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Works Orders Trial Kitting

You can use Works Order Trial Kitting to check whether there is sufficient component stock to build your Works Orders. It identifies and displays any potential shortages.

Trial Kitting also calculates the lead time and unit cost of each Bill of Materials, including a breakdown of resource times.

Works Orders can be trial kitted one at a time, or multiple orders can be trial kitted together. Trial kitting multiple orders can give a more accurate way of checking for shortages in common components.

For example, a component that is required on multiple orders, has sufficient stock to fulfil each one with the available stock, but not sufficient to fulfil all orders.

In this example, trial kitting the orders individually would not identify a shortage; trial kitting the orders together would identify the shortage.

 

 

Trial Kitting Works Orders

Open: Works Orders > Works Order List

  • Select the works order(s) you want to trial kit.
  • Select the Trial Kitting button above the list view.

From the menu:

Open: Cim200 Works Orders > Enquiries > Trial Kitting

  •  In the Works Orders To Trial Kit area, set the order(s) to be trial kitted.

 

The Trial Kitting window is split into two main parts:

Works Orders to Trial Kit

This is the top part of the window, where the Works Order(s) to be trial kitted should be entered.

 

1. Enter the Quantity required. This defaults to the Quantity Outstanding on the works order, but it can be changed to a different quantity for the trial kitting session. The unit of measure for the quantity is also shown.

2. Lead Time shows the total time required to build the product. This is calculated as:

    • The time it takes to manufacture + The longest material lead time.

3. In the Options button you can set several options to use during trial kitting. These default settings for these options can be defined in the Bill of Materials Settings screen, on the Trial Kitting tab.

  • Treat Stock On-Order as available
    • Tick this option to have the Trial Kitting routine include any outstanding Purchase Orders for the item included in available stock. If there is sufficient stock quantity on order to cover any shortage of free stock, the item will not be treated as a shortage.

Note: If you are using Manufacturing, trial kitting is not a substitute for MRP. MRP considers the total demand; trial kitting considers only what you enter here.

  • Only show shortages in the results
    • Tick this to exclude from the results all items which have sufficient stock, displaying only the items found to have a shortage. This can make it easier to focus on the items that require action.

 

  • Report shortages for components

 

  • Report shortages for sub-assemblies
    • Items that do not allow negative stock will always display a shortage where one is found. For items that do allow negative stock, if there is insufficient stock this could either be treated as a shortage or ignored and stock will be expected to go negative. To treat it as a shortage, tick the option to report shortages. There is a separate option for components and sub-assemblies.

 

  • Sub-Assemblies
    • For sub-assembly items, choose whether trial kitting should :
      • Ignore free stock          Instead treat as build to order the full required quantity and check for shortages of its BOM components.
      • Only use free stock      If there is insufficient free stock treat it as a shortage; do not continue to check for shortages of its BOM components.
      • Build when required   If there is insufficient free stock check for shortages of its BOM components to make the quantity that is short.

 

  •  Decide when to stop processing if shortages are found
    • Select whether to Continue, Stop Immediately or Stop after processing Bill of Material when you are trial kitting multiple BOMs and shortages are encountered.
      • Continue – Continue through to completion of trial kitting for all Works Orders, for a full list of requirements and/or shortages.
      • Stop Immediately – Stop the trial kitting as soon as a shortage is found.
      • Stop after processing Works Order – Stop the trial kitting once a shortage is found, but only after completing the process for the current Works Order.

4. To delete a Works Order from the list, select the line and click Delete.

5. To run the trial kit, click Display.

 

The results display

This area displays the results of the Trial Kit, grouped into separate tabs for Components, Labour, Machine, Tooling and Subcontract.

The results are calculated and displayed in the following tabs:

 

Components

This tab lists the components and sub-assemblies required to build the tasks.

Quantities have been converted to stock units.

Sub-assemblies are highlighted in colour (blue by default).

Shortages are highlighted in colour (red by default).

  • If the item allows negative stock levels and the options, Report shortages for Components or Report shortages for Sub-Assemblies have not been selected, N/A is displayed in the Shortage column for components or sub-assemblies.
  • If the item is a miscellaneous stock item, N/A is displayed in the Shortage column.

 

Labour

Shows the total labour time required, analysed by process.

Note: This is not necessarily the lead time. It does not consider if some resources can run in parallel.

 

Machines

Shows the total machine time required on each machine, analysed by process.

Note: This is not necessarily the lead time. It does not consider if some resources can run in parallel.

 

Tooling

Shows the total tooling time required on each machine, analysed by process.

Note: This is not necessarily the lead time. It does not consider if some resources can run in parallel.

 

Subcontract

Shows the total time required for each subcontract operation required for the BOM.

 

6. Click Print to produce a printed copy of your trial kitting results.

7. After trial kitting, purchase orders (for bought items) and works orders (for built items)                        can be actioned from within screen to cover any shortages that are identified.

 

Create Works Order(s)

8. Click the Create Works Orders button to create new Works Orders for any subassemblies that have a shortage on the Trial Kit results.

9. The Create Works Orders screen lists any built items that are short. Set the Quantity as the quantity to order. This defaults as the shortage quantity found on the trial kit. Only lines with a quantity set will generate a new works order.

10. Set the Warehouse, Bin and Due Date to use for the Works Order.

11. If works order numbers are set manually, set the Order No to use; otherwise it will display TBA and will be generated automatically on order creation.

12. Click OK to generate works orders. Click Cancel to cancel without creating new works orders.

Create Purchase Order(s)

13. Click the Create Purchase Orders button to create new Purchase Orders for any bought items that have a shortage on the Trial Kit results.

14. The Create Purchase Orders screen lists any bought items that are short. Set the Quantity as the quantity to order. This defaults as the shortage quantity found on the trial kit. This can be changed but if you try to enter less than the shortage value a warning is given. Only lines with a quantity set will generate a new purchase order.

15. Set the Warehouse.

16. The bought item’s preferred Supplier account code is displayed by default. Select an alternative supplier if required.

17. If purchase order numbers are set manually, set the Order No to use; otherwise, it will display TBA and will be generated automatically on order creation.

18. The Supplier Ref. No displays the supplier’s item reference for the bought item. It defaults from the preferred supplier record in Stock Item Details.

19. The Delivery Requested date calculates using the lead time on the bought item’s preferred supplier record, but can be changed.

Note: Changing the supplier recalculates the Order Date by applying the new Lead Time value.

20. Click OK to generate purchase orders. Click Cancel to cancel without creating new works orders.

21. To close the Trial Kitting window, click Close.