Background: Manufacturing Order Maintenance
Use the Manufacturing Order Maintenance (MIM) program to enter, change or close regular manufacturing and rework and repair orders. See Background and Road Map for more information.
This topic has these subtopics:
Manufacturing Orders
You typically enter a manufacturing order for a parent item of a finished good or subassembly. You cannot enter a manufacturing order for a pseudo, configured product, prompt, or family item. A phantom item (bypass code of 1) is allowed if you selected the Allow stocking of phantoms? option in the System Options Maintenance (XM) program (Inventory Control Options). If the Workorderless? field is selected in the Branch Item Maintenance (IMB) program for the item you enter, the program displays a message but allows you to continue.
Manufacturing Order Maintenance is not the only method of creating manufacturing orders. You can use this program to change a manufacturing order that was created by:
Sales Order Maintenance (OE) when you enter an order for an immediate supply item.
Releasing a requisition with the Requisition Maintenance (IRM) program.
Releasing planned orders with the Order Release Selection (MRR) program.
The system creates the manufacturing order for a parent item that has subassemblies that you make or assemble. See Cascading Manufacturing Orders.
When you are creating a new order and click on the Obligate or Component buttons, the program attempts to release the order, and displays the order number. If you have not created a bill of material, the program prompts There is no Bill of Material for this ECL; continue? If you have not created a routing for this item, or the Routing rev lvl field is blank, the program prompts There is no routing for this routing revision level; continue?. If you click Yes, the Mfg order no [number] has been created message displays. Click OK.
Bulk Movement Items
You may receive raw material in a large container (for example, a 55-gallon barrel). You may pick a portion of it for one manufacturing order and use the remaining amount for other orders. Because the container is large and heavy, you probably do not want to return the unused quantity to the stockroom between picks.
A bulk movement item must be warehouse/bin controlled. You should obligate a bulk movement item manually to specify that you either want to use the ALWM feature to issue a new container to the order or that you want to use a remaining quantity that is already on the floor, either at the same location or to move it from another location.
For more information on bulk movement items and how to track them, see Overview: Automated Location Warehouse Movement.
Cascading Manufacturing Orders
The system can create manufacturing orders for subassemblies that you make or assemble when you create the manufacturing order for the parent item. See Overview: Cascading Manufacturing Orders.
Change a Manufacturing Order
You can change the due date and quantity ordered at any time before you receive the order complete with the Receiver Maintenance (IRC) program.
Due Date
If this order has a linked sales order, the due date is determined by the order line's Expected ship date. You can change the due date after you obligate and pick components.
Quantity Ordered
When you increase the Qty ordered, the program adjusts the Qty required even though you have already picked the original quantity required. The program does not, however, allow reducing the quantity ordered to less than the picked quantity.
If the order has been fully picked, you can use the Picking Confirmation (MPK) program to reverse confirmation and delete the shipment. This returns all components to inventory. Then run Manufacturing Order Maintenance, change the quantity ordered, and re-obligate components for the order. When you click Pick, the program creates shipment 002.
When you change the Qty ordered, the system recalculates the hours remaining in the WIP Movement (WIPM) program. If you already entered some good and/or scrap pieces, the system also recalculates the percent complete.
When you receive the completed order into finished goods with the Receiver Maintenance (IRC) program, you can receive less than ordered and close the order short. Alternatively, you can receive more than the quantity ordered.
Change Operation Sequences
You can change operation sequences and re-calculate manufacturing order cost with the alternate operation sequences you selected for your manufacturing order.
You can add operation sequences or alternate operation sequences with the Routing Maintenance (RTM) program. Then use the Chg oper button in Manufacturing Order Maintenance to select the operation sequences you want to specify for the order.
You can choose to recalculate standard labor and labor overhead cost with the new operation sequences or retain the original standard costs and to adjust operation start dates using the changed operations.
Close a Manufacturing Order
An order cannot be closed if:
You have entered WIP for an operation sequence in the Work in Process Movement (WIPM) program.
You have entered hours worked for an operation sequence in Labor Entry (LLE) program or imported this data with the Labor Import (LEI) program.
The order is partially received.
Serial linking is active (maintained in System Options Maintenance - Manufacturing Options) and the order has failures or repairs.
Use Receiver Maintenance (IRC) to close these orders.
Consume Planned Orders
If you selected the MIM consume planned orders? option in the System Options Maintenance (XM) program (Manufacturing Options) and enter a manufacturing order, the system reduces the quantity for a planned order. For example, suppose that you plan to manufacture a quantity of 50 of an item this month. If you released a manufacturing order for a quantity of 10, the system changes the quantity of the planned order to 40 (50 - 10 = 40).
If you do not select this option, the released order will be in addition to the planned order. In this example, 50 + 10 = 60.
Management Priority
The number you enter in the Mgmt priority field when you create a manufacturing order with Manufacturing Order Maintenance program is tracked throughout the order process. The lower the number, the higher the priority.
The Manufacturing Order Picking Selection (MSS) program lists the manufacturing orders by order number. However, you can Click Prog opts and sort the orders in management priority order.
The number you enter in the Mgmt priority field may influence the priority of this order at a work center. The Priority Dispatch Report (MPD) program calculates priorities and lists the management priority on the Priority Dispatch Report. The program offers four methods of calculation, and you select one at run time. The effect of the value in this Mgmt priority field depends on the method you select.
If you select |
The impact of this field |
Critical ratio |
The order's priority increases as the value in this field increases |
Management priority |
Lower values in this field result in higher priorities |
Operation start date |
None |
Operation priority |
The order's priority increases as the value in this field increases |
Obligate Components and Raw Material
Obligation assigns specific components and raw materials to a manufacturing order. You cannot create a shipment for components from the stockroom to the shop floor or confirm picking until you have obligated components.
You can click Obligate in Manufacturing Order Maintenance to have the program obligate components for this order for you. For other methods of obligation, see Overview: Obligation and Shipment Creation. If you are using approvals, the Obligate button will be inactive if the bill of material is pending approval.
If you click Obligate and components are not obligated, check the bill of material. The components may be set up for picking by operation sequence. In that case, obligation and picking occurs when you enter an operation sequence with the WIP Movement (WIPM), Labor Entry (LLE), or Labor Import (LEI) program.
The system considers existing outside supply. Suppose a manufacturing order requires a quantity of 10 is tied to a purchase order for a quantity of 7. When you select that component and click Obligate, the displayed quantity is 3.
One-Step Order
You can manufacture all or selected items in one step. When you create a one-step manufacturing order, the system obligates the components, creates a shipment, confirms picking, and prints the shop paper all in one step without any user intervention.
The requirement for creating a one-step manufacturing order is to select the One-step mfg? field in the Branch Item Maintenance (IMB) program for that item. Since the option is set at the branch level, each manufacturing branch can set its own one-step requirements. When you click OK and the program assigns a manufacturing order number, the program obligates the components, creates a shipment, confirms picking, and prints the shop paper. The order remains open until you close it. You cannot modify the quantity.
You can create one-step manufacturing orders for controlled items. You cannot use a one-step order for cascading orders, configured products, or bulk movement items.
Pre-Assign Control Numbers
You can pre-assign control numbers for parent items that you manufacture. The parent item must have two conditions set for the program to pre-assign control numbers:
The Serial/Lot field must be set to S for Serial control or M for Lot Number in the Enterprise Item Maintenance (IM) program.
The Pre-assign ctrl no? field must be selected in the Enterprise Item Maintenance program.
When you create a manufacturing order, you will be prompted to supply the starting control number. The program pre-assigns each ordered item a number. After these numbers are assigned, they cannot be assigned to another item. If you add more items to the order, you will be prompted to assign additional numbers. If you cancel out of supplying control numbers, the manufacturing order will be un-receivable and will have to be closed manually.
When you receive the items, the Receiver Maintenance (IRC) program displays the numbers. You can receive complete, in which case each item gets the allocated assigned number. If you receive a partial quantity, you can select which numbers you want to assign to each received item. The remainder of the numbers display when you receive the remainder of this order.
Assigned control numbers that become unassigned as a result of reduced quantities, closing short, or reversing a receiver, are not saved for reuse. The last number issued is tracked and sequential numbers advance from the last number issued.
Print Shop Paper
The Shop paper release time option in the System Options Maintenance (XM) program (Manufacturing Options) and how you have set up your Document Management System determine when shop paper prints.
If Shop paper release time is set to |
Shop paper prints when |
O |
You create a manufacturing order with this program. For immediate supply items, a manufacturing order can be created by Sales Order Maintenance (OE). You can create a manufacturing order by releasing a requisition with the Requisition Maintenance (IRM) program. You can release planned orders with the Order Release Selection (MRR) program. |
S |
You create a shipment with the Manufacturing Order Picking Selection (MSS), Picking Confirmation (MPK), Secured Picking (SMPK), Manufacturing Order Maintenance (MIM), or Material Usage Maintenance (MUA) program. |
In the Document Output Parameters Maintenance (TDOC) program, you can set shop paper to print immediately or be sent to the print queue. Run the Shop Paper Print Queue Maintenance (MSPPM) program to process the print queue. You can run the Shop Paper Print (MSP) program to print or reprint shop paper for a specific manufacturing order. See Overview: Document Management System for more information.
You also can reprint paperwork for a manufacturing order by clicking Shop paper in Manufacturing Order Maintenance. When you select Process now?, shop paper prints to your default printer.
Release Creates a Purchase Service Requisition
When you release a manufacturing order for an item that has an operation sequence for a purchased service, the system creates an purchase requisition, regardless of whether the Disable purchase order firewall? option in the System Options Maintenance (XM) program (Purchasing Options) is selected or not.
You can run the Requisition Maintenance (IRM) program to release the requisition and create a purchase order. Alternatively, your purchasing department can reference the requisition when it enters a purchase order for the purchased service.
Rework and Repair Orders
You can create a manufacturing order for rework of a parent item in the Manufacturing Order Maintenance (MIM) program. When you create a rework order, you have the ability to select only those components and operation sequences that are pertinent to the rework of a parent item. The program automatically picks the components when you release the order as long as there is stock available.
Rework orders follow the same process as a one-step order—the system obligates the components, creates a shipment, confirms picking, and prints the shop paper all in one step without any user intervention. You complete the order by receiving the order with the Receiver Maintenance (IRC) program.
Another way to create a rework order is during the disposition process in Rejected Material Disposition (MRB) program. When you select the disposition code of the rejected component to be 4, Manufacturing rework, the program prompts Do you want to release a rework order at this time?. If you click Yes to create the rework order, you can select your operation sequences and components for the rework and the program returns with a rework order number.
Demand Order Link
If you selected the Link mfg orders to demand in MIM? option in the System Options (XM) program (Manufacturing Options), the system creates a link between the sales (demand) and RMA demand, and manufacturing (supply) orders.
You can also create a link manually except if:
The quantity open on the sales order is 0.
The quantity open is greater than the quantity ordered for the manufacturing order.
Existing linked orders total the open order quantity.
If you link a manufacturing order to multiple sales order lines, you can partially ship the sales order only if you do so in line number order. For example, suppose that you enter a sales order that has four lines, all for the same item with the same Expected ship date, but with different prices. When you receive two into finished goods inventory, the system creates shipments for lines 1 and 2. You cannot delete the shipments and obligate lines 3 and 4 instead of 1 and 2.
Demand Order Deletion
You may delete the demand source of a sales order and an RMA. Manufacturing demands from cascading orders may not be deleted.
Audit Trail
To activate an audit trail, select one of the files listed below in the Audit Trail Maintenance (XAT) program. The system records all transactions. You can then run the Audit Trails (ATR) program and select that file to print a report of these transactions.
I4RQ: Requisition Master
MP2: Mfg Order Master
MP9: Mfg Order Components
O1S: Shipment Header
O1SB: Shipment Addresses
O1SF: Shipment Freight Detail
O1SL: Shipment Lines
WIPF: Work in process Header