlight the DMR (discrepant material return) # you want printed and depress the > button.  If you want all of them, depress the >> button.

The following will print:

Optional Prerequisites for Entering a New KITTING & SHORTAGE

Main Screen Field Definitions

Component Section - NOTE:  Items will appear on screen only if the "Used in Kit" on the BOM is "Y".  For further detail see Article #34.

	This is the “Ignore Shortage” box: If you want to remove the component from the shortage reports and MRP, check the box at the left of the part number.  Note:  the box for checking KITTED shortages only works with those items that are kitted based on the BOM for the assembly. Checking the boxes means that the part on the BOM will NOT be considered for MRP purposes, and not show up on shortage lists. This is the only way you can get a part on the BOM off of the shortage list. Line shortages, however, can be edited to make them larger or completed.  The user will not be able to create a line shortage, then try to check the “ignore shortage” box, this box is disabled for added line shortages.
	This symbol before a part number is to inform the user that this part is originating from a Phantom BOM.
	When shortages have been saved for the work order, they will be added to the Kit Status section of the main information tab. The item will be preceded with the rho (? ) symbol to differentiate it from a kit shortage.
Part Number	The part number of a component belonging to the Bill of Materials for the assembly
Rev	The part number revision of the component
Ref Designator	The Reference Designator as assigned in the BOM Module
Required Qty	The number of parts required of the component in the work center shown. (A component may be used in more than one work center.) This qty may include Setup Scrap if the "Setup Stcrp" box is check on the BOM Header Information and/or Run Scrap if selected to include scrap in the Kit Default Setup .
Picked Qty	The number of parts already picked from stores for the work order
Shortage	The quantity of parts short for the work order will be displayed as a positive number, the quantity of parts issued as an overage will be displayed with a negative number.
Part Source	The source code for the part, BUY, MAKE, Phantom or Consigned
Work Center	The work center in which the part is needed and to which it is to be kitted
Rej Qty	If parts have been rejected during the kitting process, the quantity of parts rejected

DIRECTIVE BUTTONS

The following buttons are displayed on the Kitting Main screen

	Kit Note will bring up any notes entered concerning the kitting or shortages
	BOM Note will show any notations entered at the Bill of Material level
	W/O Note will display any notes entered about the work order
	Item Mstr Note will display any notes entered in the Inventory Control Item Master about the part highlighted
	On Order button will display information about any open orders that may exist for the part highlighted, as shown below

The user may sort by Date, Supplier, PO Number or Manufacturer by depressing any of those buttons.

The Inventory button will display on hand and location information for the part highlighted, as shown below

     

 

 

 

Status of Kit:  Released is a term that means the work order has moved from the initial input condition, where it is possible to check on details of the work order and to utilize a check list to indicate certain functions (established in the setup) have been completed (e.g., necessary documents have been received, shortages have been resolved, tooling is available, etc.). An unreleased work order cannot be kitted, nor moved on the shop floor.

KIT (a logic field) means that the work order has been released for production to work on it. This includes kitting and SFT. It means that in the WO screen, the user has clicked on the “Work Order Released” checkbox. Or, this box is automatically checked when all of the items on a work order check list have been completed. It does not mean that the work order or the kit have been started. Until this box is checked, no kitting nor SFT activities can begin.

Issue Screen Fields

KIT STATUS SECTION

Part Number	The part number of a component belonging to the Bill of Materials for theAssembly.
Rev	The part number revision of the component
Shortage	The quantity of parts short for the work order.

INVENTORY STATUS SECTION

Part Mfg	The name of the manufacturer for the highlighted part
Warehouse	The name of the warehouse
Location	The location within the warehouse listed, such as Row 2, Bin 34
Available Qty	The quantity available for this part for this work order
WO Alloc	The quantity allocated to other Work Orders.
Pjct Alloc	The quantity allocated to other projects.

PICKED STATUS SECTION

	An "A" will be displayed in this column if the Manufacturer is approved
Part Mfgr	The name of the manufacturer for the highlighted part.
Mfgr Part Number	The manufacturer number for the part highlighted
Pick Qty	The qty required for this WO.   See Article #1240 for more detail on why the system will not allow user to enter in a fraction of a number, and an alternative.
Over issued Qty	The qty over issued to this WO.  See Article #1240 for more detail on why the system will not allow user to enter in a fraction of a number, and an alternative.
Lot Code	The manufacturers lot code for the part highlighted
Total Picked Qty	The quantity of the highlighted part already picked. Below that is the part number of the completed assembly.
Total Overissued Qty	Any quantity issued over what the Bill of Materials depict. Below that is the revision number of the completed assembly.
	When depressing this button a bar code label will be printed
	The "Next" button should be used with the top "part number (type or scan)" field. When user types (or scans) the part number the user wants to issue, the cursor on the left list will move to the right part number record, then user can issue it. After the user is done, click the "Next" button, the system will save the issued record, and the cursor will move to top "part number" field again for user to enter whatever part number the user wants to issue next.  It doesn't mean the "next one" record in sequence.
	When the user is finished pulling the parts to the kit, they would depress this button and it will bring them back to the Main screen

  LOT CODE INFORMATION

Mfgr Part Number	The manufacturer number for the part highlighted
Lot Code	The manufacturers lot code for the part highlighted
Lot Qty alloc to this PRJ	The quantity allocated to this specific project.
Int. Lot Code	The users internal lot code for the part highlighted.
Exp Date	The assigned date of expiration for the lot.
Avail Lot Quantity	The quantity available for that lot which is available to assign to the work order.
Lot Qty alloc to this WO	The quantity allocated to this specific work order.

ADDITIONAL PART INFORMATION

The Utility Tab has four functions:

1.  Close Kit - This section is used to close the kit from further transactions. Once closed, no further parts may be issued to or from the work order.

Once the Close Kit button has been depress the following screen will appear, this screen will list all over-issues for disposition, it defaults all items to have the over-issue qty returned to stock.  If the users wants to return all to stock they just have to click the OK button.  If they want to assign all the over-issue to the Work Order (kit) they can do so by depressing the "Issue All to Kit" button.  

The act of closing the kit sets up the material variance entry for the Accounting module if more parts or less parts than called for by the Bill of Materials were actually used. Note:  Only an accounting password can close the kit.

The manufacturing variance is based on what should have been kitted according to the BOM for the work order. Under issues, overissues and alternate parts are considered as variances.

If a part is allocated to a Work Order or a Project (linked to the work order), when the KIT over-issues to WO-WIP location.  Once the WO is closed, and user chooses to return stock, the WO allocation will be cleared, but the Project allocations will be retained and carry back to stock as still allocated to that project. 

What are the actions that would cause a work order to appear on the “Kits to Close” report?

The action that causes a work order to appear on the Kits to Close report is when the Work order is closed. (In the Shop floor tracking module, the units are transferred to the Finished Goods work center). There is no longer a balance due on the order but the work order has not yet had the kit closed. There are two aspects of closing a work order activity – 1, closing the work order; and 2, closing the kit. The work order closes when all of the scheduled parts are either in finished goods or scrap. This happens automatically when the last transfer is made in the shop floor tracking module. The kit closing is a manual function. It is separate, because even though the work order may be closed, somebody may not have completed kitting all the parts to the work order, nor moved all of the over-issue out of the work order. These actions are prompted for when the kit is closed. The user may close the kit without addressing the open issues, but if that happens, each will become a variance within accounting. Unfilled shortages will become a positive variance and overissued parts will become a negative variance.

(Important Note: For those instances where the user didn’t issue the parts to the work order initially, but completed the work order in shop floor tracking and then closed the kit, there will be a very large positive variance created because the system will assume that the cost of the components = zero.) Therefore, do not close a kit if it was never pulled.

2.  Re-open kit - If the user wishes, he/she may re-open the kit once it has been closed. Note: Only an accounting password can re-open the kit.

 

3.  De-Kit -  The act of de-kitting will return all of the previously picked parts to inventory.  If a part is allocated to a Work Order or a Project (linked to the work order), once the part is issued to the WO (not over-issue) the allocation will be removed,  only the allocation for over-issue parts can be kept. Once the WO is closed, and user chooses to return stock, the WO allocation will be cleared, but the Project allocations will be retained and carry back to stock as still allocated to that project.  The appropriate accounting entry will also be generated to return all parts to Raw materials inventory from Work in Process. The system will not allow you to de-kit with product in finished goods.

 

4.  Update Kit - The Update Kit button will update the work order with any BOM changes.

Depress the Update Kit button. Type in your password. You will receive a confirmation message.

Enter Inventory Mgt/Kitting, Allocating & Shortage Management/Kitting & Shortage Management.

The following screen will appear:

If you select by Work Order Number the following screen will appear. Type the work order number in the red box, or highlight the work order number and double click to select.

If you select by Product Number the following screen will appear. Type the part number in the red box, or highlight the part number and double click to select. After selecting the product number, a screen is displayed listing work orders for the selected product.
Type the work order number in the red box, or highlight the work order number and double click to select.

 

If you select by Customer Name the following screen will appear. Type the customer name in the red box, or highlight the customer name and double click to select. After selecting the customer name, a screen is displayed listing work orders for the selected customer
Type the work order number in the red box, or highlight the work order number and double click to select.

If you select by Sales Order Number the following screen will appear.   Type the sales order number in the red box, or highlight the sales order number and double click to select.    After selecting the sales order number, a screen is displayed listing work orders for the selected sales order
Type the work order number in the red box, or highlight the work order number and double click to select.

After finding the Work Order, the Main KITTING screen appears, populated with any current information about the work order, as displayed.

After Finding a kit and if it has NOT been previously pulled, the following procedure is performed

Press the Edit action button. This selection will appear: Select between Manual Kit and Auto Kit.  The user may abort the process by clicking on the X button to exit without pulling the kit.
When Selecting either "Manual Kit" or "Auto Kit" and this message appears the WO has a status of Mfgr Hold and the kitting procedure cannot continue until this WO status has been changed.

Selecting Manual Kit and typing in the password will bring up this selection screen: Depress the "YES" button and user will be presented with this screen: (Note: the Kit Status has been updated to "Kit in Process")     NOTE:  If user selects "Yes" to continue and is using the WO Release CheckList the "Kit Released" box will be checked at this time.

If you would like to see if there is part availability for the highlighted part number before going to the next step depress the "Inventory" button. 

Depress the Edit action button again and the following selection will appear: Depress the Issue Parts button to continue or X to cancel.  If you depress the Issue Parts button and type in the password the Issue Tab screen is displayed:

This screen is divided into four operational sections.

The left side of the screen will show the kit status, or parts to be kitted, and the current shortage for each part
On the upper right side of the screen, ManEx will display either all the AVL's or only the approved AVL's depending on how the Kit Default setup is setup.   If the "Show all Manufacturers" is selected in the Kit Default screen the kitting module will display ALL AVL's and then indicate the approved ones with an "A" on the screen and will allow user to pick from the non-approved AVL's as well as the approved AVL's.    If the "Show only Approved Manufacturers" is selected in the Kit Default screen the kitting module will ONLY display the approved AVL's and so users will only be able to pull parts from the Approved AVL's.    An "A" will appear in the left column for the approved AVL's.  Then the Mfgr, WH and Location will be displayed along with the current inventory status of the part highlighted on the left side of the screen, plus whether or not there has been any quantity allocated to this Work Order or project.    User also has the option to Allow use of non-nettable warehouse locations by checking or unchecking the box located in the Kit Default  Setup screen.
In the center of the right side of the screen,  the Picked Status section, ManEx will display the part manufacturer/mfg. part number, kit qty, over issued qty, and lot code for the work order.

In the lower right side of the screen, Mfgr part number, Lot code information, Part Class, Type, source, Work Center, and Description, about the inventory part highlighted in the upper right side of the screen, along with the Product number and Revision.

The user first selects a part from the kit status section.

Place the cursor on a part manufucturer in the inventory status screen and drag it to the Picked Status section in the center of the right side of the screen. To drag, place the cursor on the line indicating an available quantity. Do not remove your finger from the mouse. While you are in the process of dragging, you will see an outline of a hand holding a document. Pull the cursor down to the Pick quantity section. To drop, remove your finger from the mouse. Those manufacturers approved for the bill of material will have the manufacturer preceded with an A.

When you first enter the ISSUE screen and if you just continue through and Drag & Drop items as described above all of the transactions will be saved to the system upon depressing the Save Record Icon. But as soon as you depress the Next button the system will begin to save the records immediately and the Save and Cancel icons will became inactive. This has been added so our users can begin real-time kitting and since intended for a wireless network connection we need to save individual pulled records instead of the entire kit pull save. Below is a description of how this feature is intended to operate:

1. User has a Pull Cart with a wireless laptop along with a wireless label printer.
2. The barcode scanner will be hooked to the laptop.
3. User takes the Kit Pick Worksheets with the items needed to be pulled.
4. Goes down the isles and scans the part being pulled and enters in the pick qty.
5. Then depresses the Next button. That record will be saved immediately.
6. Prints the 4 x 3 label by depressing the Print a Label button. (if you need 3 labels, then depress the Print a Label button 3 times).
7. Continue going through pulling parts for that kit as you go through the isles.
8. Then when user is finished pulling parts for that kit they can depress the Done button.

This will then bring them back to the Main Kitting screen.

This field will allow you to type or scan in the Part number you are wishing to pick parts for.

ENTER SERIAL NUMBERS

If the Part Number highlighted in the left column, is a serialized part, highlight the Available Quantity.  Drag and drop into the Pick Quantity space (as described above). The quantity will appear as 0 in pick quantity. Click on pick quantity and manually fill in quantity. The following screen will appear:

All serial numbers for this part number will appear in the left hand column. Highlight the serial numbers you want used for this work order click on the > arrows. They will appear in the right hand column. If you overissued you must highlight the serial numbers for the overissued quantity click on the > arrows and they will appear in the bottom right hand screen. Once the serial numbers that are to be used for this work order appear in the right hand column depress the OK button.

Depress the ‘DONE’ Button or ‘Save’ button.

The completed Main tab screen appears as below:

 

 

 

NOTE:  MRP is designed to calculate from the Kit Shortage and not from the Lead times once the parts have been pulled to the kit and the kit status is changed to "Kit in Process".   Once the parts have been pulled to the kit, the systems is assuming that the shortages are needed by the WO due date, rather than the Prooduction lead time, so MRP then calculates using the due date of the WO as the date the materials must be on hand, MRP no longer takes the production lead time into consideration.

 

AUTO KIT

If you select Auto Kit, user must enter in a password, and the parts will be pulled automatically to the kit. Parts will ONLY be pulled from Stock, Allocation, or Lot Coded Parts and Approved AVL's.  Note:  Auto Kit will NOT pull parts from WO-WIP locations.

If there are serialized parts assigned to the work order you will receive the following message and will NOT be allowed to Auto kit. The system will allow you to auto kit the non-serialized parts within that kit. But if there are any serialized parts you will have to pull those items manually.

If the Bill of Material does not have any components that are kitted, then no kitting will be done.

Kitting Preference Hierarchy

When Kitting

Manex picks from Approved AVL's then in numeric sequence. (1 before 2, 2 before 3, etc.) "99" is the default preference number, if no preferences are entered, then other un-controllable factors affect which is picked first.

If the user wants to have a specific warehouse picked first, then they are to enter a preference number such as "1" in the preference field  within the Quantity Info screen within  Inventory Control Mgmt  . 

 

COMPLETING KIT

 

 

 

When kit is completed, all shortage filled, etc. check the kit complete box, and the date, time, and users initials will defaulted in. This box must be checked when usiing the Unreleased Work Order List  and the Work Center Checklist