Background: Material Usage Maintenance
Use the Material Usage Maintenance (MUA) program to add a component to a manufacturing order, change component quantities, pick selected components, substitute components, and close all open components. See Road Map for work flow.
This topic has these subtopics:
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Add a Component
A manufacturing order is based on the parent item's bill of material, which defines the components and the quantity per for each component. Changes that you make to a bill of material after you release a manufacturing order do not affect the released order.
You can use the Material Usage Maintenance program to add components to a manufacturing order. You can run Material Usage Maintenance from a menu or access the program by clicking Component in the Manufacturing Order Maintenance (MIM), Picking Confirmation (MPK), or Secured Picking (SMPK) program.
Adding a component allows you to compensate for an error in the original BOM created with the Bill of Material Maintenance (MPS) program (not with the Configured Product Maintenance (MBM) program).
Adding a component applies only to a specific manufacturing order. The bill of material does not change.
Substitute a Component
For a specific order, you may want to substitute one component for another. You may do this because a component is in short supply or you want to use a different quality component.
You can identify possible substitutes for a component and part designator on the bill of material with the Bill of Material Maintenance (MPS) program. You may prefer to identify substitutes for a component in the Item Substitution Maintenance (ISM) program. These substitutes are not limited to a specific bill of material.
However, your setting for the Substitutions allowed on mfg orders? option in the System Options Maintenance (XM) program for your manufacturing branch determines the substitutes you can select. If you selected this setting for the option:
If |
Material Usage Maintenance |
C BOM component (MPS) |
Displays substitutes set up in the Bill of Material Maintenance program |
I Item (ISM) |
Displays substitutes set up in both the Bill of Material Maintenance and Item Substitution Maintenance programs |
A BOM component or item |
Displays substitutes set up in both the Bill of Material Maintenance and Item Substitution Maintenance programs; in addition, you can enter an item not identified as a substitute in either program |
N None |
Does not allow you to substitute |
You are not allowed to substitute if you selected the Subs prohibited? field for a component in the Bill of Material Maintenance program. When you click Substitute, Material Usage Maintenance displays the message Substitutions are not allowed for this item. The program does not allow substitutions for a by-product item.
If you select a component that has been fully obligated and click Substitute, the program displays the message No quantity remains to be substituted. You can release the obligation and click Substitute again.
Change Quantities
You can use the Material Usage Maintenance program to change the Qty required or Current qty per fields for a component that is not obligated. If you have already obligated the component and need to make a change, you must release the obligation, change either field, and obligate again.
If you change the Current qty per field, the program updates the Qty required field. When you change the Qty required field, the program recalculates the Current qty per field and may display a fractional quantity. The calculation takes into account the Scrap %: Current qty per x Quantity ordered + (Current qty per x Quantity ordered x Curr scrap % x .01) rounded to up the next integer.
When a purchase order references a manufacturing order for a component that is not on the bill of material, the system adds the component to the manufacturing order. You should run Material Usage Maintenance to check and set the Current qty per field.
You cannot delete a component from a manufacturing order. However, you can set the Current qty per field to zero, which in effect removes the component from the order.
Close Short
When you obligate and pick the quantity required, the program closes the component. If you need less than you expected, you can close short an individual component or all components. For components with obligated quantities, either release the obligation or select Pick, and then Close short.
Floor stock and yield components cannot be closed short—these types of components are updated when the manufacturing order is received.
Re-Open
Once a component line has been closed, you must select the detail display to re-open the line. The quantity closed for the component is added back to the component's committed quantity and the quantity closed is reset to zero, enabling the item to be obligated and picked in the normal manner.
Picking
You can change the quantity required if you have not obligated the component. You can obligate more than the quantity required and then over pick a component. Similarly you can obligate less than the quantity required, under pick, and close the component short.
After you pick a component, you can enter a negative quantity to obligate to correct a previous over picking. When you click Pick, the quantity picked changes accordingly.
The quantity picked should be correct when you run the Manufacturing Order Picking Register (MPKJ) program, which updates the general ledger if you have inventory interfaced to GL. However, in the event that you made a mistake, you can select the component, click Obligate, and enter a negative quantity to correct a previous picking error. When you click Pick, the quantity picked changes. Then you need to run the Manufacturing Order Picking Register for this order again.
Backflushing by Operation Sequence
You can set system options to have the system backflush (reduce) your inventory of components automatically after completion of an operation sequence. The system eliminates the obligation step and picking occurs at the completion of an operation sequence.
Select the Backflush components by operation seq? option in the System Options Maintenance (XM) program (Manufacturing Options) for your manufacturing branch. Use the Bill of Material Maintenance (MPS) program to specify at what operation sequence you want the system to pick the component. For example, if a component is not required until the fourth operation, enter 4 for the sequence number. If you substitute a component, the system obligates and picks it also.
Component Cost
When you click Pick. the system updates the cost of the components for a manufacturing order. Adding a component, changing the quantity required, substituting a component, and closing a component short can affect the order's material cost-to-date.
The manufacturing order's standard material cost is based on the standard unit cost of the components on the bill of material at the time you release the order. Adding, changing, or substituting components has no effect on the standard material cost.
Program Options
You can set options that determine how the Material Usage Maintenance program functions. Each user can set these options themselves by clicking Prog opts. Alternatively, your system administrator may set the same options for all uses with the User Options Maintenance (UOPT) program.
If you do not have controlled components, you probably want the program to obligate components for you. You should select A for the Select obligation mode program option. If you select M, there is an extra step to select the specific control number or warehouse/bin location for the component you want to pick.
If you use the Material Usage Maintenance program to add components, change quantities, substitute components, and close short, you may want to select the Skip MUA header maintenance? program option. If you select this option, the fields on the first screen do not display when you enter or exit the program. If you access Material Usage Maintenance from the Manufacturing Order Maintenance, Picking Confirmation), or Secured Picking program, this option has no affect.
When you click Pick, the program creates a shipment of all components that are obligated and assigns a shipment number. If you pick components one at a time, the program creates multiple shipments. If you need to know the shipment number, select the Display shipment created msg? program option. If you do not need to know the number, you will probably find the Shipment number [number] has been confirmed message annoying.
If you rarely change the Current qty per or Qty required field, substitute components, or close short, you may want to select the Double-click comp to obligate? program option. Then you can double-click a component to enter the quantity you are obligating. If you are more likely to change quantities or substitute components, you probably want to leave this option blank. Then when you double-click a component, you display the component's record with those fields and the Substitute button.
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.
MP2: Mfg Order Master
MP9: Mfg Order Components
O1S: Shipment Header
O1SB: Shipment Addresses
O1SL: Shipment Lines