ACTIVANT D2K. Bill of Material User's Guide. Release 3.0 Version 9

Transcription

1 ACTIVANT D2K Bill of Material User's Guide Release 3.0 Version 9

2 This manual contains reference information about software products from Activant Solutions Inc. The software described in this manual and the manual itself are furnished under the terms and conditions of a license agreement. The software consists of software options that are separately licensed. It is against the law to copy the software on any medium, or to enable any software options, except as specifically permitted under the license agreement. In addition, no part of this manual may be copied or transmitted in any form or by any means without the prior written permission of Activant Solutions Inc. From time to time, Activant makes changes to its software products. Therefore, information in this manual is subject to change, and the illustrations and screens that appear in the manual may differ somewhat from the version of the software provided to you. Created by: Yardley Technical Communication 2006, Activant Solutions Inc. All rights reserved. Activant and the Activant logo are registered trademarks and Activant Prophet 21 is a trademark of Activant Solutions Inc. All other company or product names are the trademarks or registered trademarks of their respective companies. Activant Solutions Inc Southfront Road Livermore, CA Release 3.0 Version 9 Publication Date:

3 Table of Contents Preface Overview to the User s Guide...1 How to Use the User s Guide...3 Chapter 1 - Introduction to Bill of Material Processing Overview The Bill of Material Module Features and Benefits The Interface to Other D2K Applications What is a Bill of Material? Single and Multi-Level Bills of Material Kits and Phantom Kits Methods Used to Replenish Kit Item Inventory The Kit Assembly Process Knowledge Check Knowledge Check Answers Chapter 2 - Creating and Maintaining a Bill of Material Overview The Bill of Material Creation Process The MNT.BOM Function How to Create a New Bill of Material (MNT.BOM) How to Copy a Similar Bill of Material (MNT.BOM) The COPY.KIT Function How to Copy an Identical Bill of Material Structure (COPY.KIT) The BOM.MASS.REPLACE Function How to Replace or Delete Components in all Kits (BOM.MASS.REPLACE) Knowledge Check Knowledge Check Answers Continued on next page i

4 Table of Contents, Continued Chapter 3 - Entering and Printing Kit Orders Overview What is Allocation? Released and Unreleased Kit Orders The Kit Order Entry Process How Kit Orders Affect Inventory Using the IVC.ACTIVITY Function to Monitor Kit Orders The ENTER.KIT.ORDER Function Allocation of Components on a Kit Order How to Create a Kit Order (ENTER.KIT.ORDER) How to Release a Kit Order for Allocation (ENTER.KIT.ORDER) The PRINT.KIT.PACKET Function The Kit Order and Picklist Documents How to Print a Kit Order or Picklist (PRINT.KIT.PACKET) How to Delete a Kit Order (ENTER.KIT.ORDER) Knowledge Check Knowledge Check Answers Chapter 4 - Picklist Processing for Kit Orders Overview The Kit Order Picklist Process How Picklist Processing Affects Inventory The Options Used to Update Kit Picking Information The BOM.TRANSACTIONS Function - Pick Reporting Screens How to Confirm Kit Order Picking Information (BOM.TRANSACTIONS - Option 1) How to Enter Kit Order Picking Information (BOM.TRANSACTIONS - Option 2) Guidelines for Canceling Component Allocations Knowledge Check Knowledge Check Answers Continued on next page ii

5 Table of Contents, Continued Chapter 5 - Kit Receipts Overview Section A - An Overview of the Kit Receipt Process Overview...5-A-1 The Kit Receipt Process...5-A-3 How Kit Receipts Affect Inventory...5-A-5 Cost Updates Performed by Kit Receipts...5-A-7 Knowledge Check...5-A-8 Knowledge Check Answers...5-A-9 Section B - Kit Receipts and Reversals Overview... 5-B-1 The Options Used to Enter Kit Receipt Information... 5-B-3 The BOM.TRANSACTIONS Kit Receipts Entry Screen... 5-B-5 The BOM.TRANSACTIONS Picked Quantities Entry Screen... 5-B-9 The BOM.TRANSACTIONS Lot Number Entry Screen... 5-B-13 The BOM.TRANSACTIONS Component Lot/Serial Number Screen... 5-B-15 The BOM.TRANSACTIONS Kit Receipts Reversal Screen... 5-B-19 The BOM.TRANSACTIONS Reversal Component Putaway Screen... 5-B-21 Guidelines for Entering Kit Receipts... 5-B-22 How to Enter a Kit Receipt (BOM.TRANSACTIONS - Option 3)... 5-B-23 Guidelines for Reversing a Kit Receipt... 5-B-29 How to Reverse a Kit Receipt (BOM.TRANSACTIONS - Option 4)... 5-B-30 Knowledge Check... 5-B-34 Knowledge Check Answers... 5-B-36 Chapter 6 - Phantom Kit Processing Overview What is a Phantom Kit? Constants Which Control Phantom Kit Processing The Phantom Kit Process Example: Entering a Phantom Kit on a Sales Order Printing the Bill of Material Structure for a Phantom Kit How Phantom Kit Processing Affects Inventory Knowledge Check Knowledge Check Answers Continued on next page iii

6 Table of Contents, Continued Chapter 7 - Kit Reports and Inquiries Overview Key Inquiries and Reports Finding the Report or Inquiry You Want The Kit Receipts Cost Register (KIT.RECEIPT.AUDIT) The Kit Comparison Report (COMPARE.KIT) The Kit Listing Report (LIST.KITS) The Where Used Audit Report (LIST.ALL.WU) The Unreleased Kit Orders Report / Inquiry (SHOW.UNRELEASED.KITS) The Bill of Material Inquiry (SHOW.SLK) The Where Used Inquiry (SHOW.SL.WU) Creating Custom Bill of Material Reports Using IEP Knowledge Check Knowledge Check Answers Summary Putting These Ideas to Work iv

7 Overview to the User s Guide Preface Introduction Welcome to the Bill of Material User s Guide. We hope you enjoy learning about your D2K system. We also hope you will use all of the resources available to you to learn the Bill of Material D2K module as thoroughly as possible. Purpose The purpose of this User s Guide is to introduce you to the Bill of Material module, and to provide procedures and guidelines for using the functions within the module. This User s Guide has been designed as both a self-study training tool and a reference manual. Objectives Upon completion of this User s Guide, you will be able to describe the Bill of Material module describe the differences between kits and phantom kits identify the three methods of processing kit order processing create and maintain a bill of material using a variety of methods and functions describe the Kit Assembly Order process create and print a kit assembly order allocate component inventory to a kit order describe the kit order picklist process confirm and/or enter kit order picking information cancel component allocations created by kit assembly orders describe the kit receipt process enter receipts against an existing kit order, or receive a kit directly reverse a kit receipt describe phantom kit processing, and identify reports and inquiries available in the Bill of Material module. Continued on next page Preface 1

8 Overview to the User s Guide, Continued Guide content This guide contains the following chapters: Chapter 1 - an introduction to Bill of Material processing Chapter 2 - guidelines for creating and maintaining bills of material Chapter 3 - procedures for entering and printing kit assembly orders Chapter 4 - procedures for confirming and entering kit picking information Chapter 5 - procedures for receiving kit assembly orders, and for receiving kit items directly into inventory (1-Stage method) Chapter 6 - an overview of phantom kit processing Chapter 7 - a description of reports and inquiries found in the Bill of Material module Summary - a summary of this user s guide 2 Preface

9 How to Use the User s Guide Introduction This User s Guide has been designed as both a self-study training tool and a reference manual. Audience The concepts and procedures presented in this guide are appropriate for new D2K Bill of Material users. Note: If you are already familiar with D2K, you may find the procedures in this guide to be helpful as you perform your job tasks. Recommended prerequisite We recommend that you complete the D2K System Conventions User s Guide before completing this guide. D2K System Conventions User s Guide provides you with the basic D2K concepts and navigation instruction that you will need to complete this guide. Customizing your User s Guide This is your User s Guide. Please make notes and customize the guide to help you complete the tasks for your job. Menus, screens, and prompts This User s Guide displays standard D2K menus, screens, and prompts. Your system may be customized to meet your company s needs. Therefore, your menus, screens, and prompts may not look the same. We provide a space called Accessing the function with each procedure in this guide. This space is for you to write in your system s menu path to each function. Example: Use the boxes below to write your menu path to the AGE.AR function. DIST-2000 D2K GA AR AR.RPTS AGE.AR Continued on next page Preface 3

10 How to Use the User s Guide, Continued The learning environment To help you learn the contents of this guide, your System Administrator will provide a place where you can work without interruption follow your progress assist when difficulties arise, and clarify the content when you need further explanation. Review chapter objectives Your first step in completing this guide is to review the objectives displayed in each chapter s overview. If the material the objectives cover seems unfamiliar, assume that you need to study the entire chapter s content. Knowledge checks This User s Guide provides knowledge checks at the end of each chapter, that will assess your learning of Bill of Material concepts. Answers to the knowledge check are found on the pages following the questions. Responding to the knowledge checks helps you evaluate your learning. Review the text if you have trouble answering the questions correctly. Proceed at a comfortable rate. If you reach your limit of concentration, stop at a natural division in the text so that you can continue later without difficulty. Completion time The time you need to complete this guide depends on your previous experience with the concepts, and on the pace you set for your learning. The average time estimate for completion of this guide is 2 to 4 hours. 4 Preface

11 Chapter 1 Introduction to Bill of Material Processing Overview Introduction D2K is designed to integrate processing between the sales entry, inventory control, purchasing and accounting departments. When a customer orders an item that is assembled from multiple components, the transaction initiates a series of processes that affect these many areas of your business. The Bill of Material (BOM) module contains the necessary tools to manage the kit picking and assembly process, and to accurately control on hand balances and cost data for kit items and their components. Purpose The purpose of this chapter is to introduce the Bill of Material module, which is used to create and maintain kit and phantom kit structures, and to process assembly orders for kits. This chapter will also describe the kit order process. Depending on your system setup and processing requirements, your company will use one of three methods described in this section to replenish inventory for kit items. Objectives Upon completion of this chapter, you will be able to describe the Bill of Material module, and identify its major processes identify the features and benefits of the Bill of Material module describe the system integration of the Bill of Material module with other D2K applications define terminology used in the Bill of Material module define single and multi-level Bills of Material describe the differences between kits and phantom kits identify the methods used to replenish kit inventory, and describe the kit order process. Introduction to Bill of Material Processing 1-1

12 The Bill of Material Module Introduction The Bill of Material module (BOM) is supports the creation, maintenance, and processing of kit and phantom kit items. Kits and phantom kits A kit is a collection of components that are assembled for stock. A phantom kit is a collection of components that are assembled only when a sales order is generated for it. Note: You will learn more about kits and phantom kits later in this chapter. Description The Bill of Material module (BOM) is designed to create and maintain kit and phantom kit structures, and to process internal assembly orders for kits. Using the BOM functions, the user ensures that all components are available early enough to complete picking and assembly activities before a kit item is due to be shipped or transferred. In addition, the sales order entry clerk can check component availability when an order is placed for a phantom kit item (one assembled at the time of shipment). The BOM module includes the following major processes: kit and phantom kit creation and maintenance calculation of kit costs kit order entry, allocation, picking, and receipt inventory updating for kit and component items kit order and picklist printing, and build customized kits or phantom kits in sales functions (Configure to Order). The Bill of Material module also has the reporting capability to provide important inventory and assembly information to all areas of your business. Continued on next page 1-2 Introduction to Bill of Material Processing

13 The Bill of Material Module, Continued Example 1 Sunco Pool Service sells and installs above ground pools, spas, and other supplies. Pools are sold as a complete package, including all necessary chemicals, supplies, and liner. Sunco pre-builds and stocks these pool packages in their warehouse, in anticipation of their busy seasonal business. Using the Bill of Material module, kits are created to identify the component items needed to build each pool. Kit orders are generated prior to the start of their selling season, to stock the warehouse. Once a kit is assembled, the kit order is received, updating the kit on-hand, and reducing component quantities. By automatically updating the cost of the kit with component item costs, Sunco s management can then determine the proper selling price for each pool to insure their target gross profit. Example 2 EJ s Specialty Gifts is a nationwide mail-order distributor, who sells gift, gourmet, and fruit baskets. Since their items consist of perishable goods, customer orders are picked, packaged, and shipped the day prior to the requested delivery date to assure the highest quality in their product. Baskets are not built to stock, but are assembled when the customer order is ready for shipment. Using the Bill of Material module, phantom kits are created to identify the component items needed to build each basket. When a customer places an order for a basket, the phantom kit s bill of material structure is printed on the sales order document. The basket is assembled, and component inventory is relieved once the sales order is invoiced. Note: For more information about phantom kits, refer to the topic Kits and Phantom Kits in this chapter. Learning advice While the creation of customized kits and phantom kits in sales functions (Configure to Order) is a major process in the Bill of Material module, it is not covered in this user s guide. For more information on this feature, refer to the Configure to Order (CTO) User s Guide for Learning and Reference. Introduction to Bill of Material Processing 1-3

14 Features and Benefits Introduction There are many features and benefits to using the Bill of Material module. Features and benefits The table below describes some of the features of the Bill of Material module and their benefits. Feature Ability to create single or multiple level kit structures. Ability to replace one component with another in all kits. Allows a kit structure to be copied to another. Ability to create and maintain kit orders. Ability to enter a kit order start and due date. Allows kit orders or picklists to be printed. Optionally skip the kit order entry process, and enter kit receipts directly. Ability to revalue the kit cost by rolling-up the component costs used to build the finished good. Benefit Defines the complete structure of the finished good, and allows component quantities and kit costs to be adjusted automatically through the BOM process. Eliminates the need to perform maintenance on individual kits when a component item is replaced due to unavailability or obsolescence. Saves operator entry time when two kit structures are almost identical. Allows component requirements for kit orders to be considered when planning new purchases with vendors. Allows assembly time to be considered when planning how to fulfill kit order requirements. Provides the user with a source document for gathering components needed to assemble the kit. For businesses where kit assembly time is minimal, this allows inventory quantities to be properly updated for both the kit and component items without having to create a kit order. Eliminates manual calculation of the kit cost, and prevents errors when valuing kit inventory. 1-4 Introduction to Bill of Material Processing

15 Figure 1-1. The Interface to Other D2K Applications. Sales Order Processing General Ledger Bill of Material Purchasing Inventory Control Introduction to Bill of Material Processing 1-5

16 The Interface to Other D2K Applications Introduction The Bill of Material module interfaces with many other D2K applications. Illustration Figure 1-1 is an illustration showing how the Bill of Material module interfaces to other D2K applications. Interfacing applications The table below describes how the Bill of Material module interfaces to other D2K applications. Application Sales Order Processing Description The Sales Order Processing module (SOP) is used to sell merchandise to your customers. The interface to the Bill of Material module allows the order entry clerk to check component availability when an order is placed for a phantom kit allows the order entry clerk to build customized kits on the fly, and Purchasing posts sales demand to kit items, which can alert management to the need to assemble additional kits. The Purchasing module (PUM) is used to replenish on-hand stock. The interface to the Bill of Material module allocates inventory to open kit orders when a purchase order is received for components needed to build kit assemblies, and creates a need for a purchase order when a kit assembly order depletes component stock. Continued on next page 1-6 Introduction to Bill of Material Processing

17 The Interface to Other D2K Applications, Continued Interfacing applications (continued) Application Inventory Control Description The Inventory Control module (IVC) provides accurate and current inventory status information for kits and components. The Bill of Material module will decrease component inventory and increase kit inventory when a kit assembly order is received, and General Ledger decrease component inventory when a phantom kit item is invoiced. The General Ledger module (GL) reflects changes to assets due to inventory entries. General ledger entries are made when kit orders are received, and when the material cost of the kit is updated based on component costs (dependent on your system s BOM Receipts Costing option). Introduction to Bill of Material Processing 1-7

18 What is a Bill of Material? Definition A bill of material defines the structure of an item that is assembled from components. Once assembled, it may be stocked, and is sold as a unique item number. Example American Tool Supplies stocks and sells tool sets. An item number is created in the Item Master file to identify the finished tool box: Item # TB1000. A bill of material is created in the Bill of Material file, identifying the item s structure (the components and quantities used to assemble the item). TB1000 is made up of the following component item numbers: 1 box 1 hammer (Component # 24992) (Component # ) 2 screwdrivers 1 pliers (Component # ) (Component # 109) 1 needle-nose pliers and 1 wrench (Component # 105) (Component # ) Conclusion The Item Master TB1000 holds information about the finished good, such as item description, list price, weight, and product line. The bill of material for item TB1000 holds information about the item s structure. It identifies the component item numbers and quantities needed to build one tool set. 1-8 Introduction to Bill of Material Processing

19 Single and Multi-Level Bills of Material Introduction The D2K system allows you to create and maintain both single and multilevel bill of material structures. Definitions A single level bill of material is a structure that is assembled using only components which are purchased from an outside source. A multi-level bill of material is a structure whose assembly contains at least one component which is itself assembled as a bill of material (a kit within a kit). Example: Single level BOM On the previous page, the tool box was an example of a single level bill of material. TB1000 was made up of components, all of which are purchased from an outside source. Continued on next page Introduction to Bill of Material Processing 1-9

20 Single and Multi-Level Bills of Material, Continued Example: Multi-level BOM An example of a multi-level bill of material would be when the box (Item # 24992) is not purchased, but assembled itself as a kit, using one metal casing (Item # MT-653) and two plastic shelves (Item # SH-700). This kit item is then used as a component in another bill of material: Kit Item # 24992: 1 metal casing 2 plastic shelves (Item # MT-653) (Item # SH-700) Kit Item # TB1000: 1 box 1 hammer (Item # 24992) (Item # ) 2 screwdrivers 1 pliers (Item # ) (Item # 109) 1 needle-nose pliers and 1 wrench (Item # 105) (Item # ) 1-10 Introduction to Bill of Material Processing

21 Kits and Phantom Kits Introduction A bill of material defines the structure of an item that is assembled from components. On your D2K system, this item may be defined as either a kit or a phantom kit. Definition: kit A kit is a collection of components that are assembled into a finished good. The item (or kit) can then be stocked and sold. For example, a first aid kit is made up of individual items, but when the components are packaged, they become part of a separate, distinct product (kit). When a customer orders a kit item, inventory is committed for the kit. To replenish inventory for a kit, an internal kit order is entered through the ENTER.KIT.ORDER function. Kits are received into inventory through the kit receipt process, where inventory is automatically reduced for the component items and increased for the kit (finished good). When the sales order is invoiced, inventory is reduced for the kit item. Definition: phantom kit A phantom kit is an item that is not preassembled or stocked in inventory. The phantom kit is a collection of components which are assembled only when a sales order is generated for it. When a customer orders a phantom kit item, inventory is committed for the components of the phantom kit. Typically, the kit structure is printed on the order or picklist document, and the phantom kit is assembled as the components are picked. When the sales order is invoiced, inventory is reduced for the components. Inventory replenishment processes do not plan for phantom kits, but do plan inventory for the components. Continued on next page Introduction to Bill of Material Processing 1-11

22 Kits and Phantom Kits, Continued Identifying an item as a kit or phantom kit An item is identified as a kit or a phantom kit using the Replenishment Code field in the item maintenance function. This code identifies the source of inventory replenishment for the item. Note: K = Kit PK = Phantom Kit MNT.ITEM - Create, Maintain Item Record General Info "ADD" Mode Item/Part Nbr TB Description TOOL BOX 03 Extended Desc.01) Entries.02) 17 List Price 04 GL Account Number 05 Internal Item Nbr COST DATA Item Status Code A Active 18 Material 07 Replenishment Code K KIT 19 Burden 08 Sales Product Code 20 Freight 09 Lot Tracing Flag 14 Serial Nbr Trace 21 Other 1 10 Nonstock Flag 15 Direct Ship Flag 22 Other 2 11 Inventory ABC Class 16 MSDS Nbr 12 ABC Cls Update Code 13 Product Line Code UNITS OF MEASURE INFORMATION Base/Stocking U/M EA Each Qty/ 24 Sales U/M EA Each Pack 1 26 Costing U/M EA Each 27 Pricing U/M EA Each Purchasing U/M Change Which Field, END, TOP, \P... Learning advice You will learn more about phantom kit processing in Chapter Introduction to Bill of Material Processing

23 Methods Used to Replenish Kit Item Inventory Introduction As you just learned, kit items are pre-assembled and stocked in the warehouse for sale. Your D2K system provides flexible software to manage the process of replenishing a kit item s inventory. This process may require a 1, 2, or 3 Stage method, depending on your system setup and business requirements. Methods Your company may choose to replenish kit item inventory using one of these three methods: Method Description Used when 1-Stage Receipt Processing only. The kit is received directly (no kit order is entered), increasing kit inventory and decreasing component inventory. balances. 2-Stage Order and Receipt Processing. A kit order is entered, and components allocated. The kit order is then received, increasing kit inventory and decreasing component inventory. 3-Stage Order, Picklist, and Receipt Processing. A kit order is entered, and components allocated. Components are picked, and the inventory quantities moved to a work in process location. The kit order is then received, increasing kit inventory and decreasing component inventory. kit assembly time is short, and the main objective for the BOM module is to properly update component and kit inventory the facility does not use Multiple Location processing, and when kit assembly time is significant. This method allows entry of a kit order prior to, or at the time a kit needs to be assembled. Order processing assists the replenishment planning process by reporting the allocation of components to kit orders. the facility uses Multiple Location processing, when components are held in a work in process location for assembly, and when kit assembly time is significant. This method assists the replenishment planning process as above, plus separates components reserved for kit orders within the inventory data base. Introduction to Bill of Material Processing 1-13

24 Figure 1-2. The Full Kit Assembly Process. User creates Kit Order. System allocates components. Order Processing User prints Kit Assembly Order or Picklist. System allocates inventory on orders with shortages. User picks components User updates Kit Order with quantities picked. Inventory is moved to a "KIT.WIP" location. Picklist Processing User assembles kit. Receipt Processing User prints BOM receipts audit report. User receives assembled kits against Kit Order. System updates inventory. If necessary, user reverses kit receipts. System may update kit costs Introduction to Bill of Material Processing

25 The Kit Assembly Process Description The full kit assembly process is broken down into three major stages. Your company may use one, two, or all three stages as described below. Order Processing: A kit order is entered to track the request for assembly of a kit. Note: Components needed to build the kit are determined by the bill of material structure. The system allocates available component inventory to an in picking status, based on system options when the kit order is filed. Kit orders or picklists may be printed for internal processing. Note: The system will attempt to re-allocate component inventory to kit backorders (orders where shortages existed). Component items are picked by warehouse personnel. Picklist Processing: (Multiple Location users only) The kit order is updated with the component quantities picked. Inventory is moved from the component stock locations to a work in process location. Receipt Processing: The kit is assembled by warehouse personnel. The kit is received against the kit order, increasing the kit on-hand and reducing the component on-hand. Illustration Figure 1-2 is an illustration of the full kit assembly process. Process The table below describes the full kit assembly process. Stage Description Order Processing 1 The user creates a kit order, requesting the assembly of a kit item for stock (ENTER.KIT.ORDER). 2 The system allocates available components to an in-picking status based on system options when the kit order is filed. Continued on next page Introduction to Bill of Material Processing 1-15

26 The Kit Assembly Process, Continued Process (continued) Stage Description 3 The user may print a kit order or a kit picklist for internal processing (PRINT.KIT.PACKET). Note: If components were not allocated when the kit order was created due to insufficient stock, the system rechecks inventory levels and allocates components whenever kit picklists are generated. 4 The user picks component items from stock. Picklist Processing 5 If using Multi-Location Processing, the user updates the kit order, confirming component quantities picked and moving inventory to a work in process location (BOM.TRANSACTIONS). Receipt Processing 6 The user assembles the kit. 7 The user receives assembled kits against the kit order, increasing the kit item s on-hand quantity and reducing the component items on-hand quantity (BOM.TRANSACTIONS). Note: If the system uses Average or Replacement Costing for bill of material receipts, the cost for the kit item may be adjusted when the kit order is received. 8 The user may print an audit report showing kit receipts and changes to kit item cost (KIT.RECEIPT.AUDIT). 9 If necessary, the user may reverse kit order receipts when processing errors occur, or when a kit is disassembled (BOM.TRANSACTIONS). Learning advice You will learn more about the affects to kit and component inventory during each of the three major stages in the following sections of this chapter Introduction to Bill of Material Processing

27 Knowledge Check Directions Answer the following questions. This knowledge check is based on the objectives stated in the beginning of this chapter. Question 1 Name four major processes that are considered part of the Bill of Material module. Question 2 Mark these statements true or false. TRUE or FALSE TRUE or FALSE TRUE or FALSE On the D2K system, a kit structure must always be a single-level bill of material. The BOM module allows you to optionally skip the kit order entry process, and enter kit receipts directly. The BOM module automatically increases component inventory and decreases kit inventory when a kit assembly order is received. Question 3 Which of these statements best defines a bill of material? a. Holds information about the finished good, such as item description, list price, weight, and product line. b. Provides the user with a source document for gathering components needed to assemble the kit. c. Defines the structure (components and quantities) used to assemble a kit or a phantom kit item. d. Defines the assembly process, including step-by-step instructions, for a kit or a phantom kit item. Continued on next page Introduction to Bill of Material Processing 1-17

28 Knowledge Check, Continued Question 4 What is the difference between a single and multi-level bill of material? Question 5 Read the following scenario, then complete the statements by circling the correct answer found in the parentheses: Wright s Container Store sells closet shelving and drawers. When a customer orders shelving, it can be purchased for a standard closet dimension, or for any custom dimension and configuration. a. Wright s stocks pre-packaged shelving sets for 8 foot, 10 foot, and 12 foot closets. These types of pre-packaged items, stocked in the warehouse, are examples of (kit or phantom kit) items. a. When a customer orders a special dimension or configuration, Wright s will package all the necessary shelving and material as a custom set at the time of sale. This type of item is an example of a (kit or phantom kit) item. Question 6 Describe the three methods in which kit orders may be processed: 1-Stage: 2-Stage: 3-Stage: Continued on next page 1-18 Introduction to Bill of Material Processing

29 Knowledge Check, Continued Question 7 In order to use Picklist Processing for kit orders (where components are held in a work in process location for assembly), the facility must be set up to use. What s next? Compare your answers to the ones provided on the next page. The information in this chapter provides a foundation for other chapters within this user s guide. If you were unable to complete this knowledge check, please review the chapter before proceeding. If you are still uncomfortable with the information provided, or have specific questions regarding your system, contact your System Administrator or D2K Customer Care Consultant. Introduction to Bill of Material Processing 1-19

30 Knowledge Check Answers Answer 1 Name four major processes that are considered part of the Bill of Material module. (your answers may be any of the four listed below) kit and phantom kit creation and maintenance calculation of kit costs kit assembly order entry, allocation, picking, and receipt inventory updating for kit and component items kit assembly order and picklist printing, and kits on the fly creation in sales functions (Configure to Order). Answer 2 Mark these statements true or false. TRUE or FALSE On the D2K system, a kit structure must always be a single-level bill of material. Explanation: The D2K system supports both single and multi-level bill of materials. TRUE or FALSE TRUE or FALSE The BOM module allows you to optionally skip the kit order entry process, and enter kit receipts directly. The BOM module automatically increases component inventory and decreases kit inventory when a kit assembly order is received. Explanation: When a kit assembly order is received, component inventory is decreased, and kit inventory is increased. Continued on next page 1-20 Introduction to Bill of Material Processing

31 Knowledge Check Answers, Continued Answer 3 Which statement below best defines a bill of material? c. Defines the structure (components and quantities) used to assemble a kit or phantom kit item. Answer 4 What is the difference between a single and multi-level bill of material? A single level bill of material is a structure that is assembled using only components which are purchased by the user. A multi-level bill of material is a structure whose assembly contains at least one component which is itself assembled as a bill of material. Answer 5 Read the following scenario, then complete the statements by circling the correct answer found in the parentheses: Wright s Container Store sells closet shelving and drawers. When a customer orders shelving, it can be purchased for a standard closet dimension, or for any custom dimension and configuration. a. Wright s stocks pre-packaged shelving sets for 8 foot, 10 foot, and 12 foot closets. These types of pre-packaged items, stocked in the warehouse, are examples of kit items. a. When a customer orders a special dimension or configuration, Wright s will package all the necessary shelving and material as a custom set at the time of sale. This type of item is an example of a phantom kit item. Continued on next page Introduction to Bill of Material Processing 1-21

32 Knowledge Check Answers, Continued Answer 6 Describe the three methods in which kit orders may be processed: 1-Stage: Receipt Processing only The kit order is entered and received at the same time, increasing kit inventory and decreasing component inventory. 2-Stage: Order and Receipt Processing A kit order is entered, and components allocated. The kit order is then received, increasing kit inventory and decreasing component inventory. 3-Stage: Order, Picklist, and Receipt Processing A kit order is entered, and components allocated. Components are picked, and their inventory quantities are moved to a work in process location. The kit order is then received, increasing kit inventory and decreasing component inventory from the work in process location. Answer 7 In order to use Picklist Processing for kit orders (where components are held in a work in process location for assembly), the facility must be set up to use Multiple Location Processing Introduction to Bill of Material Processing

33 Chapter 2 Creating and Maintaining a Bill of Material Overview Introduction One of the most crucial parts of the bill of material process involves the creation and maintenance of the bill of material structures. The structure, which identifies the components and quantities used to build the kit, must be correct in order for the D2K system to commit and relieve component inventory accurately. Purpose The purpose of this chapter is to describe how a bill of material is created on the D2K system. The functions used to build and maintain bills of material are described, and procedures to use these functions are provided. Objectives Upon completion of this chapter, you will be able to describe the processes of creating a bill of material describe the MNT.BOM function, and identify its key fields create a bill of material using MNT.BOM describe the COPY.KIT function, and identify its key fields copy and modify a bill of material using COPY.KIT describe and identify the key fields in the BOM.MASS.REPLACE function, and replace or delete components from all bills of material using the BOM.MASS.REPLACE function. Creating and Maintaining a Bill of Material 2-1

34 Figure 2-1. The Bill of Material Creation Process. Create component items (MNT.ITEM) Create kit item (MNT.ITEM) Create BOM structure using one of these methods: First Method: Copy BOM structure using COPY.KIT Yes Is the BOM EXACTLY like an existing BOM? No Access MNT.BOM function Second Method: Is the BOM SIMILAR to an existing BOM structure? No Create new BOM by identifying its components and quantities Yes Third Method: Copy BOM structure from a similar kit, making changes to components & quantities 2-2 Creating and Maintaining a Bill of Material

35 The Bill of Material Creation Process Description There are three major steps to creating a bill of material: create the component Item Master records used in the kit or phantom kit assembly create an Item Master record to identify the kit or phantom kit, and create a bill of material, identifying the components and quantities needed to build the kit or phantom kit. In addition, the D2K system provides three ways in which the bill of material can be created: 1. When the bill of material is exactly the same as an existing BOM, it may be copied using the COPY.KIT function. 2. If the bill of material is similar to an existing BOM, it may be copied and then modified using the MNT.BOM function. 3. If the bill of material is unlike any existing BOM, its structure is created using the MNT.BOM function. Illustration Figure 2-1 is an illustration of the bill of material creation process. Process The table below describes the bill of material creation process. Note: In the process below, the term kit will be used to describe the creation and maintenance of both kit and phantom kit items. Stage Description 1 User creates the component Item Master records to be used in the kit, using an item maintenance function (e.g., MNT.ITEM, or MNT.ITEM-SERIES). 2 User creates the Item Master record used to identify the kit, using an item maintenance function (e.g. MNT.ITEM, or MNT.ITEM- SERIES). Note: The item must have a replenishment source code of K (kit) or PK (phantom kit). Continued on next page Creating and Maintaining a Bill of Material 2-3

36 The Bill of Material Creation Process, Continued Process (continued) Stage Description 3 User creates the bill of material using one of these methods: IF the bill of material is exactly the same as an existing bill of material similar to an existing bill of material unlike any other bill of material THEN the user accesses the COPY.KIT function and copies the BOM structure to a new BOM. accesses the MNT.BOM function and copies the BOM structure from the similar BOM, making any necessary changes to the components or quantities. accesses the MNT.BOM function and creates the BOM structure, identifying its components and quantities. Note: A new kit Item Master record may be created by the MNT.BOM function when copying the bill of material, if this was not done in Stage Creating and Maintaining a Bill of Material

37 Figure 2-2. The MNT.BOM Function. MNT.BOM - Create, Maintain Bills of Material "CHG" Mode Page 1 of 1 Kit Number TB Copy From Kit 03 Description TOOL BOX 04 Base U/M EA Tot Comp Cost Replen Code K KIT 07 Lead Time 2 Ref Component Item Number Component Description Base Qty / Quantity Lne Entries 006 U/M Kit Avail METAL BOX EA HAMMER EA NEEDLE NOSE PLIERS EA PLIERS EA PHILLIPS SCREWDRIVER EA ADJUSTABLE WRENCH EA 1 47 Change Which Line, (A)dd, (F)n, (B)n, (P)n, LT, DELETE, TOP, END:... Creating and Maintaining a Bill of Material 2-5

38 The MNT.BOM Function Description The function MNT.BOM is used to create and maintain single or multi-level bill of material records. It may also create item records for new kits and phantom kits in the Item Master file. MNT.BOM allows you to copy an existing bill of material as the bill of material (structure) for a newly created kit item. This is beneficial when creating a new kit whose structure closely resembles that of another. During the copy process, each component and its quantity in the existing bill of material is duplicated for the new kit's bill of material. The user may then change component quantities, or add and delete components as needed. Illustration Figure 2-2 is an illustration of the MNT.BOM screen. Fields and descriptions The table below describes the key fields on the MNT.BOM screen. Field Kit Number Description A unique identification number associated with the kit item in the Item Master file. This number may be: an existing item number, or a new item number, when the user wants to copy an existing BOM structure and add a record to the Item Master file for the kit or phantom kit. Copy From Kit Note: The function BOM.COMMON identifies common fields which are copied into a new item record added in this function. For more information, refer to the topics The BOM.COMMON Function and How to Define Common Fields in the Configure to Order (CTO) User s Guide. The item number of the kit from which you want to copy the bill of material structure. Note: A response in the Copy From Kit field is required if you are creating a new item record and bill of material, or optional if you are creating a bill of material for an existing item record. Continued on next page 2-6 Creating and Maintaining a Bill of Material

39 The MNT.BOM Function, Continued Fields and descriptions (continued) Field Tot Comp Cost Lead Time Component Item Number Qty / Kit Quantity Avail Description Display only: When creating a new bill of material, the total of the costs of each component, extended by the component's quantity per kit, is displayed. This total is revised and redisplayed each time a change is made to the bill of material in this function. If MNT.BOM creates a new kit item record (when a BOM is copied), this cost is updated to the kit item's Material cost. Material cost is not updated for existing kit item records, but may be changed by using the function MNT.ITEM or MNT.ITEM-SERIES. Material cost for a kit item may also be updated during the kit receipt process, depending on the COST.CONSTANTS Kit Receipt Costing method. The number of calendar days needed to assemble the kit. The item number of the component that is used to build the kit. Notes: The component item number must exist in the Item Master file. All component items must be from the same facility as the kit item. A component may also be a kit, but it cannot be a phantom kit. The quantity of a component that is used to build one kit. Display only: The current quantity available for each component used to build the kit. Quantity available is calculated according to the Net Availability Calculation Rule specified in IVC.CONSTANTS. Note: When using MNT.BOM as an inquiry for a kit structure, this field can be used to identify components with inventory shortages that would prohibit a kit from being assembled. Creating and Maintaining a Bill of Material 2-7

40 How to Create a New Bill of Material (MNT.BOM) Introduction The function MNT.BOM is used to create and maintain bill of material records for kit or phantom kit items. Accessing the function Use the boxes below to write your menu path to the MNT.BOM function. Before you begin Before accessing this function, make sure the kit item and all its components have been created using an item maintenance function. Procedure Complete the steps in the table below to create a new bill of material for either a kit or a phantom kit item. Step Action 1 Access the function MNT.BOM. Result: The prompt Enter the Kit Item Number, NEXT displays. 2 Type the kit item number and press [Enter]. Result: The prompt Enter the Kit Item Number to copy from displays. 3 Press [Enter]. Result: The prompt Enter the Component Item Number displays. 4 Type the component item number to be included in the kit and press [Enter]. Result: The current quantity available for the component appears, and the prompt Enter the Quantity Per Kit, DEL, SUB displays. Continued on next page 2-8 Creating and Maintaining a Bill of Material

41 How to Create a New Bill of Material (MNT.BOM), Continued Procedure (continued) Step 5 Make the following decision: Action IF you want to identify the quantity of the component to use in the kit display a list of substitute item numbers for this component Note: You may want to use a substitute component when the quantity available on the original component is not sufficient to build the kit. THEN type the quantity used to build one kit and press [Enter]. SUB and press [Enter]. Select a substitute component from the list displayed, or type END and press [Enter] to retain the original component. Result: If a substitute was selected, the component item is replaced, and the prompt Enter the Quantity Per Kit, DEL, SUB displays. Type the quantity used to build one kit and press [Enter]. Result: The prompt Enter the Component Item Number displays. 6 Repeat from Step 4 until all components have been added, then press [Enter]. Result: The Command Line Change Which Line, (A)dd, (F)n, (B)n, (P)n, LT, DELETE, TOP, END displays. Continued on next page Creating and Maintaining a Bill of Material 2-9

42 How to Create a New Bill of Material (MNT.BOM), Continued Procedure (continued) Step 7 Make the following decision: Action IF you want to modify the quantity entered on a line THEN type the line number and press [Enter]. Type the new quantity used to build one kit and press [Enter]. delete a line item the line number and press [Enter]. Type DEL and press [Enter]. Note: For the above two options, the cursor will move to the next line item s Qty / Kit column, or to the Command Line (if this was the last line item on the bill of material). You may: enter a new quantity for the component type SUB and press [Enter] to display a list of substitute item numbers for this component press [Enter] to retain the existing quantity type DEL and press [Enter] to delete the line item, or type END and press [Enter] to access the Command Line. identify the number of days needed to assemble the kit LT and press [Enter]. Type the number of calendar days needed to assemble the kit and press [Enter]. Continued on next page 2-10 Creating and Maintaining a Bill of Material

43 How to Create a New Bill of Material (MNT.BOM), Continued Procedure (continued) Step Action 8 Repeat Step 7 as necessary, then type END and press [Enter]. Result: The bill of material is filed. 9 Do you wish to enter another bill of material? If yes, return to Step 2. If no, type END and press [Enter]. Result: You are exited from the function and returned to the menu. Creating and Maintaining a Bill of Material 2-11

44 How to Copy a Similar Bill of Material (MNT.BOM) Introduction The function MNT.BOM can be used to copy a similar bill of material record for a kit or phantom kit item, then maintain its components and/or quantities. Accessing the function Use the boxes below to write your menu path to the MNT.BOM function. Before you begin Before accessing this function, make sure the kit item and all its components have been created using an item maintenance function. Note: The item number which identifies the kit may be created as part of the bill of material creation copy process. When the kit item number is not on file, the system allows you to copy information from the kit item whose bill of material is being copied. Procedure Complete the steps in the table below to copy a similar bill of material for either a kit or a phantom kit item, then make changes to its components and/or quantities. Step Action 1 Access the function MNT.BOM. Result: The prompt Enter the Kit Item Number, NEXT displays. Continued on next page 2-12 Creating and Maintaining a Bill of Material

45 How to Copy a Similar Bill of Material (MNT.BOM), Continued Procedure (continued) Step Action 2 Was the item number used to identify this kit already created using an item maintenance function? If yes, type the kit item number and press [Enter]. Go to Step 4. If no, type the item number that will identify the kit and press [Enter], or type NEXT and press [Enter] for a system-assigned item number. Note: Your system must be set up for next number assignment in the Item Master file to use the NEXT option. Result: The prompt Enter the Kit Item Number to copy from displays. 3 Type the item number of the kit whose bill of material structure you wish to copy and press [Enter]. Create the Item Master Record for the Kit: 4 Does the prompt Enter the Description display? If yes, type a description for the new kit item and press [Enter], or press [Enter] to use the description of the kit being copied. Result: The prompt Enter the Replenishment Source Code displays. If no, go to Step 10. Note: You will be asked to enter general information if the kit item number entered in Step 2 is not found in the Item Master file. Continued on next page Creating and Maintaining a Bill of Material 2-13

46 How to Copy a Similar Bill of Material (MNT.BOM), Continued Procedure (continued) Step 5 Make the following decision: Action IF the item is a kit (assembled to be stocked and sold) phantom kit (not preassembled or stocked) THEN type K and press [Enter]. PK and press [Enter]. Result: The prompt Enter the Kit Lead Time Days displays. 6 Type the number of calendar days needed to assemble the kit and press [Enter], or press [Enter] to use the default displayed. Result: The system displays the component line items from the kit copied, and the prompt Enter the Quantity Per Kit, DEL, SUB displays for the first line item. 7 Make the following decision: IF you want to enter a new quantity for the component display a list of substitute item numbers for this component THEN type the quantity used to build one kit and press [Enter]. type SUB and press [Enter]. Select a substitute from the list displayed, or type END and press [Enter] to retain the original component. Result: If a substitute was selected, the component item is replaced and the prompt Enter the Quantity Per Kit, DEL, SUB displays. Type the quantity used to build one kit and press [Enter]. Continued on next page 2-14 Creating and Maintaining a Bill of Material

47 How to Copy a Similar Bill of Material (MNT.BOM), Continued Procedure (continued) Step Action 7, con d. IF you want to THEN retain the existing quantity press [Enter]. delete the line item type DEL and press [Enter]. access the Command Line type END and press [Enter]. Result: The cursor will move to the next line item s Qty / Kit column, or to the Command Line (if this was the last line item on the bill of material). 8 Repeat Step 7 as necessary until the Command Line is accessed. Result: The Command Line Change Which Line, (A)dd, (F)n, (B)n, (P)n, LT, DELETE, TOP, END displays. 9 Go to Step 13. Create a New Bill of Material Structure: 10 Type the component item number to be included in the kit and press [Enter]. Result: The current quantity available for the component appears, and the prompt Enter the Quantity Per Kit, DEL, SUB displays. Continued on next page Creating and Maintaining a Bill of Material 2-15

48 How to Copy a Similar Bill of Material (MNT.BOM), Continued Procedure (continued) Step 11 Make the following decision: Action IF you want to identify the quantity of the component to use in the kit display a list of substitute item numbers for this component Note: You may want to use a substitute component when the quantity available on the original component is not sufficient to build the kit. THEN type the quantity used to build one kit and press [Enter]. SUB and press [Enter]. Select a substitute component from the list displayed, or type END and press [Enter] to retain the original component. Result: If a substitute was selected, the component item is replaced, and the prompt Enter the Quantity Per Kit, DEL, SUB displays. Type the quantity used to build one kit and press [Enter]. Result: The prompt Enter the Component Item Number displays. 12 Repeat Step 10 as necessary until all components have been entered for the bill of material, then press [Enter]. Result: The Command Line Change Which Line, (A)dd, (F)n, (B)n, (P)n, LT, DELETE, TOP, END displays. Continued on next page 2-16 Creating and Maintaining a Bill of Material

49 How to Copy a Similar Bill of Material (MNT.BOM), Continued Procedure (continued) Step Action Command Line Decisions: 13 Make the following decision: IF you want to modify the quantity entered on a line THEN type the line number and press [Enter]. Type the new quantity used to build one kit and press [Enter]. delete a line item the line number and press [Enter]. Type DEL and press [Enter]. Note: For the above two options, the cursor will move to the next line item s Qty / Kit column, or to the Command Line (if this was the last line item on the bill of material). You may: enter a new quantity for the component type SUB and press [Enter] to display a list of substitute items for this component press [Enter] to retain the existing quantity type DEL and press [Enter] to delete the line item, or type END and press [Enter] to access the Command Line. identify the number of days needed to assemble the kit LT and press [Enter]. Type the number of calendar days needed to assemble the kit and press [Enter]. Continued on next page Creating and Maintaining a Bill of Material 2-17

50 How to Copy a Similar Bill of Material (MNT.BOM), Continued Procedure (continued) Step Action 14 Repeat Step 13 as necessary until all components have been entered correctly for the bill of material, then type END and press [Enter]. Result: The bill of material is filed. Note: If the kit item number was created as part of this procedure, the total component cost is updated to the kit item in the Item Master file. 15 Do you wish to copy and modify another bill of material? If yes, return to Step 2. If no, type END and press [Enter]. Result: You are exited from the function and returned to the menu Creating and Maintaining a Bill of Material

51 Figure 2-3. The COPY.KIT Function. COPY.KIT - Copy a BOM from One Kit to Another 01 Copy from Kit : TB TOOL BOX 02 Copy to Kit : TB TOOL BOX Change Which Field, END, TOP, \P... Creating and Maintaining a Bill of Material 2-19

52 The COPY.KIT Function Description The function COPY.KIT is used to duplicate bill of material structures from one to another. This is done to save entry time when two BOM structures are identical. Slight changes to components and/or quantities can then be made using the function MNT.BOM. Both kit item numbers must exist in the Item Master file, and must be defined as kits or phantom kits. In addition, both kits must be located in the same facility (if multiple facility processing is in use). Illustration Figure 2-3 is an illustration of the COPY.KIT screen. Fields and descriptions The table below describes the key fields on the COPY.KIT screen. Field Copy from Kit Copy to Kit Description The kit number from which the bill of material structure will be copied. This kit must already have a bill of material structure (i.e. the kit structure was previously entered in the function MNT.BOM). The kit number to which the bill of material structure will be copied. WHEN the Copy to Kit does not have a bill of material structure defined has a bill of material structure defined THEN the bill of material structure is created by copying the structure from the Copy From kit. existing components or quantities are not altered; only new components will be copied into the structure from the "Copy From" kit Creating and Maintaining a Bill of Material

53 How to Copy an Identical Bill of Material Structure (COPY.KIT) Introduction The COPY.KIT function is used to copy a bill of material structure (the components and quantities) from one to another when two kits are identical. Accessing the function Use the boxes below to write your menu path to the COPY.KIT function. Procedure Complete the steps in the table below to copy a bill of material structure from one kit to another. Step Action 1 Access the function COPY.KIT. Result: The prompt Enter the Kit Number to copy from displays. 2 Type the kit number to copy and press [Enter]. Note: The kit number to copy must already have its components identified in the MNT.BOM function. Result: The prompt Enter the Kit Number to copy to displays. 3 Type the kit number to copy the bill of material structure to and press [Enter]. Result: The Command Line Change Which Field, END, TOP displays. Continued on next page Creating and Maintaining a Bill of Material 2-21

54 How to Copy an Identical Bill of Material Structure (COPY.KIT), Continued Procedure (continued) Step Action 4 Type END and press [Enter]. Result: The system adds all new components and quantities found in the Copy From kit to the Copy To kit. Errors (such as components not copied) appear and the message Copy Completed. Press <CR> displays. 5 Press [Enter]. Result: You are returned to the menu. Note: If necessary, you may now modify the bill of material structure on the kit just copied using the MNT.BOM function Creating and Maintaining a Bill of Material

55 Figure 2-4. The BOM.MASS.REPLACE Function. BOM.MASS.REPLACE - Replace or Delete a Component in All Kits Item Description 01 Current Item Number METAL BOX 02 Replacement Item Number MOLDED PLASTIC BOX Item Number will be replaced by Item Number in every Kit in which it is used. An Audit Report will be printed later when you exit this function. Change which field, END, TOP:... Figure 2-5. The Product Structure Substitution Audit Report. BOM.MASS.REPLACE 10:36:54 28 APR YYYY Acct ivc Process Product Structure Substitution Audit Report Kit Item Number Component Item Number Qty per Kit Action... TB DELETED TB ADDED TB DELETED TB ADDED Creating and Maintaining a Bill of Material 2-23

56 The BOM.MASS.REPLACE Function Description The function BOM.MASS.REPLACE is used to replace all occurrences of a component item number with a new component item number in all kits. This function is also used to delete all occurrences of a component item number from all kits. If the current item number and the replacement item number are both used in the same kit, the system will add the quantities used of both items to arrive at a new kit quantity. Example: The bill of material for Kit PRS-20 is: Item Number Quantity / Kit If item# 200 is replaced by item# 400, the new quantity per kit of item# 400 will be 4 (the original quantity of 3, plus a replacement quantity of 1, which was the original quantity of item 200). The new bill of material structure would be: Item Number Quantity / Kit Learning advice To replace or delete individual occurrences of item numbers, use the MNT.BOM function. Illustration Figure 2-4 is an illustration of the BOM.MASS.REPLACE screen. Figure 2-5 is an illustration of the Product Structure Substitution Audit Report. This report automatically prints when the BOM.MASS.REPLACE function is exited, and audits changes made to bills of material. Continued on next page 2-24 Creating and Maintaining a Bill of Material

57 The BOM.MASS.REPLACE Function, Continued Fields and descriptions The table below describes the key fields on the BOM.MASS.REPLACE screen. Field Current Item Number Replacement Item Number Description The component item number that will be replaced or deleted from all kits. Identifies the action that will be performed: Operator Entry component item number DELETE Action Performed replaces all occurrences of the Current Item Number with the Replacement Item Number. deletes the component item from all kits that use it. Creating and Maintaining a Bill of Material 2-25

58 How to Replace or Delete Components in all Kits (BOM.MASS.REPLACE) Introduction The BOM.MASS.REPLACE function is used to replace all occurrences of a component number with a new component in all kits. It can also be used to delete all occurrences of a component number in all kits. Accessing the function Use the boxes below to write your menu path to the BOM.MASS.REPLACE function. Procedure Complete the steps in the table below to replace or delete a component number in all kits. Step Action 1 Access the function BOM.MASS.REPLACE. Result: The prompt Enter the Current Component Item Nbr displays. 2 Type the component number to replace or delete and press [Enter]. Result: The prompt Enter the Replacement Item Nbr, DELETE displays. Continued on next page 2-26 Creating and Maintaining a Bill of Material

59 How to Replace or Delete Components in all Kits (BOM.MASS.REPLACE), Continued Procedure (continued) Step 3 Make the following decision: Action IF you want to replace the entered component with a new component number delete the entered component number from all kits THEN type the new component number and press [Enter]. DELETE and press [Enter]. Result: The system displays a message indicating what action will take place, and the Command Line Change which field, END, TOP displays. 4 Type END and press [Enter]. Result: An audit report prints identifying changes to kits, and the message Substitution/Deletion Completed, Press <CR> displays. 5 Press [Enter]. Result: The prompt Enter the Current Component Item Nbr displays. 6 Do you wish to replace or delete another component from kits? If yes, return to Step 2. If no, type END and press [Enter]. Result: You are returned to the menu. Creating and Maintaining a Bill of Material 2-27

60 Knowledge Check Directions Answer the following questions. This knowledge check is based on the objectives stated in the beginning of this chapter. Question 1 Mark these statements true or false. TRUE or FALSE TRUE or FALSE Prior to creating a bill of material using MNT.BOM, all of its component items must first be created using an item maintenance function (MNT.ITEM or MNT.ITEM- SERIES). Prior to creating a bill of material using MNT.BOM, the kit item must first be created using an item maintenance function (MNT.ITEM or MNT.ITEM-SERIES). Question 2 The MNT.BOM function allows you to create the bill of material structure for kit and phantom kit items. How does the system know whether an item is a kit or a phantom kit? Continued on next page 2-28 Creating and Maintaining a Bill of Material

61 Knowledge Check, Continued Question 3 Mark all statements that are true about the function MNT.BOM: a. Allows the user to create a bill of material by identifying all the components and quantities used to assemble one kit. b. Allows you to delete all occurrences of a component item number from all kits. c. Displays the total of the costs of each component, extended by the component s quantity per kit. d. Allows you to identify the number of calendar days needed to assemble a kit item. e. Automatically prints an audit report of changes to bill of material structures once you exit the function. What s next? Compare your answers to the ones provided on the next page. The information in this chapter provides a foundation for other chapters within this user s guide. If you were unable to complete this knowledge check, please review the chapter before proceeding. If you are still uncomfortable with the information provided, or have specific questions regarding your system, contact your System Administrator or D2K Customer Care Consultant. Creating and Maintaining a Bill of Material 2-29

62 Knowledge Check Answers Answer 1 Mark these statements true or false. TRUE or FALSE TRUE or FALSE Prior to creating a bill of material using MNT.BOM, all of its component items must first be created using an item maintenance function (MNT.ITEM or MNT.ITEM- SERIES). Prior to creating a bill of material using MNT.BOM, the kit item must first be created using an item maintenance function (MNT.ITEM or MNT.ITEM-SERIES). Explanation: The kit item may be created in MNT.BOM when copying a bill of material to an item number that does not yet exist in the Item Master file. The required item data for the new kit item will be duplicated from the kit being copied. Answer 2 The MNT.BOM function allows you to create the bill of material structure for kit and phantom kit items. How does the system know whether an item is a kit or a phantom kit? The item for which a bill of material is created must have a Replenishment Source Code of K (kit) or PK (phantom kit) in the Item Master file. Continued on next page 2-30 Creating and Maintaining a Bill of Material

63 Knowledge Check Answers, Continued Answer 3 Mark all statements that are true about the function MNT.BOM: a. Allows the user to create a bill of material by identifying all the components and quantities used to assemble one kit. c. Displays the total of the costs of each component, extended by the component s quantity per kit. d. Allows you to identify the number of calendar days needed to assemble a kit item. Creating and Maintaining a Bill of Material 2-31

64 Chapter 3 Entering and Printing Kit Orders Overview Introduction In Chapter 1, you learned that a kit is a collection of components which are assembled for inventory. When kit inventory runs low, new kits must be assembled to replenish stock. The D2K Bill of Material module is very flexible, allowing the user to choose a 1, 2, or 3-Stage method of replenishing kit inventory. Purpose The purpose of this chapter is to describe the kit order entry and print processes. This chapter will review how a kit order is created, and will discuss how component inventory is allocated. It will then review how to print kit orders or picklists, and also how to allocate component inventory to kit backorders. Objectives Upon completion of this chapter, you will be able to define allocation describe the difference between released and unreleased kit orders describe the kit order entry process describe how kit order affect inventory describe the ENTER.KIT.ORDER function identify the key fields in the ENTER.KIT.ORDER function enter a kit order describe how component inventory is allocated using the Pick Complete Flag describe the PRINT.KIT.PACKET function print kit orders and kit picklists describe how kit and component inventory is affected by the kit order entry and printing functions, and delete a kit order. Entering and Printing Kit Orders 3-1

65 What is Allocation? Introduction One of the benefits to using kit order entry is that the system will allocate available component inventory when the kit order is filed. Definition Allocation is a process of assigning inventory for a specific transaction. On the D2K system, allocated inventory is also defined as inventory In Picking. Note: Inventory quantities In Picking consist of allocations for kit orders, sales orders, and warehouse transfer orders. Example In the illustration below, a kit order has been entered, and a quantity of 25 was allocated for the component. This means that out of the 180 on-hand, 25 have been earmarked for assembly into a kit item. Note: Prior to entering the kit order, the component s In Picking quantity was 0 (zero). LOOK.STOCK - Display Current Availability Info for an Item Page No. 1 Item Number : 100 Description : SCREWDRIVER Ext`d Desc : Facility: 01 MAIN FACILITY Sell UM : EA Each Ship Loc Permanent Loc A1 Replenishment Code LP Storage A Location Total Comm`td In Transfr Sch`ld Available Fac Location F On-Hand On-Hand Qty Picking Qty Qty To Pick 01 A1 Y A2 Y 14 Enter "X" to exit the function, <CR> or "END" to continue... End of Pages to display for this Inquiry 3-2 Entering and Printing Kit Orders

66 Released and Unreleased Kit Orders Introduction When entering a kit order, you must decide whether to create it as a released or unreleased order. It is important to understand the difference between the two. Definitions A released order is one which should immediately allocate component inventory. An unreleased order is one which should not allocate component inventory. Example The kit order entry function allows you to enter kit orders with a start date and a due date. These dates define when the process of picking components must begin to ensure that the kits are assembled and in inventory by the date they are needed. Typically, a business would not want to allocate component inventory to a kit order with a future date. For example, a kit order is created with a start date three weeks from the current date. Since the allocation of components to this kit order would unnecessarily tie up the inventory for a long period of time, the kit order is entered as an unreleased order. Later, when it is closer to the start date, the kit order is maintained and released for allocation. The D2K system provides an Order Status Code in the ENTER.KIT.ORDER function, and a report that shows unreleased kit orders, to facilitate this process. Entering and Printing Kit Orders 3-3

67 Figure 3-1. The Kit Order Entry Process. User determines a need to replenish kit inventory. User enters kit order and identifies "Start Date". No Future Start Date? Yes Order is Released. User files the kit order. Order is created as Unreleased. System allocates components for "Released" orders. User releases kit orders when necessary. User prints or displays SHOW.UNRELEASED.KITS. 3-4 Entering and Printing Kit Orders

68 The Kit Order Entry Process Description Using a 2 or 3-Stage method of kit assembly processing, a kit order is created when the user determines a need to replenish kit item inventory. Orders are entered as either Released or Unreleased, depending on when the kit item needs to be assembled. Component inventory is allocated only for released orders, based on a Pick Complete Flag entered on the order. The user periodically prints the SHOW.UNRELEASED.KITS report, and uses the information to release kit orders at the appropriate time for component allocation. Illustration Figure 3-1 is an illustration of the kit order entry process. Process The table below describes the kit order entry process. Stage Description 1 The user determines a need to replenish kit inventory. 2 The user creates an order in the ENTER.KIT.ORDER function, identifying a start and due date. WHEN the kit order should be assembled immediately in the future THEN the order is entered as a Released order. an Unreleased order. 3 The kit order is filed, and the system allocates component inventory to released orders only, based on the Pick Complete Flag. 4 The user periodically prints the SHOW.UNRELEASED.KITS report, which identifies unreleased kit orders, along with their start and due dates. 5 When appropriate, the user releases unreleased kit orders using the ENTER.KIT.ORDER function. 6 When the kit order is released and filed, and the system allocates component inventory, based on the Pick Complete Flag. Entering and Printing Kit Orders 3-5

69 How Kit Orders Affect Inventory Introduction When a released kit order is filed, the system attempts to allocate component inventory based on the order s Pick Complete Flag. The affect to component inventory after allocation is discussed in the topic What is Allocation? earlier in this chapter. Kit order entry, however, also affects the inventory status of the kit item. Kit item: after filing the kit order In the illustration below, a kit order has been entered and filed for kit item TB1000. Regardless of whether the order is released or unreleased, the system updates the kit item s inventory status, showing the kit order quantity in the Sch ld Qty column. LOOK.STOCK - Display Current Availability Info for an Item Page No. 1 Item Number : TB1000 Description : TOOL KIT Ext`d Desc : Facility: 01 MAIN FACILITY Sell UM : EA Each Ship Loc Permanent Loc B125 Replenishment Code K Storage A Location Total Comm`td In Transfr Sch`ld Available Fac Location F On-Hand On-Hand Qty Picking Qty Qty To Pick Comm td Qty = Customer Sales Orders Sch ld Qty = Kit Assembly Orders Enter "X" to exit the function, <CR> or "END" to continue... The Availability Window (sales functions) The scheduled kit order quantity does not appear in the sales order functions Availability Window for the kit item. The Availability Window displays only scheduled quantities due in on vendor purchase orders. Sales Order Entry - Detail Screen Entries 1 Order Merch Total Del Date Weight Customer Number 100WC YY ACE HARDWARE OF SAN DIEGO Pack On Hand Committed Available In Picking Ref Nbr On Order Due Date EA Item Number UOM Order Qty / Selling Total Description Balance Qty Price Amount 001) TB EA TOOL BOX Entering and Printing Kit Orders

70 Using the IVC.ACTIVITY Function to Monitor Kit Orders Introduction Since scheduled kit order quantities do not appear in the Availability Window in sales functions, a different inquiry is needed to determine if a kit order exists for an item. The IVC.ACTIVITY function provides the necessary information for analyzing inventory replenishment activity for a kit item. Description The Pegged Summary or Pegged Detail screens of the IVC.ACTIVITY function will identify kit orders entered for an item. In the illustration below, Kit Order # 5011 has been entered to replenish stock for the item. The Date listed in the far left column is the Due Date for the kit order. Note: The Balance for the item shows an inventory shortage of 11. Another kit order needs to be processed to fulfill the customer sales order requirement of 36. IVC.ACTIVITY Item Activity 08:40:12 11 JUN 1998 Page 1 Item: TB Base UM EA Description: TOOL BOX Review Group/Type Replen Src K Safety Days Order Plcy Item Status A Safety Qty 0 Order Qty Hold Qty 0 Order Point Days Sply On Hand 0 Plng Type Min Order Pt Order Min Buyer Code Max Stock Order Max Begin Lead Time 10 Order Mult Balance Date Type Ref Qty In Qty Out Balance Avl.Use YY WO 5011 Kit order YY SO 68* End of List Balance of -11 identifies an inventory shortage 6 Select (T)ime Phased, (P)egged Summary, X to Exit, END for New Item:... Entering and Printing Kit Orders 3-7

71 Figure 3-2. The ENTER.KIT.ORDER Function. ENTER.KIT.ORDER - Create, Maintain Kit Assembly Orders "ADD" Mode Kit Order Number : 5001 Kit Number : TB TOOL BOX Base/Stocking UOM : 04 Start Date : YY 05 Due Date : YY 06 Order Quantity : 12 Lot Traceable : Balance Due : Comments and Special Instructions Entries 3.01) Sales Order #40023 has a backorder of 3 for this.02) kit - notify Jim in shipping when this order.03) is complete..04).05) 10 Assembly Location : KIT.WIP Kit Packaging 11 Order Status Code : 3 Released 12 Pick Complete Flg : N Change Which Field, END, TOP, \P Entering and Printing Kit Orders

72 The ENTER.KIT.ORDER Function Description The ENTER.KIT.ORDER function allows the creation and maintenance of internal orders for kit items. A kit order may be created with a start and due date. These dates define when the process of picking the components must start to ensure that the kit is assembled and in inventory when needed. The ENTER.KIT.ORDER function also allocates available component inventory to an In Picking status, based on a Pick Complete Flag. Reference: For more information about allocation of components, refer to the topics What is Allocation? and Allocation of Components on a Kit Order in this chapter. Note Before creating an order, the kit item must have a bill of material defined through the function MNT.BOM. Illustration Figure 3-2 is an illustration of the ENTER.KIT.ORDER screen. Fields and descriptions The table below describes the key fields on the ENTER.KIT.ORDER screen. Field Kit Order Number Start Date Due Date Order Quantity Description A unique identification number which identifies a kit order, which may be system or user-assigned. The date on which the component picking process must begin in order to ensure enough time to complete subsequent activities, such as assembly and shipping, by the kit due date. The date on which an assembled kit is scheduled for receipt to inventory. This date may be determined based on when inventory activity, such as shipment of a sales order, is scheduled to occur. The number of kits to be assembled and sent to inventory. Continued on next page Entering and Printing Kit Orders 3-9

73 The ENTER.KIT.ORDER Function, Continued Fields and descriptions (continued) Field Balance Due Description Display only: The balance quantity of assembled kits due to be received on this kit order. Example: A kit order is entered for a quantity of 36. Because of component shortages, the warehouse assembles and receives only 32 of the kit items. Therefore, the Balance Due on the kit order is 4. Lot Traceable A flag indicating whether the kit item uses lot tracing. Comments and Comments and/or special instructions which apply to Special the kit order. Instructions Assembly Location The warehouse location in which a kit is assembled. The use of this field depends on whether the facility has Multiple Location Processing enabled. Multiple Location The picklist reporting process (3-Stage method) moves components into this location for kit assembly. A default location is defined in IVC.CONSTANTS, and will automatically display in this field. Non Multi-Location May be optionally used as memo information. Note: The Assembly Location prints on the kit order and kit picklist documents, regardless of whether Multiple Location Processing is used. Continued on next page 3-10 Entering and Printing Kit Orders

74 The ENTER.KIT.ORDER Function, Continued Fields and descriptions (continued) Field Order Status Code Description A code indicating the status of a kit order. When creating a kit order, the user must set this code to either a 2 or a 3. The system changes the code after the released order is filed, to indicate the condition of the kit order after component allocation. Code Description User-Assigned Codes 2 Unreleased for picking - order is on hold. Note: Use this code with a future Start Date, when you do not wish to allocate component inventory immediately. 3 Released for picking. When the order is filed, the system allocates component inventory based on availability and the Pick Complete Flag. Note: This is the default setting. System-Assigned Codes 4 Shortage, not allocated. No components were allocated to the kit order due to inventory shortages. 5 Allocated, shortage. Some of the components were allocated to the order, but inventory shortages exist. 6 Allocated, no shortage. All components needed for the kit order were allocated. Continued on next page Entering and Printing Kit Orders 3-11

75 The ENTER.KIT.ORDER Function, Continued Fields and descriptions (continued) Field Description Order Status Code, con d. Code Description 7 Printed, picking, short. A picklist document was printed for an order where some of the components were allocated, but where inventory shortages still exist. 8 Printed, picking, avail. A picklist document was printed for an order that has been allocated completely. Pick Complete Flg A flag which controls the allocation of components for picking when shortages exist. Flag N S Y Description Allocate each component based on its availability. The system does not require the order to be picked complete. Allocate each component based upon the number of sets of components available. A set is the quantity of all components needed to assemble one kit. Allocate components for picking only if the components for the entire kit order are available. Reference: For an example of how the Pick Complete Flag works, refer to the topic Allocation of Components on a Kit Order on the following page Entering and Printing Kit Orders

76 Allocation of Components on a Kit Order Introduction When using kit order entry, the system allocates available components needed to build a kit when the kit order is filed. How the system allocates components is based on an option specified on the kit order. Example The bill of material for Kit PRS-20 is: Component# Quantity / Kit A kit order is entered to build 5 of Kit PRS-20. When the kit order is filed, the system checks the quantities needed to build the kit against the current quantity available for each component. Inventory is allocated based on the order s Pick Complete Flag. Component# Qty Needed Qty Available Pick Complete Flag = N When the Pick Complete Flag = N, the system allocates what it can for each component. Component# Qty Allocated Continued on next page Entering and Printing Kit Orders 3-13

77 Allocation of Components on a Kit Order, Continued Pick Complete Flag = S When the Pick Complete Flag = S, the system allocates components to build 2 kits. Component #200 has only enough inventory to assemble 2 kits (sets), and components must be allocated based on the number of complete sets which can be built. Component# Qty Allocated Pick Complete Flag = Y When the Pick Complete Flag = Y, the system will not allocate any components until inventory is replenished on component #200. Component# Qty Allocated Entering and Printing Kit Orders

78 How to Create a Kit Order (ENTER.KIT.ORDER) Introduction The ENTER.KIT.ORDER function is used to create an internal order for assembly of a kit. By creating a kit order, either the 3-Stage kit order process (order entry, picking, and kit receipt) or 2-Stage kit order process (order entry and kit receipt) may be utilized. Accessing the function Use the boxes below to write your menu path to the ENTER.KIT.ORDER function. Procedure Complete the steps in the table below to create a kit order. Step Action 1 Access the function ENTER.KIT.ORDER. Result: The prompt Enter the Kit Order Number, or <CR> for next available number displays. 2 Do you want the system to assign the kit order number? If yes, press [Enter]. If no, type the kit order number and press [Enter]. Result: The prompt Enter the Kit Number displays. 3 Type the item number of the kit to be assembled and press [Enter]. Result: The prompt Enter the Start Date displays. 4 Type the date on which you want to start the inventory picking process and press [Enter]. Result: The prompt Enter the Due Date displays. Continued on next page Entering and Printing Kit Orders 3-15

79 How to Create a Kit Order (ENTER.KIT.ORDER), Continued Procedure (continued) Step Action 5 Type the date on which the assembled kit must be received into inventory, and press [Enter]. Result: The prompt Enter the Kit Order Quantity displays. 6 Type the number of kits to be assembled and press [Enter]. Result: The prompt Enter the Comments displays. 7 Do you wish to enter any comments or special instructions for this kit order? If yes, type comments, pressing [Enter] after each line, then press [Enter] when done. If no, press [Enter]. Result: The Command Line Change Which Field, END, TOP displays. The system sets the Order Status Code field to 3 (Released). 8 Is the Start Date for this kit order a future date? If yes access the Order Status Code field, and change it to a 2 (Unreleased). If no, no action is required. Note: The Order Status Code determines if component inventory will be allocated when the kit order is filed, based on availability and the Pick Complete Flag. Continued on next page 3-16 Entering and Printing Kit Orders

80 How to Create a Kit Order (ENTER.KIT.ORDER), Continued Procedure (continued) Step Action 9 Review and modify the Pick Complete Flag prompt, if necessary: CHANGE the Pick Complete Flag to N S Y WHEN components should be allocated based on their availability. The order does not have to be picked complete. based on the number of sets of components available. when the entire kit order must be picked complete. Reference: For more information about the Pick Complete Flag, refer to the topic Allocation of Components on a Kit Order in this chapter. 10 Type END and press [Enter]. 11 Did you request a system-assigned kit order number? If yes, a message identifying the number displays. Press [Enter] after noting the order number. If no, go to Step 12. Result: The kit order is filed. If the order was Released, the system attempts to allocate component inventory based on availability and the Pick Complete Flag. The Order Status Code is changed to reflect the system action. 12 Do you want to enter another kit order? If yes, return to Step 2. If no, type END and press [Enter]. Result: The function is exited and you are returned to the menu. Entering and Printing Kit Orders 3-17

81 How to Release a Kit Order for Allocation (ENTER.KIT.ORDER) Introduction When a kit assembly order is created with an Order Status Code of 2 (Unreleased), the system will not attempt to allocate component inventory when the kit order is filed. To release a kit order for allocation, the Order Status Code must be modified, and the kit order re-filed. Learning advice The function SHOW.UNRELEASED.KITS may be used to print or display unreleased kit assembly orders. For more information about this function, refer to the topic The SHOW.UNRELEASED.KITS Function in Chapter 7. Accessing the function Use the boxes below to write your menu path to the ENTER.KIT.ORDER function. Procedure Complete the steps in the table below to release a kit order for allocation. Step Action 1 Access the function ENTER.KIT.ORDER. Result: The prompt Enter the Kit Order Number, or <CR> for next available number displays. 2 Type the kit order number to release and press [Enter]. Result: The data for the selected kit order appears, and the Command Line Change Which Field, END, TOP displays. 3 Type 11 and press [Enter]. Result: The Order Status Code field is accessed. Continued on next page 3-18 Entering and Printing Kit Orders

82 How to Release a Kit Order for Allocation (ENTER.KIT.ORDER), Continued Procedure (continued) Step 4 Type 3 and press [Enter]. Action Result: The Order Status Code field is changed to Released. 5 Type END and press [Enter]. Result: The kit order is filed. The system attempts to allocate component inventory based on availability and the Pick Complete Flag. The Order Status Code is changed to reflect the system action. 6 Do you want to release another kit order for allocation? If yes, return to Step 2. If no, type END and press [Enter]. Result: The function is exited and you are returned to the menu. Entering and Printing Kit Orders 3-19

83 Figure 3-3. The PRINT.KIT.PACKET Function. PRINT.KIT.PACKET - Print Kit Orders, Allocate/Print Picklists --- Available Selection Options Selection Option : 3 1. New Orders (with released status) 2. Review existing orders for pickable backorders 3. New Orders - and - Review existing orders 4. Kit Order Number List 02 Print a Kit Order? : Y 03 Print a Picklist? : Y --- Available Picklist Sort Options Picklist Sort Option : L C - Component Sequence/Location L - Location/Component Sequence 05 Component Ext Descr? : N.01).02).03).04).05) 06 Kit Order Number Entries Change Which Field, END, TOP, \P Entering and Printing Kit Orders

84 The PRINT.KIT.PACKET Function Description The PRINT.KIT.PACKET function is used to print order documents and/or picklists for kit orders. Orders and picklists may be reprinted as needed. Depending on the Selection Option chosen, the PRINT.KIT.PACKET function can also perform the allocation process for kit backorders. (A backorder exists when components are not allocated due to stock shortages after a released kit order is filed.) The original printed picklist includes only the quantities available to pick when the kit order was filed. Subsequent picklists include only the components for which there is a pickable backorder. Important This function can print two types of source documents: An order is a document which lists all components and quantities needed to build the kit order, regardless of component availability. A picklist is a document which prints only those components and quantities that have been allocated to the kit order (the quantities are In Picking ). A kit order may have numerous picklists printed throughout the kit order process. Reference: For samples of an order and picklist document, refer to the topic The Kit Order and Picklist Documents in this chapter. Illustration Figure 3-3 is an illustration of the PRINT.KIT.PACKET function. The answers to the prompts on this screen determine which documents are printed, and also determine whether backorders are reviewed for allocation. Setup The form name KIT.PACKET must be assigned to a form queue (printer) in SYS.USERS prior to using this function. Continued on next page Entering and Printing Kit Orders 3-21

85 The PRINT.KIT.PACKET Function, Continued Fields and descriptions The table below describes the key fields on the PRINT.KIT.PACKET screen. Field Selection Option Description This field determines which kit orders are selected for document printing. This field is used in conjunction with the Print a Kit Order? and Print a Picklist? fields. Option Description 1 Selects only new, unprinted kit orders with an Order Status Code of 3 (Released) for either order and/or picklist printing. 2 Selects only existing kit orders that have been previously printed and that now have pickable backorders (allocations) for picklist printing. 3 Combines selection options 1 and 2: Selects new, unprinted kit orders for either order and/or picklist printing, and selects existing kit orders that have pickable backorders (allocations) for picklist printing. 4 Selects specific kit orders for order and/or picklist printing. Print a Kit Order? Determines whether an order document will be printed for orders selected through the Selection Option field. Note: A kit order is not reprinted for existing orders (selection options 2 and 3) regardless of your entry here. To reprint an order you must select option 4, enter "Y" at this prompt, and enter the specific kit order number at the Kit Order Number prompt. Continued on next page 3-22 Entering and Printing Kit Orders

86 The PRINT.KIT.PACKET Function, Continued Fields and descriptions (continued) Field Print a Picklist? Picklist Sort Option Component Ext Descr? Kit Order Number Description Determines whether a picklist document will be printed for orders selected through the Selection Option field. Note: The first time a picklist is printed for a kit order, it includes the quantities required and the allocated quantities ( In Picking ) for all components. Subsequent reprinted picklists include only the components for which there is a pickable backorder. If a selected order has no components available to pick, no picklist is printed. When a picklist is chosen as the document to print, this field determines the order in which the picklist line items are sorted: C - Component Number Sequence / Bin Location L - Bin Location Sequence / Component Number Identifies whether the extended description for each component will print on the chosen document(s). Identifies the specific kit order numbers for which documents should be printed when the Selection Option field = 4. Entering and Printing Kit Orders 3-23

87 Figure 3-4. The Kit Assembly Order Document. ******************************* Page Number : 1 Order Number : 5002 * KIT ASSEMBLY ORDER * Date Printed : 05/04/YY Kit Item Number : TB ******************************* Quantity Ordered : 12 Description : TOOL BOX Order Comments : Balance Quantity : 12 Ext Description : Start Date : 05/04/YY Due Date : 05/06/YY Assembly Location : KIT.WIP Stock UM : EA Ref Component Item Number Description/ Stock Qty per Bal Qty -- Allocations -- Shortage Bal Sets Nbr UM Kit Required Location Quantity Quantity Available NEEDLE NOSE PLIERS EA 1 12 A PLIERS EA 1 12 A HAMMER EA 1 12 H PHILLIPS SCREWDRIVER EA 2 24 F ADJUSTABLE WRENCH EA 1 12 F MOLDED PLASTIC BOX EA 1 12 G Entering and Printing Kit Orders

88 Figure 3-5. The Kit Picklist Document. ********************************** Page Number : 1 Order Number : 5003 * KIT PICKLIST - ORIGINAL * By Location Date Printed : 05/04/YY Kit Item Number : TB ********************************** Quantity Ordered : 12 Description : TOOL BOX Order Comments : Balance Quantity : 12 Ext Description : Start Date : 05/04/YY Due Date : 05/06/YY Assembly Location : KIT.WIP Stock UM : EA Ref Component Item Number Description Stock Bal Qty Pick Picking - Actual Picking Data - Nbr UM Required Quantity Location Quantity Location ADJUSTABLE WRENCH EA SHORTAGE NEEDLE NOSE PLIERS EA 12 3 SHORTAGE 9 A HAMMER EA 12 4 SHORTAGE 8 H PLIERS EA 12 9 SHORTAGE 3 A PHILLIPS SCREWDRIVER EA F MOLDED PLASTIC BOX EA G16 Figure 3-6. The Kit Picklist Document - Pickable Backorder (Supplement #1). ********************************** Page Number : 1 Order Number : 5003 * KIT PICKLIST - SUPPLEMENT #1 * By Location Date Printed : 05/04/YY Kit Item Number : TB ********************************** Quantity Ordered : 12 Description : TOOL BOX Order Comments : Balance Quantity : 12 Ext Description : Start Date : 05/04/YY Due Date : 05/06/YY Assembly Location : KIT.WIP Stock UM : EA Ref Component Item Number Description Stock Previous Pick Picking - Actual Picking Data - Nbr UM shortage Quantity Location Quantity Location NEEDLE NOSE PLIERS EA 3 3 A HAMMER EA 4 4 H ADJUSTABLE WRENCH EA F PLIERS EA 9 9 A547 Entering and Printing Kit Orders 3-25

89 The Kit Order and Picklist Documents Description The PRINT.KIT.PACKET function can print Kit Assembly Orders or Kit Picklist documents. These documents are designed to be printed on blank paper. Illustrations Figure 3-4 is an illustration of the Kit Assembly Order document. An order document can be printed for new kit orders (selection option 1), or can be reprinted for existing kit orders (selection option 4). Figure 3-5 is an illustration of the Kit Picklist document. Figure 3-6 is an illustration of a Supplemental Picklist. An original picklist can be printed for new kit orders (selection option 1). In addition, supplemental picklists may be printed for components having a pickable backorder (selection options 2, 3 and 4). Note The illustrations of the Kit Assembly Order and Kit Picklists have been reduced to fit the page, and are not exact size Entering and Printing Kit Orders

90 How to Print a Kit Order or Picklist (PRINT.KIT.PACKET) Introduction The function PRINT.KIT.PACKET is used to print Kit Assembly Orders or Picklists. This function also allocates components for picking when an existing kit order has a pickable backorder. Learning advice The first prompt in this function asks you to enter a Selection Option. The Selection Option determines which kit orders to consider for printing. When using the 3-Stage method of kit assembly processing, it is recommended that you choose Selection Option 3 (New Orders - and - Review Existing Orders). This allows you to print documents for kit orders that have components allocated, and allocate component inventory to pickable backorders in one step. Accessing the function Use the boxes below to write your menu path to the PRINT.KIT.PACKET function. Procedure Complete the steps in the table below to print Kit Assembly Orders or Picklists, and to allocate inventory to existing kit orders with pickable backorders. Step Action 1 Access the function PRINT.KIT.PACKET. Result: The prompt Enter the Selection Option (1-4) displays. Continued on next page Entering and Printing Kit Orders 3-27

91 How to Print a Kit Order or Picklist (PRINT.KIT.PACKET), Continued Procedure (continued) Step Action 2 Do you want to reprint a Kit Assembly Order document? If yes, type 4 and press [Enter]. If no, go to Step 8. Result: The prompt Do you want to print a Kit Order? (Y,N) displays. Reprint Kit Orders 3 Type Y and press [Enter]. Result: The prompt Do you want to print a Picklist? (Y,N) displays. 4 Type N and press [Enter]. Note: You cannot reprint an original picklist. Result: The prompt Do you want to include Component Extended Descriptions? (Y,N) displays. 5 Make the following decision: IF you want to print component extended descriptions on the order do not want component extended descriptions to print on the order THEN type Y and press [Enter]. press [Enter]. Result: The prompt Enter the Kit Order Number displays. Continued on next page 3-28 Entering and Printing Kit Orders

92 How to Print a Kit Order or Picklist (PRINT.KIT.PACKET), Continued Procedure (continued) Step Action 6 Type the kit order numbers to reprint, pressing [Enter] after each. Press [Enter] when done. Result: The Command Line Change Which Field, END, TOP displays. 7 Go to Step 13. Print New Orders and/or Picklists 8 Make the following decision: IF you want to print documents for new released orders review existing orders for pickable backorders, and select these transactions for picklist printing print documents for new released orders and review existing orders for pickable backorders THEN type 1 and press [Enter]. 2 and press [Enter]. 3 and press [Enter]. Note: When using the 3-Stage method of kit assembly processing, it is recommended that you use Selection Option 3. This option prints documents for kit orders that have components allocated, and allocate component inventory to pickable backorders in one step. Result: The prompt Do you want to print a Kit Order? (Y,N) displays. Continued on next page Entering and Printing Kit Orders 3-29

93 How to Print a Kit Order or Picklist (PRINT.KIT.PACKET), Continued Procedure (continued) Step Action 9 Do you want to print kit assembly orders for each order selected? If yes, press [Enter]. If no, type N and press [Enter]. Result: The prompt Do you want to print a Picklist? (Y,N) displays. 10 Do you want to print a picklist document for component allocations? IF yes no THEN press [Enter]. Result: The prompt Enter the Sort Option for Picklists (S,L) displays. type N and press [Enter], then go to Step 12. Note: To allocate component inventory to kit backorders, a picklist must be printed. 11 Make the following decision: TO sort picklists by component number location, then component number THEN type C and press [Enter]. press [Enter]. Result: The prompt Do you want to include Component Extended Descriptions? (Y,N) displays. Continued on next page 3-30 Entering and Printing Kit Orders

94 How to Print a Kit Order or Picklist (PRINT.KIT.PACKET), Continued Procedure (continued) Step Action 12 Do you want to print component extended descriptions on the order and/or picklist? IF yes no THEN type Y and press [Enter]. press [Enter]. Result: The Command Line Change Which Field, END, TOP displays. 13 Type END and press [Enter]. Result: The selected documents print and the system displays a status of the kit order processing performed. The message Print Kit Packet processing is complete. When ready you may Press <CR> displays. 14 Press [Enter]. Result: You are returned to the menu. Entering and Printing Kit Orders 3-31

95 How to Delete a Kit Order (ENTER.KIT.ORDER) Introduction A kit order may be deleted entirely from the system when you do not wish to assemble the kit, or when you wish to delete the remaining kit backorder (kit quantities not yet assembled). Learning advice When deleting a kit order, the system performs the following actions: the Scheduled Quantity of the kit item is reduced the In Picking quantity of all allocated components is reduced, and a warning message displays if Kit Order Picks have been entered for an allocated component. The message reminds the user to transfer the picked quantities from the Work in Process location to the component s warehouse storage location. Note: This is done using the Transfer option in the function ENTER.INV.ADJUSTMENTS. Accessing the function Use the boxes below to write your menu path to the ENTER.KIT.ORDER function. Procedure Complete the steps in the table below to delete a kit order. Step Action 1 Access the function ENTER.KIT.ORDER. Result: The prompt Enter the Kit Order Number or <CR> for next available number displays. Continued on next page 3-32 Entering and Printing Kit Orders

96 How to Delete a Kit Order (ENTER.KIT.ORDER), Continued Procedure (continued) Step Action 2 Type the kit order number you wish to delete and press [Enter]. Result: The information for the kit order appears, and the Command Line Change Which Field, END, TOP displays. 3 Type DELETE and press [Enter]. Result: The prompt Is This the Correct Record to Delete? (YES,Y, NO,N) displays. 4 Type Y and press [Enter]. Result: The system performs the proper updates to the kit and components. The prompt Enter the Kit order Number or <CR> for next available number displays. Note: If components had been moved to the Work in Process location, press [Enter] after reading the messages displayed. Example: The reduction of this kit s order quantity has resulted in an excess of component in the kit assembly area. 50 EA should be returned from loc KIT.WIP to normal stock. Press <CR> 5 Do you need to delete another kit assembly order? If yes, return to Step 2. If no, type END and press [Enter]. Result: The function is existed and you are returned to the menu. Entering and Printing Kit Orders 3-33

97 Knowledge Check Directions Answer the following questions. This knowledge check is based on the objectives stated in the beginning of this chapter. Question 1 Mark all statements that are true about allocations. a. The ENTER.KIT.ORDER function allocates component inventory for both released and unreleased kit orders. b. Allocation is the process of assigning inventory for a specific transaction. c. Allocated inventory is also known as inventory In Picking on the D2K system. d. The D2K system only allocates component inventory when you print a kit picklist document. e. The ENTER.KIT.ORDER function allocates component inventory based on a Pick Complete Flag. Question 2 TRUE or FALSE Typically, a kit order is entered as an unreleased order when the kit needs to be assembled immediately. Question 3 TRUE or FALSE In the ENTER.KIT.ORDER function, the system changes the Order Status Code after a released order is filed, to indicate the condition of the kit order after component allocation. Continued on next page 3-34 Entering and Printing Kit Orders

98 Knowledge Check, Continued Question 4 A kit order is entered to build 10 of a kit item. The table below identifies the components used to build the kit, and their current quantities available. Fill in the Qty Needed column to indicate how many of each component is needed to assemble the kit order. Component# Quantity / Kit Qty Needed Qty Available A B 1 5 C 2 15 The Pick Complete Flag on the kit order is set to N (Allocate each component based on its availability). Indicate in the table below the quantities that would be allocated for each component item, based on the Qty Available shown above. Component# A B C Qty Allocated The Pick Complete Flag on the kit order is set to S (Allocate each component based on the number of sets that can be assembled). Indicate in the table below the quantities that would be allocated for each component item, based on the Qty Available shown above. Component# A B C Qty Allocated The Pick Complete Flag on the kit order is set to Y (Allocate components only if the entire kit order can be assembled). Indicate in the table below the quantities that would be allocated for each component item, based on the Qty Available shown above. Component# A B C Qty Allocated Continued on next page Entering and Printing Kit Orders 3-35

99 Knowledge Check, Continued Question 5 By creating a kit order using the ENTER.KIT.ORDER function, which method(s) can be utilized for kit order processing? a. 1-Stage processing b. 2-Stage processing c. 3-Stage processing Question 6 Fill in the statements below with the correct word: order or picklist. A is a document which prints only those components and quantities that have been allocated to the kit order (the quantities are In Picking ). A is a document which lists all components and quantities needed to build the kit order, regardless of component availability. Question 7 TRUE or FALSE A kit order may have numerous picklists printed throughout the kit order process. What s next? Compare your answers to the ones provided on the next page. If you were unable to complete this knowledge check, we recommend that you review the chapter before continuing. If you are still uncomfortable with the information provided, or have specific questions regarding your system, contact your System Administrator or D2K Customer Care Consultant Entering and Printing Kit Orders

100 Knowledge Check Answers Answer 1 Mark all statements that are true about allocations. b. Allocation is the process of assigning inventory for a specific transaction. c. Allocated inventory is also known as inventory In Picking on the D2K system. e. The ENTER.KIT.ORDER function allocates component inventory based on a Pick Complete Flag. Answer 2 TRUE or FALSE Typically, a kit order is entered as an unreleased order when the kit needs to be assembled immediately. Explanation: When the kit needs to be assembled immediately, the kit order is entered as a released order. This allows the system to allocate available component inventory. Answer 3 TRUE or FALSE In the ENTER.KIT.ORDER function, the system changes the Order Status Code after a released order is filed, to indicate the condition of the kit order after component allocation. Continued on next page Entering and Printing Kit Orders 3-37

101 Knowledge Check Answers, Continued Answer 4 A kit order is entered to build 10 of a kit item. The table below identifies the components used to build the kit, and their current quantities available. Fill in the Qty Needed column to indicate how many of each component is needed to assemble the kit order. Component# Quantity / Kit Qty Needed Qty Available A B C The Pick Complete Flag on the kit order is set to N (Allocate each component based on its availability). Indicate in the table below the quantities that would be allocated for each component item, based on the Qty Available shown above. Component# Qty Allocated A 100 B 5 C 15 The Pick Complete Flag on the kit order is set to S (Allocate each component based on the number of sets that can be assembled). Indicate in the table below the quantities that would be allocated for each component item, based on the Qty Available shown above. Component# Qty Allocated A 50 B 5 C 10 The Pick Complete Flag on the kit order is set to Y (Allocate components only if the entire kit order can be assembled). Indicate in the table below the quantities that would be allocated for each component item, based on the Qty Available shown above. Component# Qty Allocated A 0 B 0 C 0 Continued on next page 3-38 Entering and Printing Kit Orders

102 Knowledge Check Answers, Continued Answer 5 By creating a kit order using the ENTER.KIT.ORDER function, which method(s) can be utilized for kit order processing? b. 2-Stage processing c. 3-Stage processing Answer 6 Fill in the statements below with the correct word: order or picklist. A picklist is a document which prints only those components and quantities that have been allocated to the kit order (the quantities are In Picking ). An order is a document which lists all components and quantities needed to build the kit order, regardless of component availability. Answer 7 TRUE or FALSE A kit order may have numerous picklists printed throughout the kit order process. Entering and Printing Kit Orders 3-39

103 Chapter 4 Picklist Processing for Kit Orders Overview Introduction When using the 3-Stage method of processing kit assemblies, component inventory is picked and moved into a special work in process location. Component quantities, and the locations from which they were picked, are updated using the BOM.TRANSACTIONS function. Purpose The purpose of this chapter is to describe Picklist processing for kit orders. You will learn about the two options used to enter picked quantities in the BOM.TRANSACTIONS function. This chapter will also provide procedures used to enter and confirm kit picks. Objectives Upon completion of this chapter, you will be able to describe the kit order picklist process describe how picklist processing affects inventory identify the options used to update kit picking information identify and describe the key fields on the Pick Reporting screens confirm and enter kit picks using the BOM.TRANSACTIONS function, and identify guidelines for canceling component allocations. Learning advice Picklist processing is used only when the facility is set up for Multiple Location processing. If your facility does not use Multiple Location processing, or if you will use the 1-Stage method of Kit Assembly Processing, you may skip this chapter. Picklist Processing for Kit Orders 4-1

104 Figure 4-1. The Kit Order Picklist Process. System has allocated components and moved them to "In Picking". User picks components from their stock locations. User puts components in an assembly area. User updates kit order with quantities picked using BOM.TRANSACTIONS function. System moves component inventory from stock location to KIT.WIP location. 4-2 Picklist Processing for Kit Orders

105 The Kit Order Picklist Process Introduction Picklist Processing may be used for kit orders only when the facility uses Multiple Location processing. Description When utilizing kit order picklist processing (the 3-Stage Method), component inventory is physically moved from a stocking warehouse location to a work in process location, after inventory has been allocated. When a kit order has not been picked complete (due to insufficient component inventory), movement of allocated components to the work in process location reserves the inventory, and insures that it will not be used for other allocations. Illustration Figure 4-1 is an illustration of the kit order picklist process. Process The table below describes the kit order picklist process. Stage Description 1 When the user files the kit order, component inventory is allocated. Result: The D2K system shows the allocated quantity in the In Picking column on inventory reports and inquiries. 2 The user removes (picks) the allocated components from their stocking warehouse locations. Note: A picklist is typically used as the source document to identify allocated quantities and their stocking warehouse locations. 3 The user places the allocated components in a special area in the warehouse, used for kit order assembly (KIT.WIP). 4 The user updates the kit order on the D2K system, identifying the stocking locations from which components were moved. Result: The D2K system shows the allocated quantity in the Location On-Hand for bin location KIT.WIP. Picklist Processing for Kit Orders 4-3

106 How Picklist Processing Affects Inventory Introduction Picklist processing, used when a facility has Multiple Location processing, affects the inventory status on components only (the kit item s inventory status is unaffected). After allocation As a review, the illustration below shows the affect to inventory once a component has been allocated to a kit order. The item s In Picking quantity is increased by the quantity allocated. LOOK.STOCK - Display Current Availability Info for an Item Page No. 1 Item Number : 100 Description : SCREWDRIVER Ext`d Desc : Facility: 01 MAIN FACILITY Sell UM : EA Each Ship Loc Permanent Loc A1 Replenishment Code LP Storage A Location Total Comm`td In Transfr Sch`ld Available Fac Location F On-Hand On-Hand Qty Picking Qty Qty To Pick 01 A1 Y A2 Y 14 Enter "X" to exit the function, <CR> or "END" to continue... End of Pages to display for this Inquiry After picking The illustration below shows the affect to inventory once a component has been picked, and the kit order updated to reflect the location from which it was picked. The item s In Picking quantity remains the same, but the Location On-Hand quantities are adjusted. LOOK.STOCK - Display Current Availability Info for an Item Page No. 1 Item Number : 100 Description : SCREWDRIVER Ext`d Desc : Facility: 01 MAIN FACILITY Sell UM : EA Each Ship Loc Permanent Loc A1 Replenishment Code LP Storage A Location Total Comm`td In Transfr Sch`ld Available Fac Location F On-Hand On-Hand Qty Picking Qty Qty To Pick 01 A1 Y A2 Y 14 KIT.WIP N 25 Enter "X" to exit the function, <CR> or "END" to continue... End of Pages to display for this Inquiry 4-4 Picklist Processing for Kit Orders

107 Figure 4-2. The BOM.TRANSACTIONS Selection Screen. BOM.TRANSACTIONS - Record Kit Order Picking and Receipt Transactions Entry Process Options Process Descriptions PICK REPORTING CONFIRM KIT ORDER PICKS Report Order Picked, Exception Entry 2. ENTER KIT ORDER PICKS Report Order Picked, Individual Entry --- KIT RECEIPTS ENTER KIT RECEIPTS Enter Kit Assembly Receipt Transactions 4. REVERSE KIT RECEIPTS Enter Kit Receipt Reversal Transactions 01 Entry Process Option : 1 Enter the Entry Process Option (1-4), END:... Picklist Processing for Kit Orders 4-5

108 The Options Used to Update Kit Picking Information Introduction The BOM.TRANSACTIONS function is used to update the kit order with the quantities picked, and the picked from warehouse locations. There are two ways in which this can be performed. Note: A picklist is typically used as the source document to perform the actual picking of components in the warehouse. Any changes to the information that printed on the picklist (such as the quantity picked or the locations from which the components were removed) must be updated to the kit order using one of these options. Options and descriptions The table below describes the two options available in the BOM.TRANSACTIONS function to update kit picking information. Option Confirm Kit Order Picks Enter Kit Order Picks Description This option is used to confirm the picking quantities and locations that were printed on the picklist document. The picking information that printed on the picklist is displayed, and the user may accept the information, or make changes as necessary. The Confirm Kit Order Picks option is best used when most or all of a kit order is picked, as printed on the picklist document. This option is used to enter picking quantities and locations for a kit order. The picking information that printed on the picklist document is displayed, but the user must enter the quantities and picked from locations for all components. The Enter Kit Order Picks option is best used when only a few of the components for a kit order have been picked. Illustration Figure 4-2 is an illustration of the BOM.TRANSACTIONS selection screen. Options 1 and 2 are used for picklist processing. 4-6 Picklist Processing for Kit Orders

109 Figure 4-3. The BOM.TRANSACTIONS Confirm Kit Order Picks Screen. CONFIRM KIT PICKS - Kit Order Picking Confirmation Screen Page 1 of 1 Order Number 5003 Reference TB Order Type Kit Lne Item Number Picking Qty to Stock Qty From Nbr Entries 009 Location Pick U/M Picked Location A25 9 EA 9... A H126 8 EA 8 H A547 3 EA 3 A F10 24 EA 24 F G16 12 EA 12 G Enter the Quantity Picked, END: Figure 4-4. The BOM.TRANSACTIONS Enter Kit Order Picks Screen. ENTER KIT PICKS - Kit Order Picking Entry Screen Page 1 of 1 Order Number 5003 Reference TB Order Type Kit Lne Item Number Picking Qty to Stock Qty From Nbr Entries 005 Location Pick U/M Picked Location A25 9 EA H126 8 EA A547 3 EA F10 24 EA G16 12 EA Enter the Quantity Picked, END: Picklist Processing for Kit Orders 4-7

110 The BOM.TRANSACTIONS Function - Pick Reporting Screens Description The Pick Reporting screens in the BOM.TRANSACTIONS function are used to update the kit order with picking information. The screen you choose to enter kits picks is dependent on whether or not the actual quantities picked for components matched the information that printed on the picklist document. Illustrations Figure 4-3 is an illustration of the Confirm Kit Order Picks screen (Option 1) in the BOM.TRANSACTIONS function. Figure 4-4 is an illustration of the Enter Kit Order Picks screen (Option 2) in the BOM.TRANSACTIONS function. Learning advice While the fields on the screens are identical, it should be noted that the Confirm Kit Order Picks screen shows default information in the Qty Picked and From Location columns, whereas the Enter Kit Order Picks screen does not (the user must provide this information). Fields and descriptions The table below describes the key fields on the Confirm Kit Order Picks and Enter Kit Order Picks screens. Field Order Number Reference Item Number Description The unique identification number which identifies a kit order. Display only: The kit item number which is being assembled. Display only: The component item number which was allocated to the kit order. Picking Location Display only: The location from which the component item was allocated for picking. Note: This is the location that printed on the picklist document. Continued on next page 4-8 Picklist Processing for Kit Orders

111 The BOM.TRANSACTIONS Function - Pick Reporting Screens, Continued Fields and descriptions (continued) Field Qty to Pick Qty Picked Description Display only: The quantity of the component item to be picked from the associated location. Note: This is the quantity that printed on the picklist document. The actual quantity picked from the displayed location for the component item. Special entry options available at this field include: Operator Entry Description 0 (zero) Indicates that no quantity has been picked for this component, and the quantity allocated should be canceled from In Picking. Reference: Entry of zero on every line will not delete the kit order. To delete the entire kit order, refer to the topic How to Delete a Kit Order (ENTER.KIT.ORDER) in Chapter 3. * (asterisk) Indicates that no quantity has been picked for this component, but the quantity allocated should not be canceled from In Picking. Note: If the quantity picked is less than the quantity allocated, the outstanding balance is canceled from In Picking and must be reallocated later. This is done by reviewing for pickable backorders and printing a picklist document using the PRINT.KIT.PACKET function. Continued on next page Picklist Processing for Kit Orders 4-9

112 The BOM.TRANSACTIONS Function - Pick Reporting Screens, Continued Fields and descriptions (continued) Field From Location Description The warehouse location from which the component item was moved. Note: This field may be accessed only if the user enters a quantity picked at the previous prompt. In the Confirm Kit Order Picks screen, if the user presses [Enter] at the Qty Picked field (confirming the displayed quantity picked), the system assumes the From Location is also correct and bypasses this field Picklist Processing for Kit Orders

113 How to Confirm Kit Order Picking Information (BOM.TRANSACTIONS - Option 1) Introduction Option 1 in the BOM.TRANSACTIONS function, Confirm Kit Order Picks, is used to confirm the picked quantities and locations for a kit order. Learning advice Confirm Kit Order Picks is used when most or all of a kit order has been picked using the quantities and locations printed on the picklist. If only a few of the components on the picklist have been picked, use the procedure found in the following topic in this chapter: How to Enter Kit Order Picking Information (BOM.TRANSACTIONS - Option 2) Accessing the function Use the boxes below to write your menu path to the BOM.TRANSACTIONS function. Procedure Complete the steps in the table below to confirm kit order picks in the BOM.TRANSACTIONS function. Step Action 1 Access the function BOM.TRANSACTIONS. Result: The prompt Enter the Entry Process Option (1-4) displays. 2 Type 1 and press [Enter]. Result: The Kit Order Picking Confirmation Screen appears, and the prompt Enter the Kit Order Number, X, END displays. Continued on next page Picklist Processing for Kit Orders 4-11

114 How to Confirm Kit Order Picking Information (BOM.TRANSACTIONS - Option 1), Continued Procedure (continued) Step Action 3 Type the kit order number and press [Enter]. Result: The line items (components) on the kit order display. 4 Look at your screen and locate the cursor in the Qty Picked column. Note: The cursor placement determines the line item for which you are ready to confirm picking information. Result: The prompt Enter the Quantity Picked displays. 5 Is the data displayed in the Qty Picked and From Location fields correct for all component shown? If yes, type END and press [Enter]. Result: The Command Line Change which line, Fn, Bn, Pn, TOP, END displays. If no, go to Step 6. Continued on next page 4-12 Picklist Processing for Kit Orders

115 How to Confirm Kit Order Picking Information (BOM.TRANSACTIONS - Option 1), Continued Procedure (continued) Step Action 6 Is the data displayed in the Qty Picked and From Location fields correct for this component? IF THEN yes, press [Enter]. Result: The cursor is positioned in the next line item s Qty Picked column, or at the Command Line (if this was the last line item on the kit order). Repeat this Step for all subsequent components, until the Command Line Change which line, Fn, Bn, Pn, TOP, END displays, then go to Step 10. no, go to Step 7. 7 Make the following decision: IF you want to use the displayed quantity as the quantity picked, but change the From Location THEN re-type the displayed quantity and press [Enter]. Result: The prompt Enter the From Location displays. Go to Step 8. Note: If you do not re-type the quantity picked, you cannot access the From Location field. Continued on next page Picklist Processing for Kit Orders 4-13

116 How to Confirm Kit Order Picking Information (BOM.TRANSACTIONS - Option 1), Continued Procedure (continued) Step 7, con d. Make the following decision: IF you want to enter a new quantity picked Action THEN type the new quantity and press [Enter]. Result: The prompt Enter the From Location displays. cancel the allocated quantity from In Picking Go to Step 8. type 0 (zero) and press [Enter]. Result: The cursor is positioned in the next line item s Qty Picked column, or at the Command Line (if this was the last line item on the kit order). Repeat from Step 6 for all subsequent components, until the Command Line Change which line, Fn, Bn, Pn, TOP, END displays, then go to Step 10. Reference: For more information about canceling allocations, refer to the topic Guidelines for Canceling Component Allocations in this chapter. Continued on next page 4-14 Picklist Processing for Kit Orders

117 How to Confirm Kit Order Picking Information (BOM.TRANSACTIONS - Option 1), Continued Procedure (continued) Step Action 7, con d. IF you want to THEN indicate that no type * and press [Enter]. quantity was picked, and leave the allocated quantity open Result: The cursor is positioned in the next line item s Qty Picked column, or at the Command Line (if this was the last line item on the kit order). access the Command Line Repeat from Step 6 for all subsequent components, until the Command Line Change which line, Fn, Bn, Pn, TOP, END displays, then go to Step 10. type END and press [Enter]. Go to Step 10. Result: The Command Line displays. 8 Is the data displayed in the From Location field correct for this component? If yes, press [Enter]. If no, type the location from which the component was taken and press [Enter]. Result: The cursor is positioned in the next line item s Qty Picked column, or at the Command Line (if this was the last line item on the kit order). Continued on next page Picklist Processing for Kit Orders 4-15

118 How to Confirm Kit Order Picking Information (BOM.TRANSACTIONS - Option 1), Continued Procedure (continued) Step Action 9 Repeat from Step 6 for all subsequent components, until the Command Line Change which line, Fn, Bn, Pn, TOP, END displays. 10 Do you want to modify the quantity picked on any line item? If yes, type the line number to change and press [Enter]. Repeat from Step 6. If no, type END and press [Enter]. Result: The kit order is filed. Component quantities picked are moved from the displayed locations to a Work in Process location. The prompt Enter the Kit Order, X, END displays. 11 Make the following decision: IF you want to confirm picks for another kit order go back to the BOM.TRANSACTIONS selection screen exit the function THEN return to Step 3. type END and press [Enter]. Result: The selection screen is displayed. Go to Step 12. type X and press [Enter]. Result: You are exited from the function and returned to the menu. This completes the procedure. 12 Type END and press [Enter]. Result: You are exited from the function and returned to the menu Picklist Processing for Kit Orders

119 How to Enter Kit Order Picking Information (BOM.TRANSACTIONS - Option 2) Introduction Option 2 in the BOM.TRANSACTIONS function, Enter Kit Order Picks, is used to manually enter the picked quantities and locations for a kit order. Learning advice Enter Kit Order Picks is used when only a few of the components on a kit order have been picked, or when the locations from which components were picked must be changed. If most or all of a kit order has been picked using the quantities and locations printed on the picklist, use the procedure found in the following topic in this chapter: How to Confirm Kit Order Picking Information (BOM.TRANSACTIONS - Option 1) Accessing the function Use the boxes below to write your menu path to the BOM.TRANSACTIONS function. Procedure Complete the steps in the table below to enter kit order picks in the BOM.TRANSACTIONS function. Step Action 1 Access the function BOM.TRANSACTIONS. Result: The prompt Enter the Entry Process Option (1-4) displays. 2 Type 2 and press [Enter]. Result: The Kit Order Picking Entry Screen appears, and the prompt Enter the Kit Order Number, X, END displays. Continued on next page Picklist Processing for Kit Orders 4-17

120 How to Enter Kit Order Picking Information (BOM.TRANSACTIONS - Option 2), Continued Procedure (continued) Step Action 3 Type the kit order number and press [Enter]. Result: The line items (components) on the kit order display. 4 Look at your screen and locate the cursor in the Qty Picked column. Note: The cursor placement determines the line item for which you are ready to enter picks. Result: The prompt Enter the Quantity Picked displays. 5 Make the following decision: IF you want to enter a quantity picked THEN type the quantity and press [Enter]. Result: The prompt Enter the From Location displays. indicate that no quantity was picked, and leave the allocated quantity open Go to Step 6. press [Enter]. Result: The cursor is positioned in the next line item s Qty Picked column, or at the Command Line (if this was the last line item on the kit order). Go to Step 7. Continued on next page 4-18 Picklist Processing for Kit Orders

121 How to Enter Kit Order Picking Information (BOM.TRANSACTIONS - Option 2), Continued Procedure (continued) Step Action 5, con d. IF you want to THEN cancel the allocated quantity from In Picking type 0 (zero) and press [Enter]. Result: The cursor is positioned in the next line item s Qty Picked column, or at the Command Line (if this was the last line item on the kit order). Go to Step 7. access the Command Line Reference: For more information about canceling allocations, refer to the topic Guidelines for Canceling Component Allocations in this chapter. type END and press [Enter]. Go to Step 8. Result: The Command Line displays. 6 Is the data displayed in the From Location field correct for this component? If yes, press [Enter]. If no, type the location from which the component was picked and press [Enter]. Result: The cursor is positioned in the next line item s Qty Picked column, or at the Command Line (if this was the last line item on the kit order). Continued on next page Picklist Processing for Kit Orders 4-19

122 How to Enter Kit Order Picking Information (BOM.TRANSACTIONS - Option 2), Continued Procedure (continued) Step Action 7 Repeat from Step 5 as necessary, until the Command Line Change which line, Fn, Bn, Pn, TOP, END displays. 8 Do you want to modify the quantity picked on any line item? If yes, type the line number to change and press [Enter]. Repeat from Step 5. If no, type END and press [Enter]. Result: The kit order is filed. Component quantities picked are moved from the entered locations to a Work in Process location. The prompt Enter the Kit Order, X, END displays. 9 Make the following decision: IF you want to enter picks for another kit order go back to the BOM.TRANSACTIONS selection screen exit the function THEN return to Step 3. type END and press [Enter]. Result: The selection screen is displayed. Go to Step 10. type X and press [Enter]. Result: You are exited from the function and returned to the menu. This completes the procedure. 10 Type END and press [Enter]. Result: You are exited from the function and returned to the menu Picklist Processing for Kit Orders

123 Guidelines for Canceling Component Allocations Introduction Once components are allocated to a kit order, it may be necessary to cancel the allocation if the component is needed for another usage. Note: Component allocations are canceled by entering a 0 (zero) in the Qty Picked field, using either Option 1 or 2 (Confirm or Enter Kit Picks) in the BOM.TRANSACTIONS function. Inventory affect Canceling a component s allocation to a kit assembly order reduces the In Picking quantity for the component. Guidelines Follow these guidelines when canceling a component s allocation: Entering 0 (zero) on every line when confirming or entering kit picks does not delete the kit order. This only removes the component quantities from the In Picking status. Components whose allocations have been canceled are treated like kit backorders: the kit order has been Released, but component inventory was unavailable during the allocation process (components are not In Picking ). In order to reallocate component inventory, it is necessary to run the function PRINT.KIT.PACKET. Choose a selection option that will either review existing orders for pickable backorders (options 2 or 3), or print a picklist for the selected kit order number (option 4). Picklist Processing for Kit Orders 4-21

124 Knowledge Check Directions Answer the following questions. This knowledge check is based on the objectives stated in the beginning of this chapter. Question 1 Which statement best describes the kit order picklist process? a. Moves component inventory from its stocking warehouse location to a work in process location, after inventory has been allocated. b. Allocates component inventory to an In Picking status. c. Updates the kit order with the quantities assembled, increasing the kit item s on-hand quantity. Question 2 TRUE or FALSE Once picking information is entered or confirmed using the BOM.TRANSACTIONS function, a component item s In Picking quantity is reduced. Question 3 Complete these sentences by identifying the statement which describes the use of each Kit Picking option: Confirm Kit Order Picks is best used when. Enter Kit Order Picks is best used when. a. only a few of the components for a kit order have been picked. b. most or all of a kit order is picked, as printed on the picklist document. Question 4 TRUE or FALSE Entering a 0 (zero) as the Quantity Picked in the BOM.TRANSACTIONS function cancels the allocated component quantity from In Picking. Continued on next page 4-22 Picklist Processing for Kit Orders

125 Knowledge Check, Continued Question 5 A quantity of 25 was allocated to a component for a kit order. However, when the component was picked, only 23 were found in its warehouse location. The user enters a Quantity Picked of 23 in BOM.TRANSACTIONS. TRUE or FALSE As a result, the balance quantity of 2 remains allocated for the component, and will show In Picking. Question 6 TRUE or FALSE When a component s allocation has been canceled through the kit order picklist process, inventory is reallocated by setting the kit order s Status Code to Released in the ENTER.KIT.ORDER function. What s next? Compare your answers to the ones provided on the next page. If you were unable to complete this knowledge check, we recommend that you review the chapter before continuing. If you are still uncomfortable with the information provided, or have specific questions regarding your system, contact your System Administrator or D2K Customer Care Consultant. Picklist Processing for Kit Orders 4-23

126 Knowledge Check Answers Answer 1 Which statement best describes the kit order picklist process? a. Moves component inventory from its stocking warehouse location to a work in process location, after inventory has been allocated. Answer 2 TRUE or FALSE Once picking information is entered or confirmed using the BOM.TRANSACTIONS function, a component item s In Picking quantity is reduced. Explanation: The component s In Picking quantity remains the same, but the Location On-Hand quantities are adjusted. Inventory is removed from the stocking location to a work in process location. Answer 3 Complete these sentences by identifying the statement which describes the use of each Kit Picking option: Confirm Kit Order Picks is best used when b. most or all of a kit order is picked, as printed on the picklist document. Enter Kit Order Picks is best used when a. only a few of the components for a kit order have been picked. Answer 4 TRUE or FALSE Entering a 0 (zero) as the Quantity Picked in the BOM.TRANSACTIONS function cancels the allocated component quantity from In Picking. Continued on next page 4-24 Picklist Processing for Kit Orders

127 Knowledge Check Answers, Continued Answer 5 A quantity of 25 was allocated to a component for a kit order. However, when the component was picked, only 23 were found in its warehouse location. The user enters a Quantity Picked of 23 in BOM.TRANSACTIONS. TRUE or FALSE As a result, the balance quantity of 2 remains allocated for the component, and will show In Picking. Explanation: If the quantity picked is less than the quantity allocated, the outstanding balance is canceled from In Picking and must be reallocated later. This is done by reviewing for pickable backorders and printing a picklist document using the PRINT.KIT.PACKET function. Answer 6 TRUE or FALSE When a component s allocation has been canceled through the kit order picklist process, inventory is reallocated by setting the kit order s Status Code to Released in the ENTER.KIT.ORDER function. Explanation: In order to reallocate component inventory, it is necessary to run the function PRINT.KIT.PACKET. Choose a selection option that will either review existing orders for pickable backorders (options 2 or 3), or print a picklist for the selected kit order number (option 4). Picklist Processing for Kit Orders 4-25

128 Chapter 5 Kit Receipts Overview Introduction In Chapter 3, you learned that there are three methods (1-Stage, 2-Stage, and 3-Stage) which can be used to replenish a kit item s inventory. All three methods involve receiving a kit order. When a kit order is received, component inventory used to build the kit is automatically reduced, and the kit item on-hand balance is increased. Purpose The purpose of this chapter is to describe the kit order receipt process. You will learn how to receive kit orders previously entered (when using the 2 or 3- Stage method), or how to enter and receive a kit order in one step (when using the 1-Stage method). This chapter will also provide procedures used to reverse the receipt of a kit order. Objectives Upon completion of this chapter, you will be able to describe the kit receipt process describe how kit receipts affect inventory identify and describe the screens and key fields used to enter a kit receipt in the BOM.TRANSACTIONS function receive a kit order, and reverse a kit order receipt. In this chapter This chapter contains the following sections: Topic An Overview of the Kit Receipt Process Kit Receipts and Reversals See Section A B Kit Receipts 5-1

129

130 Section A An Overview of the Kit Receipt Process Overview Introduction Kit receipts are used in all three methods of processing kit assemblies. Purpose The purpose of this section is to describe the kit receipt process, and how inventory is affected for the kit item and the components used to build the kit. Objectives Upon completion of this section, you will be able to describe the kit receipt process describe how kit receipts affect inventory, and identify the cost updates that occur as a result of a kit receipt. An Overview of the Kit Receipt Process 5-A-1

131 Figure 5-A-1. The Kit Receipt Process. User assembles kit item. User accesses BOM.TRANSACTIONS to enter the kit receipt. Was kit order already created? Yes No Enter receipts against kit order. Enter kit receipt. System updates kit and component inventory. User prints the KIT.RECEIPT.AUDIT report. User reverses kit receipts, if necessary. System updates kit cost sets. 5-A-2 An Overview of the Kit Receipt Process

132 The Kit Receipt Process Description All three methods of kit assembly processing require the user to enter kit receipts. A previously entered kit order is received (2 or 3-Stage Method), or the kit is received directly when the 1-Stage Method is used. This results in an increase to the kit item s on-hand, and a decrease to the component items on-hand, based on the kit quantity received. Depending on system setup, numerous cost sets for the kit item are also updated. When an error is detected in a kit receipt, or when a kit item is disassembled, the receipt may be reversed. This decreases the kit item s on-hand, and increases the component items on-hand. An audit report, KIT.RECEIPT.AUDIT, is used to verify the accuracy of receipts and reversals. Illustration Figure 5-A-1 is an illustration of the kit receipt process. Process The table below describes the kit receipt process. Stage Description 1 User assembles the kit item. 2 User accesses the BOM.TRANSACTIONS function and selects Option 3 - Enter Kit Receipts. 3 Has a kit order already been created using the function ENTER.KIT.ORDER (2 or 3-Stage Method)? If yes, the user enters the receipt against the kit order number. If no, the user enters the kit receipt (1-Stage Method). Result: The system increases the kit item s on-hand, and decreases the component items on-hand, based on the kit quantity received. Continued on next page An Overview of the Kit Receipt Process 5-A-3

133 The Kit Receipt Process, Continued Process (continued) Stage Description 4 The system updates the Last Actual and Average Actual cost sets for the kit item when the receipt is filed. Depending on system setup, the Material cost set for the kit item may also be updated. 5 If necessary, the user may reverse a kit receipt when a kit is disassembled, or when a keying error was made during the kit receipt entry. Result: The system decreases the kit item s on-hand, and increases the component items on-hand, based on the kit quantity reversed. 6 The user may print an audit report of all kit receipts and reversals using the function KIT.RECEIPT.AUDIT. 5-A-4 An Overview of the Kit Receipt Process

134 How Kit Receipts Affect Inventory Introduction Kit receipts affect inventory on-hand balances for both the kit item and the components used to build the kit. Updates A kit receipt will perform the following inventory updates: Item Kit item Component items Updates Performed Increases the on-hand balance, and decreases the Sch ld Qty. Note: When using Multiple Location Processing, the user is prompted to enter a Putaway location for the received kit items. Decreases the on-hand balance for the components, either from the work in process location (when using the 3-Stage method), or from the component s stocking location. When a kit order was previously entered, the In Picking quantity is also decreased. Kit item: after the receipt In the illustration below, a quantity of 25 has been received for kit item TB1000. The system updates the kit item s inventory status, increasing the on-hand balance, and decreasing the Sch ld Qty. LOOK.STOCK - Display Current Availability Info for an Item Page No. 1 Item Number : TB1000 Description : TOOL KIT Ext`d Desc : Facility: 01 MAIN FACILITY Sell UM : EA Each Ship Loc Permanent Loc B125 Replenishment Code K Storage A Location Total Comm`td In Transfr Sch`ld Available Fac Location F On-Hand On-Hand Qty Picking Qty Qty To Pick 01 B125 Y On-Hand quantities have been increased. Sch ld Qty has been reduced. Enter "X" to exit the function, <CR> or "END" to continue... Continued on next page An Overview of the Kit Receipt Process 5-A-5

135 How Kit Receipts Affect Inventory, Continued Component item: after the receipt A component quantity of 25 has been used to build kit items. In the illustration below, the kit was received and the component s on-hand balance is decreased. The system also reduces the Sch ld Qty for the component item. LOOK.STOCK - Display Current Availability Info for an Item Page No. 1 Item Number : 100 Description : SCREWDRIVER Ext`d Desc : Facility: 01 MAIN FACILITY Sell UM : EA Each Ship Loc Permanent Loc A1 Replenishment Code LP Storage A Location Total Comm`td In Transfr Sch`ld Available Fac Location F On-Hand On-Hand Qty Picking Qty Qty To Pick 01 A1 Y A2 Y 14 KIT.WIP N 0 On-Hand quantities have been decreased. In Picking has been reduced. Enter "X" to exit the function, <CR> or "END" to continue... End of Pages to display for this Inquiry 5-A-6 An Overview of the Kit Receipt Process

136 Cost Updates Performed by Kit Receipts Introduction When a kit is received, the system performs cost updates to the kit item record, based on your system setup. Note: The Kit Receipt Costing method is identified in COST.CONSTANTS. The costing method used for kits may be different than the costing method used for purchase order receipts. Updates The following cost updates are performed by the BOM.TRANSACTIONS function, Option 3 - Enter Kit Receipts. These cost updates are not performed if a kit receipt is reversed using Option 4 - Reverse Kit Receipts. Updates the kit item s Material cost in the Accounting Value cost set using the sum of all the components costs (Material, Freight, Burden, Other 1 and Other 2), when using Replacement or Average Kit Receipt costing. Warning: Be aware that when a kit item has a negative on-hand quantity, the system will automatically use Replacement costing for a kit order receipt when set up to use the Average Kit Receipt Costing method. For Replacement Kit Receipt Costing only: posts a General Ledger entry for the accounting value change of existing kit item inventory, when the kit item s Material cost has changed as a result of the receipt. Updates the kit item s Average Actual and Last Actual cost sets using the sum of all the components costs, regardless of your system s Kit Receipt Costing method. These cost sets may be displayed using the function MNT.ITEM-COST. Audit report The KIT.RECEIPT.AUDIT function prints a report showing how kit receipts and reverse receipts have updated inventory value. For more information about this report, refer to the topic The KIT.RECEIPT.AUDIT Function in Chapter 7. Reference For more information about item costing, refer to the chapter titled Item Costing, in the Inventory Control User s Guide. An Overview of the Kit Receipt Process 5-A-7

137 Knowledge Check Directions Answer the following questions. This knowledge check is based on the objectives stated in the beginning of this section. Question 1 TRUE or FALSE Only the 3-Stage method of kit assembly processing requires the use to enter kit receipts. Question 2 Complete the statements by circling the correct answer found in the parentheses: A kit receipt will perform the following updates: a. For the kit item, the on-hand balance is (increased or decreased), and the Scheduled Quantity is (increased or decreased). a. For the component items, the on-hand balance is (increased or decreased), and the In Picking Quantity, when a kit order was previously entered, is (increased or decreased). Question 3 TRUE or FALSE A kit receipt will always update the kit item s Average Actual and Last Actual cost sets using the sum of all the components costs, regardless of your system s Kit Receipt Costing method. What s next? Compare your answers to the ones provided on the next page. The information in this section provides a foundation for other chapters within this user s guide. If you were unable to complete this knowledge check, please review the section before proceeding. If you are still uncomfortable with the information provided, or have specific questions regarding your system, contact your System Administrator or D2K Customer Care Consultant. 5-A-8 An Overview of the Kit Receipt Process

138 Knowledge Check Answers Answer 1 TRUE or FALSE Only the 3-Stage method of kit assembly processing requires the use to enter kit receipts. Explanation: All three methods of kit assembly processing require the user to enter kit receipts. A previously entered kit order is received (2 or 3-Stage method), or the kit order is created when the receipt is entered when the 1-Stage Method is used. Answer 2 Complete the statements by circling the correct answer found in the parentheses: A kit receipt will perform the following updates: a. For the kit item, the on-hand balance is increased, and the Scheduled Quantity is decreased. a. For the component items, the on-hand balance is decreased, and the In Picking Quantity, when a kit order was previously entered, is decreased. Answer 3 TRUE or FALSE A kit receipt will always update the kit item s Average Actual and Last Actual cost sets using the sum of all the components costs, regardless of your system s Kit Receipt Costing method. An Overview of the Kit Receipt Process 5-A-9

139

140 Section B Kit Receipts and Reversals Overview Introduction Kit receipts and reversals are processed using the BOM.TRANSACTIONS function. Depending on the method you use to process kit assemblies, the kit being received and the components used to build the kit, you may use one or multiple screens to complete these functions. Purpose The purpose of this section is to identify the screens used by the kit receipt and reverse receipt functions, and to identify the key fields found on each screen. This section will also provide the necessary procedures used to enter and reverse a kit receipt, as well as guidelines to consider when performing these tasks. Objectives Upon completion of this section, you will be able to identify the screens used to enter a kit receipt identify the screens used to reverse a kit receipt identify guidelines for entering and reversing kit receipts enter a receipt against an existing kit order, or enter a kit receipt without a kit order (1-Stage method), and reverse a kit receipt. Kit Receipts and Reversals 5-B-1

141 Figure 5-B-1. The BOM.TRANSACTIONS Selection Screen. BOM.TRANSACTIONS - Record Kit Order Picking and Receipt Transactions Entry Process Options Process Descriptions PICK REPORTING CONFIRM KIT ORDER PICKS Report Order Picked, Exception Entry 2. ENTER KIT ORDER PICKS Report Order Picked, Individual Entry --- KIT RECEIPTS ENTER KIT RECEIPTS Enter Kit Assembly Receipt Transactions 4. REVERSE KIT RECEIPTS Enter Kit Receipt Reversal Transactions 01 Entry Process Option : 1 Enter the Entry Process Option (1-4), END:... 5-B-2 Kit Receipts and Reversals

142 The Options Used to Enter Kit Receipt Information Introduction The BOM.TRANSACTIONS function is used to receive a kit item into inventory, or to reverse a kit receipt. Illustration Figure 5-B-1 is an illustration of the BOM.TRANSACTIONS selection screen. Options 3 and 4 are used for kit receipt processing. Options and descriptions The table below describes the two options available in the BOM.TRANSACTIONS function for entering and reversing kit receipts. Option Enter Kit Receipts Reverse Kit Receipts Description Used to receive a kit order previously entered on the system (2 or 3-Stage Method of Kit Order Processing), or receive a kit item into inventory without going through the complete kit order process (1-Stage Method). Used to disassemble a quantity of a kit and restock its components, or to correct a keying error when a kit receipt is entered for a quantity greater than the actual receipt quantity. Note: Reversals do not update or reopen kit orders. Also, reversals may not be made for kits which were assigned lot numbers, or for kits which contain components that are lot or serial traceable. Kit Receipts and Reversals 5-B-3

143 Figure 5-B-2. The BOM.TRANSACTIONS Kit Receipts Entry Screen. ENTER KIT RECEIPTS - Kit Receipts Entry Screen *** ATTENTION *** Use this process to enter receipt transactions for newly assembled kits. This process increases inventory for a kit and reduces inventory for its components. Kit cost data may also be updated Kit Order Number Kit Number TB TOOL BOX Base/Stocking UOM EA Each Quantity Ordered 25 Balance Quantity Received From Location KIT.WIP Kit Packaging 08 To Location B Close Short? N 10 Receipt Date YY Kit Costing Method AVE Change Which Field, END, TOP, \P... 5-B-4 Kit Receipts and Reversals

144 The BOM.TRANSACTIONS Kit Receipts Entry Screen Description The Kit Receipts Entry screen is used to enter a receipt of a kit order. It also allows the user to enter all information for a receipt of a kit item without going through the complete kit order process. Illustration Figure 5-B-2 is an illustration of the BOM.TRANSACTIONS Kit Receipts Entry screen. Fields and descriptions The table below describes the key fields on the BOM.TRANSACTIONS Kit Receipts Entry screen. Field Kit Order Number Description A unique identification number which identifies a kit order record. This number may be: an existing kit order number for which you want to process a receipt a new kit order number which will be used as a reference number to process a receipt for which no kit order exists, or Kit Number Quantity Ordered Balance the word NONE to process a receipt for which no kit order exists. "NONE" will be used as THE reference number. The kit item number which is being received. Display only: For an existing kit order number, the number of kits to be assembled and sent to inventory. Display only: For an existing kit order, the balance quantity of kits ordered, but not yet received into inventory. Continued on next page Kit Receipts and Reversals 5-B-5

145 The BOM.TRANSACTIONS Kit Receipts Entry Screen, Continued Fields and descriptions (continued) Field Description Quantity Received The quantity of the kit item being receiving into inventory. From Location Displays the Assembly Location specified at kit order entry time when receiving an existing kit order. When using the 3-Stage method of kit processing, this was the location to which components were moved for assembly. To Location Note: If using the 2-Stage method of kit processing (components are not moved to an assembly location), this data is used for informational purposes only. Multiple Location Processing only: The location into which the kit item is received. The user may specify any valid location to which the receipt quantity will be added, or use the default receiving location displayed by the system. The default location is found in the following order: the permanent location defined for the kit in MNT.ITEM-LOC or MNT.ITEM-SERIES the shipping location defined for the kit in MNT.ITEM-LOC or MNT.ITEM-SERIES the existing location with an on-hand balance (when only one location exists for the kit) the System location STOCK (if the receiving facility uses System locations only, and the quantity on-hand for the kit equals zero) Continued on next page 5-B-6 Kit Receipts and Reversals

146 The BOM.TRANSACTIONS Kit Receipts Entry Screen, Continued Fields and descriptions (continued) Field Close Short? Receipt Date Kit Costing Method Description For receipts against an existing kit order, this flag allows the kit order to be partially received and closed short. All remaining allocations will be canceled (component In Picking and kit Scheduled Qty is removed), and the kit order is deleted. The date on which the kit was received into inventory. Display only: The Kit Receipts Costing method as specified in COST.CONSTANTS. Kit Receipts and Reversals 5-B-7

147 Figure 5-B-3. The BOM.TRANSACTIONS Picked Quantities Entry Screen - Multiple Location Processing only. ENTER PICK QTYS - Picked Quantities Entry Screen Page 1 of 1 Order Number 5011 Reference TB Order Type Kit Lne Item Number Picking Qty to Stock Qty From Nbr Entries 008 Location Pick U/M Picked Location A25 7 EA 7 A EA 5 The... system detects a A EA shortage of 5 for H EA this component F10 24 EA This component was F12 10 EA allocated from two RCVNG 2 EA locations G16 12 EA Enter the From Location, END: 5-B-8 Kit Receipts and Reversals

148 The BOM.TRANSACTIONS Picked Quantities Entry Screen Description The BOM.TRANSACTIONS Picked Quantities Entry screen will automatically display when the receiving facility uses Multiple Location Processing, and when picked quantities have not been entered prior to the receipt using BOM.TRANSACTIONS Confirm or Enter Kit Picks (Options 1 or 2). This screen is used to identify the picked quantities and locations for each component used to assemble the kit order. The allocation information that printed on the picklist document is displayed, and the user must enter the actual quantities and picked from locations for each component. Important point The total Qty Picked for every component must equal the total quantities needed by the bill of material to assemble the number of kits received on the previous screen. If these quantities do not balance, the kit order cannot be received. Illustration Figure 5-B-3 is an illustration of the BOM.TRANSACTIONS Picked Quantities Entry screen. Fields and descriptions The table below describes the key fields on the BOM.TRANSACTIONS Picked Quantities Entry screen. Field Order Number Description Display only: A unique identification number which defines a kit order record. This number may be: an existing kit order number or a new kit order number which will be used as a reference number to process a receipt for which no kit order exists. Continued on next page Kit Receipts and Reversals 5-B-9

149 The BOM.TRANSACTIONS Picked Quantities Entry Screen, Continued Fields and descriptions (continued) Field Reference Item Number Description Display only: The kit item number which is being received. Display only: The component item number which was used to assemble the kit item. Picking Location Display only: The location from which the component item was allocated for picking. Note 1: When a component s inventory was allocated from more than one location, multiple lines will display. An example of this is shown on Figure 5-4, Line Nbrs 6 and 7. Component was allocated from two different locations. Qty to Pick Note 2: If an inventory shortage exists for a component, the unallocated quantity needed to satisfy the kit receipt requirement displays. An example of this is shown on Figure 5-4, Line Nbr 2. Component 105 only shows an inventory quantity of 585 in location A25. The user must identify the storage location from which the remaining quantity of 15 taken. Display only: The quantity of the component item that was allocated for picking, or that is needed to satisfy the kit receipt requirement. Continued on next page 5-B-10 Kit Receipts and Reversals

150 The BOM.TRANSACTIONS Picked Quantities Entry Screen, Continued Fields and descriptions (continued) Field Qty Picked From Location Description The actual quantity picked for the component item. Note: The total quantity picked for each component must equal the total quantities needed by the bill of material to assemble the number of kits received on the previous screen. The warehouse location from which the component item was removed. Kit Receipts and Reversals 5-B-11

151 Figure 5-B-4. The BOM.TRANSACTIONS Lot Number Entry Screen. Lot Number Entry Item Number Total Quantity 1 1-LB GOURMET MINTS 01 Lot Number 02 Location 03 Quantity.1) F127 1 Item count 1 Page 1 of 1 Change Which Field, (D)elete, END, TOP, \P... 5-B-12 Kit Receipts and Reversals

152 The BOM.TRANSACTIONS Lot Number Entry Screen Description The Lot Number Entry screen is used to identify the component lot number(s) used to build a kit item. Following the entry of lots and lot quantities for a component, the Serial Number Entry Screen displays, if serial number tracing is also utilized for the component, of if lot number tracing is used for the kit item. Illustration Figure 5-B-4 is an illustration of the BOM.TRANSACTIONS Lot Number Entry screen. Fields and descriptions The table below describes the key fields from the BOM.TRANSACTIONS Lot Number Entry screen. Field Item Number Total Quantity Lot Number Location Quantity Description The Component item which is lot traced. The total quantity of the component item used in the kit receipt. Note: The sum of the lot quantities must equal the Total Quantity field in order to continue with the kit receipt. The lot number(s) for this component used to assemble the kit receipt. Multiple Location Processing only: Identifies the location from which the lot traced component was taken to build the kit item. The quantity associated with the previously entered lot number. Kit Receipts and Reversals 5-B-13

153 Figure 5-B-5. The BOM.TRANSACTIONS Component Lot/Serial Number Screen. ENTER KIT RECEIPTS - Component Lot/Serial Number Screen Kit Number : L LIFT MASTER OVERHEAD DOOR KIT Quantity Received : 6 03 Kit Trace Number 04 Quantity ** Not Traced ** Entries Component : S MOTOR ASSEMBLY Qty Per/Kit : 1 Qty Needed : 6 Component Item 1 of Lot Number 10 Quantity 11 Serial Number.01).01) ).02) ).03) ).04) ).05) ).06) ).07).08).08) Entries 0 Entries 6 Lot or Serial Tracing for the Kit Item Serial Tracing for the Component Item Change Which Component Fld, (TOP)-Deletes all Component Info, \P, END NEXT.. 5-B-14 Kit Receipts and Reversals

154 The BOM.TRANSACTIONS Component Lot/Serial Number Screen Description The BOM.TRANSACTIONS Component Lot/Serial Number screen has two functions. It is used to enter the Kit Trace Number for the kit item (when the kit is lot or serial number traced) and/or enter the component serial number(s) used to assemble the kit (when a component uses full or outbound serial number tracing). Note: The Component lot numbers which display on the bottom of the screen were entered on the BOM.TRANSACTIONS Lot Number Entry screen. If a component is both lot and serial traced, the user must identify the serial numbers that were used per lot quantity in the kit assembly. Tracing kits which contain serial numbered components In order for the system to prompt for the Kit Trace Number (a number which identifies the quantity received for the kit item), the kit must be set up as a lot traceable kit. (While kits may be fully lot traceable, they may only be flagged for outbound serial number control. This means that the serial number is only traced when the kit is sold or transferred out of the warehouse, not when the kit is received into the warehouse.) In some instances, a distributor may want to track the kit item using the serial number of a component used to assemble the kit. In order to retain serial number tracing between kit assembly and sale/shipment, the kit item should be flagged for full lot control. The Kit Trace Number is then used to trace the serial number of the component used in the assembly. Illustration Figure 5-B-5 is an illustration of the BOM.TRANSACTIONS Component Lot/Serial Number Screen. In this example, the kit was assembled using a component that is serial number traced. The kit, however, will not be traced by any identifying number (Kit Trace Number). Continued on next page Kit Receipts and Reversals 5-B-15

155 The BOM.TRANSACTIONS Component Lot/Serial Number Screen, Continued Fields and descriptions The table below describes the key fields on the BOM.TRANSACTIONS Component Lot/Serial Number Screen. Field Description Lot Tracing for the Kit Item Quantity Received Display only: The quantity of the kit being received. Kit Trace Number A number which will identify the kit item. This number may be a new or existing lot number for the kit, or the serial number of one of the components used to assemble the kit. Quantity Component Qty Per/Kit Qty Needed Component Item nn of nn Note: To trace each individual kit by a component s serial number, enter the component serial number as the Kit Trace Number, and enter 1 as the quantity. Enter the component serial number on the bottom portion of the screen, then repeat the procedure for each individual kit being received until the quantity received is satisfied. The quantity of kits received that are to be traced by the Kit Trace Number entered at the previous prompt. Lot/Serial Tracing for the Component Item Display only: The component item number, used in the kit assembly, which is lot and/or serial number traced. Display only: The quantity of the component needed to build one kit item, as defined in the bill of material structure. Display only: The number of components needed to build the number of kits received by this transaction. Display only: Identifies the number of components for which lot and/or serial numbers must be entered for this kit receipt. Continued on next page 5-B-16 Kit Receipts and Reversals

156 The BOM.TRANSACTIONS Component Lot/Serial Number Screen, Continued Fields and descriptions (continued) Field Lot Number Quantity Serial Number Description When a component is both lot and serial number controlled, this field is used to identify the lot number (previously identified on the Lot Number Entry Screen) for which serial numbers will now be entered. Note: The user may review the lot numbers and quantities previously entered on the Lot Number Entry Screen by accessing this field and typing R (review). The component s lot quantity used in this kit receipt. This lot quantity was previously identified on the Lot Number Entry Screen, and relates to the Lot Number that displays in the previous prompt. Note: The user may review the lot numbers and quantities previously entered on the Lot Number Entry Screen by accessing this field and typing R (review). The specific component serial number(s) used in building the kit receipt. If the component is both lot and serial number controlled, the serial numbers entered must be valid for the lot number displayed on the left side of the screen. Note: The total serial numbers entered must equal the component s Qty Needed for the kit receipt, as displayed underneath the Component field. Kit Receipts and Reversals 5-B-17

157 Figure 5-B-6. The BOM.TRANSACTIONS Kit Receipts Reversal Screen. REVERSE KIT RECEIPTS - Kit Receipts Reversal Screen *** ATTENTION *** Use this process to reverse kit receipt transactions for kits which do not have assigned lot numbers and which do not contain traceable components. This process decreases inventory for a kit and increases inventory for its components Kit Number TB TOOL KIT Base/Stocking UOM EA Each 03 Quantity to Reverse 1 04 From Location F12 05 Reversal Date YY Change Which Field, END, TOP, \P... 5-B-18 Kit Receipts and Reversals

158 The BOM.TRANSACTIONS Kit Receipts Reversal Screen Description The BOM.TRANSACTIONS Kit Receipts Reversal screen is used to disassemble a quantity of a kit and restock its components, or to correct a keying error when a kit receipt is entered for a quantity greater than the actual receipt quantity. Illustration Figure 5-B-6 is an illustration of the BOM.TRANSACTIONS Kit Receipts Reversal Screen. Fields and descriptions The table below describes the key fields on the BOM.TRANSACTIONS Kit Receipts Reversal Screen. Field Kit Number Quantity to Reverse From Location Reversal Date Description The kit item number for which to reverse a receipt. The quantity to reverse. The inventory for the kit item will be decreased, and inventory for each component, extended by its use per kit, will be increased. Example: A quantity of 1 will decrease the inventory of the kit by 1 and increase inventories for one set of components. Multiple Location Processing only: The location from which the disassembled kit was picked, or to which a receipt 'error' was made. The system displays a default location, which is found in the following order: the permanent location defined for the kit in MNT.ITEM-LOC or MNT.ITEM-SERIES the shipping location defined for the kit in MNT.ITEM-LOC or MNT.ITEM-SERIES the existing location with an on-hand balance (when only one location exists for the kit). The date on which the reversal is effective. This date cannot be within a closed GL period. Kit Receipts and Reversals 5-B-19

159 Figure 5-B-7. The BOM.TRANSACTIONS Reversal Component Putaway Screen. REVERSAL LOC ENTRY - Component Putaway Locations Screen Order Number Reversal Kit Item Number TB Page 1 of 1 Lne Item Number Stock Reversal Putaway Nbr Entries 006 U/M Quantity Location EA 1 A EA EA EA EA EA Enter the Putaway Quantity, END: 5-B-20 Kit Receipts and Reversals

160 The BOM.TRANSACTIONS Reversal Component Putaway Screen Description The BOM.TRANSACTIONS Reversal Component Putaway screen displays only when the facility is set up for Multiple Location Processing. The screen is used to identify the locations in which the components of the reversed kit were put away. Illustration Figure 5-B-7 is an illustration of the BOM.TRANSACTIONS Reversal Component Putaway screen. Fields and descriptions The table below describes the key fields on the BOM.TRANSACTIONS Reversal Component Putaway screen. Field Item Number Reversal Quantity Putaway Location Description The component item number used in the kit assembly. The quantity put away for the component. Note: The system displays the total quantity that needs to be put away. If the user changes this quantity, the system will automatically add a new line with the outstanding quantity as the displayed default. This allows you to satisfy the reversal requirement when the reversal quantity was putaway in more than one location. The location in which this component item was put away. Kit Receipts and Reversals 5-B-21

161 Guidelines for Entering Kit Receipts Introduction Before you enter a kit receipt, it is important to follow certain guidelines. Guidelines Consider these guidelines when entering a kit receipt: Receipts may be entered against a specific kit order number, previously entered in the ENTER.KIT.ORDER function. The D2K system will keep the kit order open until it is either received complete, closed short (through the receipt process), or deleted in the ENTER.KIT.ORDER function. Receipts may also be entered for a kit item, when no kit order was created in the ENTER.KIT.ORDER function. This is called the 1-Stage method of kit assembly processing. The user may either assign a kit order number to trace this transaction, let the system assign a kit order number, or use NONE as the kit order number. The 1-Stage method of kit assembly processing does not allow the user to create a kit backorder for unassembled kits. Even though this process creates a kit order when the receipt is entered, the receipt quantity equals the kit order quantity, and the kit order is closed when the receipt is filed. 5-B-22 Kit Receipts and Reversals

162 How to Enter a Kit Receipt (BOM.TRANSACTIONS - Option 3) Introduction Option 3 of the BOM.TRANSACTIONS function is used to enter receipts for a kit item, increasing the inventory balance for the kit and decreasing inventory for the components. Receipts may be entered to a kit order that was created through the function ENTER.KIT.ORDER (a 2 or 3-Stage method of processing). Full or partial receipts may be entered, and the kit order may be closed short, if necessary. Kit receipts may also be entered when an order was not previously entered through the function ENTER.KIT.ORDER (the 1-Stage method of processing). This option is used to update inventory on both the kit and component items. Learning advice When the kit or component item(s) use lot and/or serial number control, you will be required to complete screens to finish the kit receipt transaction. The following procedure does not include instructions on how to complete these screens. For more information about the screens, and the fields contained in each screen, refer to the following topics found in this section: The BOM.TRANSACTIONS Lot Number Entry Screen The BOM.TRANSACTIONS Component Lot/Serial Number Screen Accessing the function Use the boxes below to write your menu path to the BOM.TRANSACTIONS function. Continued on next page Kit Receipts and Reversals 5-B-23

163 How to Enter a Kit Receipt (BOM.TRANSACTIONS - Option 3), Continued Procedure Complete the steps in the table below to receive a kit order in the BOM.TRANSACTIONS function. Step Action 1 Access the function BOM.TRANSACTIONS. Result: The prompt Enter the Entry Process Option (1-4) displays. 2 Type 3 and press [Enter]. Result: The Kit Receipts Entry Screen appears, and the prompt Enter the Kit Order Number, NONE, <CR>, X, END displays. 3 Make the following decision: IF a kit order was previously created using the ENTER.KIT.ORDER function was not previously entered using ENTER.KIT.ORDER THEN type the kit order number to receive and press [Enter]. Go to Step 5. Result: The system displays the kit number, original quantity ordered, and balance quantity. The prompt Enter the Quantity Received displays. type any reference number and press [Enter] press [Enter] (to use NONE as the reference number), or type NONE and press [Enter] (to use NONE as the reference number). Result: The prompt Enter the Kit Item Number displays. Continued on next page 5-B-24 Kit Receipts and Reversals

164 How to Enter a Kit Receipt (BOM.TRANSACTIONS - Option 3), Continued Procedure (continued) Step Action 4 Type the kit item number and press [Enter]. Result: The prompt Enter the Quantity Received displays. 5 Type the quantity received for the kit and press [Enter]. 6 Does the prompt Enter the Putaway (To) Location display? If yes, type the location into which you are receiving the item and press [Enter], or press [Enter] to use the default displayed. If no, go to Step 7. Note: This prompt displays only when Multiple Location Processing is enabled for the receiving facility. Result: The prompt Enter the Receipt date displays. 7 Press [Enter] to use today s date, or type a new date and press [Enter]. Result: The Command Line Change which Field, END, TOP displays. 8 If the quantity received is less than the Balance Quantity, do you want to close this order short? If yes, select the Close Short? field and change it to Y using standard System Conventions. If no, go to Step 9. Note: When closing a kit order short, all remaining allocations will be canceled. You may not reopen this order. Continued on next page Kit Receipts and Reversals 5-B-25

165 How to Enter a Kit Receipt (BOM.TRANSACTIONS - Option 3), Continued Procedure (continued) Step Action 9 Type END and press [Enter]. 10 Does the Picked Quantities Entry Screen appear? If yes, go to Step 11. Note: When your system is set up for Multiple Location Processing, and when using the 1 or 2-Stage kit processing method, you must enter or confirm Kit Picks for the receipt. The Picked Quantities Entry Screen appears, and the prompt Enter the Quantity Picked displays. If no, go to Step 16. Result: The kit receipt is filed. Component quantities are reduced, and the kit item quantity is increased. The prompt Enter the Kit Order, X, END displays. Picked Quantities Entry Screen 11 Look at your screen and locate the cursor in the Qty Picked column. Note: The cursor placement determines the line item for which you are ready to enter picks. Result: The prompt Enter the Quantity Picked displays. Continued on next page 5-B-26 Kit Receipts and Reversals

166 How to Enter a Kit Receipt (BOM.TRANSACTIONS - Option 3), Continued Procedure (continued) Step 12 Make the following decision: Action IF you want to use the displayed quantity as the quantity picked enter a new quantity picked THEN press [Enter]. type the new quantity and press [Enter]. Note: The total quantity picked must equal the Qty To Pick field. If all quantities were not picked from the same bin location, the system will add additional line items on the screen to allow for additional entries. Result: The prompt Enter the From Location displays. 13 Press [Enter] to reduce the component on-hand from the displayed location, or type a new location and press [Enter]. 14 Repeat from Step 11 as necessary, until the Command Line Change which line, Fn, Bn, Pn, TOP, END displays. 15 Type END and press [Enter]. Result: The kit receipt is filed. Component quantities are reduced, and the kit item quantity is increased. The prompt Enter the Kit Order, X, END displays. Continued on next page Kit Receipts and Reversals 5-B-27

167 How to Enter a Kit Receipt (BOM.TRANSACTIONS - Option 3), Continued Procedure (continued) Step 16 Make the following decision: Action IF you want to enter receipts for another kit order go back to the Entry Option Screen exit the function THEN return to Step 3. type END and press [Enter]. type X and press [Enter]. 5-B-28 Kit Receipts and Reversals

168 Guidelines for Reversing a Kit Receipt Introduction Before you reverse a kit receipt, it is important to understand certain concepts about kit reversals. Guidelines Consider these guidelines when reversing a kit receipt: Reversals are not entered against a specific kit order number. Therefore, the reversal does not update a kit order transaction with a new balance quantity to receive. Reversals may not be made for kits which were assigned a Lot Tracing Number, or for kit items that contain components which are lot or serial traceable. To reverse a kit receipt for a kit such as these, use the function ENTER.INV.ADJUSTMENT. Kit reversals do not perform any cost updates to the kit or component items. For general guidelines on how to correct costing errors, refer to the Chapter titled Item Costing, in the Inventory Control User s Guide. Kit Receipts and Reversals 5-B-29

169 How to Reverse a Kit Receipt (BOM.TRANSACTIONS - Option 4) Introduction Option 4 of the BOM.TRANSACTIONS function allows a kit receipt to be reversed if an entry error is made. It is also used when a kit is disassembled, and the components are put back on the shelf. Accessing the function Use the boxes below to write your menu path to the BOM.TRANSACTIONS function. Procedure Complete the steps in the table below to reverse a kit order receipt. Step Action 1 Access the function BOM.TRANSACTIONS. Result: The prompt Enter the Entry Process Option (1-4) displays. 2 Type 4 and press [Enter]. Result: The Kit Receipts Reversal Screen appears, and the prompt Enter the Kit Item Number, X, END displays. 3 Type the kit item number and press [Enter]. Result: The prompt Enter the Quantity to Reverse displays. 4 Type the quantity of the kit item to reverse and press [Enter]. Note: Inventory for the parent item will be decreased and inventory for each component, extended by its use per kit, will be increased. Continued on next page 5-B-30 Kit Receipts and Reversals

170 How to Reverse a Kit Receipt (BOM.TRANSACTIONS - Option 4), Continued Procedure (continued) Step Action 5 Does the prompt Enter the From Location display? If yes, type the location from which you are removing the parent item and press [Enter], or press [Enter] to use the default displayed. If no, go to Step 6. Note: This prompt displays only when multiple location processing is enabled for the receiving facility. Result: The prompt Enter the Reversal Date displays. 6 Press [Enter] to use today s date as the reversal date, or type a new date and press [Enter]. Result: The Command Line Change Which Field, END, TOP displays. 7 Type END and press [Enter]. 8 Does the Component Putaway Locations Screen appear? If yes, go to Step 9. Note: When your system is set up for multiple locations, you must identify the putaway locations for each component s inventory. If no, go to Step 14. Result: The kit receipt is reversed. Component quantities are increased, and the kit item quantity is decreased. The prompt Enter the Kit Order, X, END displays. Continued on next page Kit Receipts and Reversals 5-B-31

171 How to Reverse a Kit Receipt (BOM.TRANSACTIONS - Option 4), Continued Procedure (continued) Step Action 9 Look at your screen and locate the cursor in the Reversal Quantity column. Note: The cursor placement determines the line item which you are ready to reverse. Result: The prompt Enter the Putaway Quantity displays. 10 Make the following decision: IF you want to use the displayed quantity as the quantity reversed enter a new quantity reversed THEN press [Enter]. type the new quantity and press [Enter]. Result: The prompt Enter the Putaway Location displays. 11 Press [Enter] to increase the component on-hand from the displayed location, or type a new location and press [Enter]. 12 Repeat from Step 9 as necessary, until the Command Line Change which line, Fn, Bn, Pn, TOP, END displays. Note: The total quantity reversed for a component must satisfy the reverse receipt requirement before you can access the Command Line. 13 Type END and press [Enter]. Result: The kit receipt is reversed. Component quantities are increased, and the kit item quantity is decreased. The prompt Enter the Kit Order, X, END displays. Continued on next page 5-B-32 Kit Receipts and Reversals

172 How to Reverse a Kit Receipt (BOM.TRANSACTIONS - Option 4), Continued Procedure (continued) Step 14 Make the following decision: Action IF you want to enter receipts for another kit order go back to the Entry Option Screen exit the function THEN return to Step 3. type END and press [Enter]. type X and press [Enter]. Kit Receipts and Reversals 5-B-33

173 Knowledge Check Directions Answer the following questions. This knowledge check is based on the objectives stated in the beginning of this section. Question 1 Match the screen on the left with the purpose on the right, by placing the appropriate letter in the column provided. a-e Screen Purpose Kit Receipts Entry a. Identifies the component lot numbers used to build a kit item. Picked Quantities Entry b. Used to disassemble a kit and restock its components, or correct a keying error when a kit receipt is entered for a quantity greater than the actual receipt. Lot Number Entry c. Enter a receipt against a kit order, or receive a kit item directly, without a kit order. Component Lot/Serial Number d. Used to enter the lot number(s) received for the kit item, and/or used to enter the component serial number(s) used to build the kit item. Kit Receipts Reversal e. For Multiple Location Processing only. Used to identify the picked quantities and locations for each component used to assemble the kit order, when picking information was not entered prior to the receipt. Question 2 TRUE or FALSE Using the 1-Stage method for kit assembly processing, a kit backorder can be created when entering a kit receipt. Question 3 TRUE or FALSE Reversals are entered against a specific kit order number. Therefore, the reversal updates the kit order with a new balance quantity to receive. Continued on next page 5-B-34 Kit Receipts and Reversals

174 Knowledge Check, Continued What s next? Compare your answers to the ones provided on the next page. If you were unable to complete this knowledge check, we recommend that you review the section before continuing. If you are still uncomfortable with the information provided, or have specific questions regarding your system, contact your System Administrator or D2K Customer Care Consultant. Kit Receipts and Reversals 5-B-35

175 Knowledge Check Answers Answer 1 Match the screen on the left with the purpose on the right, by placing the appropriate letter in the column provided. a-e Screen Purpose c. Kit Receipts Entry a. Identifies the component lot numbers used to build a kit item. e. Picked Quantities Entry b. Used to disassemble a kit and restock its components, or correct a keying error when a kit receipt is entered for a quantity greater than the actual receipt. a. Lot Number Entry c. Enter a receipt against a kit order, or receive a kit item directly, without a kit order. d. Component Lot/Serial Number d. Used to enter the lot number(s) received for the kit item, and/or used to enter the component serial number(s) used to build the kit item. b. Kit Receipts Reversal e. For Multiple Location Processing only. Used to identify the picked quantities and locations for each component used to assemble the kit order, when picking information was not entered prior to the receipt. Answer 2 TRUE or FALSE Using the 1-Stage method for kit assembly processing, a kit backorder can be created when entering a kit receipt. Explanation: The 1-Stage method of kit assembly processing does not allow the user to create a kit backorder for unassembled kits. Even though this process creates a kit order when the receipt is entered, the receipt quantity equals the kit order quantity, and the kit order is closed when the receipt is filed. Continued on next page 5-B-36 Kit Receipts and Reversals

176 Knowledge Check Answers, Continued Answer 3 TRUE or FALSE Reversals are entered against a specific kit order number. Therefore, the reversal updates the kit order with a new balance quantity to receive. Explanation: Reversals are not entered against a specific kit order number. Therefore, the reversal cannot update a kit order with a new balance quantity to receive. Kit Receipts and Reversals 5-B-37

177 Chapter 6 Phantom Kit Processing Overview Introduction In Chapter 1, you learned that the Bill of Material module supports processing of kit and phantom kit items. These two types of kits are handled much differently on the D2K system. Purpose The purpose of this chapter is to provide an explanation of phantom kit processing, and how it differs from the kit assembly process. You will learn how the sales entry functions initiate phantom kit processing, and how inventory updates are handled differently. Objectives Upon completion of this chapter, you will be able to define the term phantom kit identify the constants which control phantom kit processing describe the phantom kit process identify the two screens used by the D2K system to process phantom kits in the sales entry functions, and describe how component inventory is affected by the phantom kit process. Learning advice For specific instructions on how to enter data in the screens used by phantom kit processing, refer to the chapter titled Other Processing Features in the Sales Processing User s Guide for Learning and Reference. Phantom Kit Processing 6-1

178 What is a Phantom Kit? Introduction In Chapter 1, you learned that an assembled item can be either a kit or a phantom kit item. Definition A phantom kit is an item that is not preassembled or stocked in inventory. The phantom kit is a collection of components which are assembled only when a sales order is generated for it. Note: This differs from a kit item, which is preassembled and stocked for inventory. When a customer orders a phantom kit item, inventory is committed for the components of the phantom kit. Typically, the kit structure is printed on the order or picklist document, and the phantom kit is assembled as the components are picked. When the sales order is invoiced, inventory is reduced for the components. Inventory replenishment processes do not plan for phantom kits, but do plan inventory for the components. Example The following example was provided in Chapter 1: EJ s Specialty Gifts is a nationwide mail-order distributor, who sells gift, gourmet, and fruit baskets. Since their items consist of perishable goods, customer orders are picked, packaged, and shipped the day prior to the requested delivery date to assure the highest quality in their product. Baskets are not built to stock, but are assembled when the customer order is ready for shipment. Continued on next page 6-2 Phantom Kit Processing

179 What is a Phantom Kit?, Continued Example (continued) For example, phantom kit item # 4964X, a Hostess Basket, is made up of the following component items: Apples 1 Wicker Basket 3 Royal Gala (Item # B25) (Item # A1) 3 Royal Navel Oranges 3 Royal Pears (Item # O1) (Item # P1) Phantom Kit Processing 6-3