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

 

There are two methods of returning an over issue:

Method 1:

For the situation where the user has created a line shortage, before the Work Order has been completed (reached the Finished Goods Inventory Work Center in Production), the user has the option of returning the unused components which were over-issued to the Work Order back into Inventory.

Using the Finding a Kitting & Shortage procedure, find the Work Order with the over-issue (remembering to select ALL). You will note that the shortage column contains a negative amount, as shown in the screen below:

Depress the Edit action button. The following selection will appear: Select the Issue Parts option. Enter password.

1. Highlight the Part Number with the negative shortage.
2. Move the cursor into the Pick Quantity field.
3. Type in the corrected amount of picked quantity that was actually used in the assembly.
4. Depress the Enter key. The actual over-issue will display.  As shown in screen displayed.

 

Depress the Save action button. The difference between the original over-issue and the actual overissue will be returned to inventory. The inventory records will update and the appropriate accounting entry removing the part from WIP will also be made.  (If the parts in WO-WIP have been allocated to another work order/project user will not be able to return the over-issue qty using this method).

Method 2:

This method covers the situation where the user has a reel of 750 parts and he/she doesn't want to count out 500 for the Work Order. All of the 750 is issued by clicking on the quantity in the lower right hand screen of the Issue tab and changing the amount to 750. (Please refer to procedures above regarding the Issue tab.) Then the system will over-issue 250 parts to the Work Order.

Once the assembly has been completed and reaches the Work Center for Finished Goods Inventory, these un-used over-issued parts can now be issued to the next Work Order, or returned to stock, as follows:

Using the Finding a Kitting & Shortage procedure, find the Work Order with the over-issue (remembering to select ALL). 

1. Open the Utility tab.
2. Depress the Close Kit button, the following screen will appear.

  

3.  If then you want the un-used overissue returned to stock, depress the OK button.  Notice that the over issue has disappeared from the Main tab, as shown in the screen below: (If the user does not want the un-used over-issues returned to Raw Materials Inventory, he/she edits the Quantity Transfer Amount at the bottom right hand side of the screen. The user may transfer 0 quantity or any amount up to the amount of the over-issue). 

Once the above steps are completed, the "Qty Transfer" parts are returned to their warehouse location, WIP is relieved, the Quantity on Hand in Raw Materials Inventory is increased in the Inventory Item Master and the appropriate accounting entries are generated. 

 

Lot Coded Parts - If parts have been issued from different Lot Codes with over-issued qty, those over-issued parts are moved to "WO-WIP" location, and the system saves what lots they come from, when the Kit is closed, the system locates all the WO-WIP locations and lot information, and returns it back to the original lot, if the lot is deleted (due to the lot qty is 0), is will re-create it. 

 

Allocated Parts - If a part in WO-WIP is allocated to other work orders/projects, and user chooses to return back to stock, the program will unallocate from the work orders WO-WIP, return to the original location and then re-allocate to the original locatiion,  if user chooses to issue to work order the program will remove the allocation and  cost it to the work order.  

 

 

 

Upon attempting to close a kit, some users may report this type of message that was presented to them.   This more than likely indicates that parts that have been used on the kit are currently in an active Cycle Count or Physical Inventory. Make sure that Cycle Count or Physical Inventory have been posted to Inventory and then attempt to close the kit again.

 

 

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

To obtain the Kit reports, select the Print button from the ManEx action buttons at the top of the screen. 



The following 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.

 

 

Kit Material Availability W/AVL Detail report

Select the appropriate radio on the right hand side of the screen: Customer, Product, Work Order or Simulation.  Select the Customer from the drop down list. Select the Work Order from the drop down list.   Check the Ignore Scrap check box to exclude Scrap % and/or Setup Scrap  from the report. If these boxes are unchecked the report will include the Scrap % and Setup Scrap quantitys if they exist within inventory (regardless of the BOM setup). Depress the OK button.

 

For simulation, select the Product Number from the drop down list. Select the quantity to simulate. Enter OK and the following report will print.

Kit Pick List Work Sheet report

Select the appropriate radio on the right hand side of the screen: Customer, Product, or Work Order. Select the Work Center and depress the > button.  If you want all work centers, depress the >> button. Select the Work Order by highlighting and depress the > button. If you want all of the Work Orders, depress the >> button.  Check the Ignore Scrap check box to exclude Scrap % and/or Setup Scrap  from the report. If these boxes are unchecked the report will include the Scrap % and Setup Scrap quantitys if they exist within inventory (regardless of the BOM setup).  Check or uncheck the radio's  "Suppress Locations with 0 qty" and/or "Suppress Not Used in Kit Items" for the report to display these items or not.  These radios can be setup to default in checked or unchecked within the Inventory Part Class and Type Setup .  This report displays the requirements (from the original BOM) for the selected work order.  This report will NOT display any added Line Item Shortages.  The added line item shortages can be viewed on the Work Order Shortage report.   Depress the OK button.

The following report will be displayed:

Part Labels or Part Labels with Ref Designators

Highlighting the Part Labels or Part Labels with Ref Designators brings up a selection of printers to be used. Highlight the printer and depress the option tab.

The following screen will appear: Select the appropriate radio on the right hand side of the screen: Customer, Product, or Work Order. Select the Customer from the drop down list. Select the Work Order from the drop down list. Depress go and the items that require labels for that work order number will appear in the bottom section of the screen. Type in the qty of labels required and depress OK.

The labels printed will appear like this:

Box Labels

Highlighting the Box Labels brings up a selection of printers to be used. Highlight the printer and depress the option tab.

The following screen will appear: Select the appropriate radio on the right hand side of the screen: Customer, Product, or Work Order. Select the Customer from the drop down list. Select the Work Order from the drop down list. Depress go and the items that require labels for that work order number will appear in the bottom section of the screen. Depress go and the items that require labels for that work order number will appear in the bottom section of the screen Type in the qty of labels required and depress OK.

 

The labels printed will appear like this

Kit Traveler by WC report

Select the appropriate radio on the right hand side of the screen: Customer, Product, or Work Order. Select the Customer from the drop down list. Select the Work Order from the drop down list. Depress the OK button.

The following report will be displayed:

 

Over Issued Material report

Select Inventory type: Internal or Consign. Depress the OK button.

The following report will be displayed:

Work Order Kit & Shortage Issued Material History

Select the appropriate radio on the right hand side of the screen: Customer, Product, or Work Order. Select the Customer from the drop down list. Work Order from the drop down list. Depress the OK button.   This report will also give you Lot Code and Serial Number History for parts used on Work Orders.    The leading zero's for serial numbers will be removed from report.

The following report will be displayed:

Customer Consigned Shortage Summary report

Highlighting Customer Consigned Shortage Summary report brings up a detail screen: Highlight By Work Order or By Part No. Depress the option tab.

The following screen will appear: Select the Customers by highlighting and depress the > button. If you want all customers depress the >> button. Depress the OK button.

The following report will be displayed:

Purchased Part Shortage Summary report -

NOTE:  The kit has to be in process in order for the parts to show as a shortage on the Report

Highlighting Purchased Part Shortage Summary report brings up a detail screen: Highlight By Part No. or By Work Order Due Date   Depress the OK button.    NOTE: This report will ONLY display the actual scheduled qty’s on the PO NOT the ordered qty on the PO.  It will also, ONLY display the next due PO info. it will not display all the Open POs.  (View the PO Detail Report to get the detail PO info)

The following report will be displayed:

Work Order Shortage report or Work Order Detail Shortage report

 

NOTE:  The kit has to be in process in order for the parts to show as a shortage on the Report

Select the appropriate radio on the right hand side of the screen: Customer, Product, or Work Order. Select the Customer from the drop down list. Select the Work Order from the drop down list. Depress the OK button.

The following report will be displayed:

Buildable report or Buildable Report with Top Three Shortages

Select the Customers by highlighting and depress the > button. If you want customers depress the >> button. Depress the OK button. NOTE:  Buildable column will display KNS (Kit not started), or KIP (Kit in Process) until the Kit Complete checkbox is checked in the Kitting module.  At this time the Work Order will be listed on the Buildable reports, and the buildable qty will properly display the correct qty based on any shortages.   The Work Order Released box MUST be checked for this report to work properly. The Buildable reports are intended  to be used during the Scheduling meeting for Production scheduling only.

The following report will be displayed:

Kits to be Closed

For the Kits to close selection, mark the radial for the desired Sort by: Last Complete Date; Work Order; Product Number; Customer: Depress the OK button.   The Estimated Manufacturing Variance being displayed on this report is  calculated by taking the sum of the components (including all overissues (including line shortages)) issued to the work order at their standard cost at the time of the kit close and comparing it to the costed BOM at the time of the kit closing.    Note:  The user will still have the option to disposition the shortages and overages at the time the kit is closed.

Select the appropriate radio on the right hand side of the screen: Customer, Product, or Work Order. Select the Customer from the drop down list. Select the Work Order from the drop down list. Depress the OK button.   This report will display all the Open POs (displayed in Yellow box below) for the parts with shortages per Work Order, displays all shortages including Consigned and Make parts along with the Purchase parts and On-Hand Quantity.  The "Not Available" qty displays what the on-hand qty will be once all open PO's are received, and Kit Shortages fulfilled.

The following report will be displayed:   The "Shortage"   will be the total from Kit Shortages, etc;  the "OH Balance"   will be Available Inventory, and the "Not Available"  displays what the Balance or on-hand qty will be once the Purchase Order has been received, and Kit Shortages fulfilled.  (Multiple of 200 minus shortage of 100 and OH balance of 25 equals a balance of 125).  The report is assuming a head of time that the users will order the minimum/multiple buy qty's setup in the MRP info setup on that part.        

 

As Built Kit History form

Select the appropriate radio on the right hand side of the screen: Customer, Product, or Work Order. Select the Customer from the drop down list. Select the Work Order from the drop down list. Depress the OK button.

The following report will be displayed:

Enter the Inventory Mgmt/Kitting, Allocating & Shortage Management/WO Kitting Schedule   Note:  After activation, "Kitting & Shortage Management" access for each user must be setup in the ManEx System Security module.  Users with “Supervisor Rights” will automatically have access.

Selectr the appropriate radial to display "ALL"  open un-kitted WO's, "BOM's only", or "Released WO" records only. The user may sort by Required Date, Work Order Number, Part Number or Kit Quantity by depressing the appropriate button.

WO Kitting Schedule field definitions

Enter Inventory Mgmt/Kitting, Allocating & Shortage Management/Work Order Shortage Summary List    Note:   After activation, "Kitting & Shortage Management" access for each user must be setup in the ManEx System Security module.  Users with “Supervisor Rights” will automatically have access.  This screen provides complete visibility of component shortages by Work Order, Work Center, and Part Number.  Users can also check the current status of on hand inventory and open orders for a selected part.

The following screen will appear:

The Work Order Shortage Tab

The first screen displayed is the Work Order Shortage Tab. This tab displays open Work Orders which have at least some components pulled and these pulled components are in Work In Process. The user may sort by Work Order Number, Part Number or Due Date by depressing the appropriate button.

To view the shortage, highlight one of the Work Orders and depress the Shortage button (at the bottom of the screen). The following additional information will display:

Shortage Button field definitions

Work Center Shortage Tab

Selecting the Work Center Shortage tab will bring up the following screen:

Pressing on the Work Center field down arrow will display the component shortage by Work Center.

Press on the down arrow in the Work Center box. The following list of Work Centers will display: Select the appropriate Work Center. Once that is selected, the user may sort by Work Order Number or Part Number by depressing on the appropriate button.

Work Center Shortage field definitions

Highlight the part number of interest. Depress the Open PO button

Highlight the Part Number of interest. Depress the Inventory Status button

Information regarding the highlighted part number will display, showing current Warehouse, Location, quantity On Hand, quantity Allocated, quantity Available, Manufacturer name and Manufacturer Part Number.

Part Number Shortage Tab

Selecting the Part Number Shortage tab will bring up the following screen:

This is a list of component part numbers where shortages exist.

Part Number Shortage field definitions

Top of Screen

Bottom of Screen (for the part number highlighted)

Highlight the part number of interest. Depress the Open PO button

Highlight the Part Number of interest. Depress the Inventory Status button

Information regarding the highlighted part number will display, showing current Warehouse, Location, quantity On Hand, quantity Allocated, quantity Available, Manufacturer name and Manufacturer Part Number.

Work Order Shortage Summary List Reports 

Open the tab for which you want the report. Depress the Reports button. Send the report to the appropriate printer. A printed copy of the screen you’ve selected will be available.

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

A Work Order must exist and  be released.

The Item to be allocated must be on the products BOM.

The quantity to allocate must be available in stock (not already allocated).

The manufacturer allocated must be approved on the product BOM.

Inventory Locations  -  User has the ability to sort by Mfgr, Warehouse, Serial #, or Lot Code.  Click on the blue header and the header color will change to Red and sort by that column.

To access this module, select Inventory Mgmt/Kitting, Allocating & Shortage Management/Inventory Allocation

Find an Inventory Allocation

Depress the Find button . The following selection will be presented: If you now the specific part number or range of numbers you are interested in, enter it into the Part number Range fields. You also have the option to find allocations based on Projects, Work orders, Sales Order or Customer Name

For the selections entered into the find criteria screen, the allocations will display in the bottom of the screen for the highlight part number.

 

Enter Inventory Mgmt/Kitting, Allocating & Shortage Management/Inventory Allocation Module

The following screen will appear:

Depress the Allocation Maintenance tab

Depress the Add record action button and type in your password will bring up the following selection. Depress the “Work Order Allocation” button.

The following prompt will appear. If you select “YES” then all available inventory will be allocated automatically to the selected work order. Edit any quantities allocated by selecting the Part Number (highlighted) in the upper screen table and changing the Alloc Qty for the desired manufacturer in the lower part of the screen.  Save after all allocation editing has been completed. If you select “NO” then the system will list out all part used within the Work order (per BOM) and require the users to go through and manually allocate inventory to each desired part.

The following Work Order selection screen will then become available. Select the desired work order by Typing in the Work Order Number or highlight the Work Order and double click.

Particulars regarding that Work Order will populate the screen as displayed below:

1. Highlight the desired part number you want to allocate. Inventory AVL information for that particular part will populate the lower portion of the screen.
2. Type in the amount you want to allocate in the Alloc Qty column.
3. Depress the Save record action button. The screen will update as follows:  

Note that the Avail Qty column has updated to reflect the amount allocated.  The Inventory Master has also automatically updated, and will now display the amount allocated (“reserved”).

 

 

To Change the allocation qty, thus freeing up the amount allocated to a Work Order or Project, first go to the Allocation Maintenance screen. Depress the Edit Record button. The following find record options will be displayed

If you had selected to find per Work Order or Project the following screen will appear which lists all open WO numbers or project numbers with allocations. Type the WO or project number in the red box or double click on the number and the screen below will appear with the allocation information listed.

The following screen will appear, and the user will be allowed to modify the Alloc Qty. 

Highlight the desired part number and modify the Alloc Qty. 

Depress the Save record action button.  The program will unallocate all original qty and allocate the new quantity again.  This will create two records in the Inventory Transaction report

To Un-allocate an allocation, thus freeing up the amount allocated to a Work Order or Project, first go to the Allocation Maintenance screen. Depress the Edit Record button. The following find record options will be displayed

If you had selected to find per Work Order or Project the following screen will appear which lists all open WO numbers or project numbers with allocations. Type the WO or project number in the red box or double click on the number and the screen below will appear with the allocation information listed.

Depress the Delete button.  Enter your password and the following prompt will appear which is defaulted to "No" “No” will allow you to select which ones to un-allocate individually Yes” will un-allocate all items on screen automatically

Highlight the desired part number and then Check mark which items you wish to un-allocate.

Depress the Save record action button and any marked item should now be unallocated and be considered available inventory.

 

If you had selected to find by Part Number the following screen will appear which lists all Part Numbers with allocations. Type the Part number in the red box or double click on the number and the screen below will appear with the allocation information listed.

Depress the Delete button. Enter your password and the following prompt will appear YES” will un-allocate all items on screen automatically “No” will allow you to select which ones to un-allocate individually

Highlight the desired part number and then Check mark which items you wish to un-allocate.

Depress the Save record action button and any marked item should now be unallocated and be considered available inventory.

The Inventory Control Item Master will update automatically. Note: For reports on Allocated Inventory, please refer to the ICM reports