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Evo-ERP and DBA Classic >> Manufacturing >> Work order concepts
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Message started by heliosquare on 11/22/06 at 13:06:47

Title: Work order concepts
Post by heliosquare on 11/22/06 at 13:06:47

We manufacture products that contain many subassemblies. If I create a work order (manually) for the parent part and then use WO-K-D to create work orders for all subassemblies I end up with a minimum of 60 work orders for that particular product and, depending on the options, there can be over 100 work orders. It doesn't seem feasible to me to to create individual work orders every time we manufacture one of these products. It would be more than a full time job just to release/issue/enter finished production on 100's and 100's of work orders every day.

We'd like to use the work orders to maintain an accurate inventory. Our production schedule and purchasing schedule is done outside of DBA (meaning we don't let DBA dictate what we should make or purchase).

Since we already know fairly accurately what we are going to be producing each month I was thinking I could create one work order for each parent part each month (quantity would be what our forecast dictates) and then just issue materials and enter finished production on a weekly basis. If the original work order quantity is larger than what we actually produced that month I could just close the work order and start the process all over again. Does that make sense? Will that work or am I missing something? Thanks.

Title: Re: Work order concepts
Post by Dave Miller on 11/27/06 at 07:23:05

We have orders for parts that often extend over a 12 month period. We have found that by issuing one firmed work order for each item produced works well. As new orders are received we add that quantity to the work order. As we actually produce a quantity, we split the work order into the qty for that run, and the balance. Then we release the WO for the qty to run and process it normally. This allows us to accumulate costs, understand allocations and material availability. It does not, however, deal with time phasing material requirements. We do it this way because we get schedule changes (involving quantites and dates) from many of our customers on a weekly basis.

Title: Re: Work order concepts
Post by N_Clyde_Jenkins on 11/27/06 at 09:49:45

Can you use phantom subassemblies, type B parts? This gives you the structure in the BOM to show subassemblies and a logical assembly order. No work order needs to be generated for the subassemblies, because a work order for the parent includes all the phantom subassemblies.

Title: Re: Work order concepts
Post by heliosquare on 11/27/06 at 11:55:24

The phantom assemblies could work as we would never create individual work orders for sub-assemblies, but I see in the Help file under WO-A it says:

"NOTE: If an item in the bill of material file is an item type B (phantom), its first level components will also copy into the work order bill of material file when the file gets created."

Our sub-assemblies have more than one level so how is inventory/material allocated for 2nd, 3rd, 4th level components?

Title: Re: Work order concepts
Post by Lynn_Pantic on 11/27/06 at 13:07:29

You can nest phantoms within phantoms so the allocation is ultimately for the bottom level items.

Title: Re: Work order concepts
Post by heliosquare on 11/27/06 at 15:42:57

The existing sub-assemblies are currently part type A. Is it simply a matter of changing those part types to B in IN-B?

Why is it that only the first level components are included?

Title: Re: Work order concepts
Post by Lynn_Pantic on 11/27/06 at 18:40:57

Change the Type A to B and then run BM-G to rollup and update all the BOMs to know the subassemblies are type B.

As for why it is only one level, Work Orders always look at only one level of BOM. The Phantom assembly is a mechanism to get around that.