Feature - Create Material Shortage Tracking with Plus Work Order

Release Date: 6/23/17

Currently, Elliott assumes the materials to be issued in Work Order Plus are the actual materials being used.  If the user does not issue the material, Elliott simply assumes that the user does not need the materials, instead of treating it like a shortage or a back order. This feature introduces the shortage/back order tracking capability in Work Order Plus.

Global Setup

In Global Setup -> Dist -> BOMP Global Control-> Screen 6, the following new flags have been added:


8. Create Shortage Allocation from WO+ Material Issue? - The default is N. Setting this value to Y will enable the user to create shortage allocations.

9. Prompt Create Shortage Allocation Question? - This field is only available if field 8 is set to Y. The default value is Y, which means the system will prompt if users wish to create shortage tracking when reporting that actual materials required are less than expected.  If this flag is set to N, the system will not prompt and will automatically create the shortage tracking when this happens.

10. Shortage Allocation Expiration Days - This field is only available if field 8 is set to Y. The default value is 30. If your production work orders can sometimes take more than 30 days to produce, this field should be set to a higher value. It is used to create shortage tracking through the I/M Hold Transaction record.  Each hold transaction record will have an expiration date, which can be purged when it is expired.

Production Transaction Processing

Material Issue Screen – Report Shortage

In Production Transaction Processing, you can manually report the material usages.   In the Material Usages reporting screen, if flag 8 = “Y” and the actual material usage is less than the plan quantity, the system will attempt to create “Shortage Allocation” using the following criteria:

If flag 8 = “Y,” then the shortage allocation is created.  
However, If flag 9 = “Y,” the system will prompt “Do You Wish to Create Shortage Allocation?”  Default value is “Y.”  If the user accepts the default, then the shortage allocation is created.  If not, then no shortage allocation is created.

When the material shortage is created, we will indicate a flag “*” beside the “Actual_Qty” column to indicate the shortage is to be created. See the following sample screen:

 

Production Transaction Edit List

The production transaction edit list will be revised to indicate the shortage quantity. The following is a sample of materials printed on the production transaction edit list and how the shortage will be printed.

 

Post Production Transaction

The production transaction posting will be revised to print the shortage quantity similar to the edit list above.  In addition, the Hold ID will be printed to the right of the shortage column as follows:

 

When the Hold ID is created, a record is being added to the Inventory Hold Transaction File (IMHLTFIL table).  The quantity allocation is increased and updated to either the Item Master (IMITMFIL) or Inventory Location Control (IMINVLOC) file.  Also, an ATP record will be created for the quantity allocation. The IMHLTFIL table contains the following fields. See below for how we are going to populate them:

  • TRX-ID - Sequentially assign next ID
  • LOCATION - The work order location
  • ITEM-NUMBER - The shortage material item number
  • SERIAL-LOT-NUMBER - Blank
  • TYPE - BMP (a new type in the hold trx file that stands for BOMP Plus Work Order)
  • USER-ID - Work order number + oper number
  • ITEM-NUMBER-ALT - Same as ITEM-NUMBER
  • LOCATION-ATL - Same as LOCATION
  • QUANTITY - The shortage quantity
  • TRANSACTION-DATE - The posting date
  • TRANSACTION-TIME - The posting time
  • EXPIRATION-DATE - Calculated based on flag 10 above
  • EXPIRATION-TIME - Same as transaction time
  • DESCRIPTION - WO# P123456 Material Shortage (this will show in ATP inquiry)
  • EMAIL-ADDRESS  - Blank

 In addition, the system will update the BMORDMTL table.  The following new columns will be added:

      BMORDMTL-HOLD-ID       
      BMORDMTL-SHORTAGE-QTY   

This information is necessary so that when a user fills the material shortage, the system can keep going back and updating the hold transaction file and ATP correctly.

Once the shortage transaction is posted, the production order edit list will indicate that there is a material shortage associated with the item.


The Work Order Inquiry program now displays an asterisk next to any components with a shortage quantity:


Material Issue Screen – Fill Shortage

To fill the shortage, you will go to Production Transaction Processing and enter a production transaction for the kitting step with “Zero” quantity.  Then enter the actual quantity being filled, as shown in the following sample screen:

 

The previous shortage quantity is now displayed at the top of the Material Issue screen.

When the fill shortage information is printed on the edit list and posting journal, the shortage column will show a “negative” value since it decreases the shortage. The hold ID will continue to be printed. The quantity filled will be deducted from the hold transaction quantity and ATP.  When the shortage is fully filled, the hold transaction & ATP will be deleted.


Work Order Production (Time Clock)

In the Work Order Production screen, the material reporting screen works in the same manner as described above when reporting production manually. 

I/M Hold Transaction Maintenance

Maintenance Screen


The maintenance screen has been changed to support the new BMP type. Users cannot manually add this type of record.  The application does allow users to change or even delete the record.  Generally speaking, we don’t want users to change or delete these types of records since they are self-maintenance.  The user will receive a warning message when attempting to change or delete a “BMP” type of hold transaction record. 


 Also, the “6. Hold User ID” is changed to “6. WorkOrder+Oper#” for a BMP type of hold transaction.

Hold Transaction Edit List


The Hold Transaction Edit List now supports the printing of the “BMP” hold type. Users can use this edit list to see a list of outstanding material shortages.  In addition, the edit list now supports the following parameters:

  •                 Starting Trans ID
  •                 Ending Trans ID
  •                 Starting Hold Type
  •                 Ending Hold Type
  •                 Starting Hold User ID
  •                 Ending Hold User ID
  •                 Starting Item Number
  •                 Ending Item Number
 

Material Shortage Report

In BOMP -> Processing -> Production Transaction Processing -> Process -> Plus Work Order -> List new sub menus  have been created:


                Production Transaction Edit List – This is the original edit list
                Material Shortage Report - This is a new report showing the BMP hold transactions

When the user chooses Material Shortage Report, the application will prompt for the following:


                Starting Work Order Number
                Ending Work Order Number
                Starting Job Number
                Ending Job Number
                Starting Item Number
                Ending Item Number

This report will print all of the "BMP" type hold transactions using the above criteria.


Hold Transaction Purge

The Hold Transaction Purge has been changed to remove the hold ID and shortage quantity from the BOMP Order Material records when the hold transaction is purged..

Various ATP Reports

There are various ATP reports that can show the hold transactions. Since the outstanding material shortage = hold transaction, we can see the material shortage on various ATP reports. Here's an example of the Available to Promise By Item Report showing the shortage hold transaction generated from the Plus Work Order.

 

ATP Inquiry

For the same reason noted above, the ATP Inquiry can now see the material shortage information.

 

Programs Added: BM18S3M
Programs Modified: BMORDMTL.FD, BMTRXMTL.FD, BMHSTMTL.FD, NSCTLFIL.FD, NSCTLFIL.W30, NSCTLMN3, NSCTLINI, BM1803, BMMTLMN3, BMPORDIQ, BM18P3, BM17P3, BM19P3, IMHLTMNT, IMHLTSCN, IMHLTPUR, IMHLTLST, SYINVAL3
CLS

Bill of Material / Work Order Plus

  1. BM0000 Bill of Material Package Overview
  2. What Is Work Order Plus And Where Can I Find The Documentation
  3. Work Order Plus Questions and Answers
  4. How to Reverse Plus Work Order Production Entries
  5. Planning Lead Time by Calendar Days or Work Days?
  6. How to See Cost in BOMP Plus Work Order Production History Report
  7. How to Close Plus Work Order
  8. Why I Received "Nothing In Range" with Plus Work Order Printing
  9. Receive "Trx Not Complete" on BOMP Production Edit List/Journal
  10. Feature - Trap Bad Date/Timestamp on Time Clock
  11. Feature - Enhanced Production Routing File Bill of Material Screen
  12. Print Plus Work Order Menu Option Is Missing
  13. Feature - Item Last Received Date to Include BOMP Production Activity
  14. BM01S1 Bill of Material Audit Trail Report
  15. BM23S1 Bill of Material Set Component Activity Flags
  16. BM24S1 Bill of Material Resequence Component Items
  17. BM26S1A Bill of Material Copy COP Orders into BOMP
  18. BM27S1 Bill of Material Purge Complete Production Orders
  19. BM29S1 Bill of Material Post Engineering Changes
  20. BM30S1 Bill of Material Engineering Change History Report
  21. BM32S1 Bill of Material Job Distribution History Report
  22. BM33S1 Bill of Material Option Item Where-Used Report
  23. BM0100 Bill of Material Product Structure File Maintenance
  24. BM0200 Bill of Material Single Level Bill of Material Inquiry
  25. BM0300 Bill of Material Indented Bill of Material Inquiry
  26. BM0400 Bill of Material Single Level Where-Used Inquiry
  27. BM0500 Bill of Material Single Level Bill of Material
  28. BM0600 Bill of Material Indented Bill of Material Report
  29. BM0700 Bill of Material Single Level Where-Used Report
  30. Feature - BOMP Integrity Check Utility
  31. BM0800 Bill of Material End Item Where-Used Report
  32. BM0900 Bill of Material Summarized Bill of Material Report
  33. BM1000 Bill of Material Print Costed Bill of Material
  34. BM1100 Bill of Material Gross Requirements Report
  35. BM1200 Bill of Material Print Picking List by Bill
  36. BM1300 Bill of Material BOMP Setup
  37. BM1400S1 Bill of Material Reset Low Level Codes
  38. BM1501 Bill of Material Feature/Option Configuration Maintenance
  39. BM1601 Bill of Material Feature/Option Configuration Inquiry
  40. BM1700 Bill of Material Production Order Entry
  41. BM1800 Bill of Material Production Transaction Processing
  42. BM1900 Bill of Material Post Production Transactions
  43. BM2000 Bill of Material Print Production Work Orders
  44. BM2101 Bill of Material Job Code File Maintenance
  45. BM2201 Bill of Material Issue Serial/Lot Component Item
  46. BM2801 Bill of Material Engineering Change Processing
  47. BM3100 Bill of Material Production Transaction History Report
  48. BMDPTMNT Bill of Material Department Maintenance
  49. BMDISCN Bill of Material B/M Distribution Report
  50. BMDPTIME Bill of Material Department Time Clock
  51. BMINQMNU Bill of Material Work Order Inquiry
  52. BMITMVRS Bill of Material Production Cost Variance Report
  53. BMLABMNT Bill of Material Labor Grade
  54. BMOIDMNT Bill of Material Operation ID
  55. BMPRDANL Bill of Material Labor Performance Report
  56. BMRTGMNU Bill of Material Production Routing
  57. BMSCHSCN Bill of Material Production Schedule Report
  58. BMSPCMNT Bill of Material Special Operation
  59. BMWCMNT Bill of Material Work Center Maintenance
  60. BMWCTIME Bill of Material Work Center Time Clock
  61. BMWIPSCN Bill of Material WIP Report
  62. BMWOPROD Bill of Material Work Order Production
  63. BMWORSCN Bill of Material Production History Report for WO+
  64. Feature - Option to Control if Item Last Received Date Is Updated from BOMP
  65. I Can Not Delete Some BOMP Work Orders
  66. Feature - BOMP Work Order Entry - F3=Copy COP Ord Function Improvement
  67. Feature - BOMP Plus WO Inquiry Detail Screen to Display Avg Dir Labor Time in HH:MM:SS Format
  68. Feature - Gross Requirements Report Item/Qty CSV Import
  69. Feature - Gross Requirements Report COP Order Import
  70. Feature - Component Qty Calculation Options In F3 Copy Function in BOMP WO Entry
  71. Plus Work Order Transaction Can't Post
  72. Feature - Production Routing File Maintenance - Show Material Cost for Std, Avg, and Last Cost
  73. Some Users Do Not Have Right for F3=Detail or F5=Order Prod Option in Plus Work Order Inquiry
  74. Feature - Print Kit Parent on Work Order
  75. Feature - Transfer Batch on Material Work Order Inquiry Screen
  76. Feature - Print User Name and Transfer Batch Status on Work Order
  77. Feature - Show “Active” Operators in Operator File Inquiry
  78. Feature - Transfer Batch on Plus Work Order Inquiry Screen
  79. Feature - Ability to Start a Material Work Order
  80. Feature - Drill Down to Where Used from Stock Status Inquiry Screen
  81. Feature - Allow User to Choose Time Format on Plus Work Order Traveler (BM20P3T)
  82. Feature - Material Work Order Copy Product Structure
  83. Feature - Plus Work Order Copy Product Structure
  84. Freezing When Printing Costed Bill of Materials
  85. Feature - Create Material Shortage Tracking with Plus Work Order
  86. Close Work Order With Quantity That Is Not Fully Reported
  87. Feature - Disable Print Costed Bill of Material to Update Parent Cost
  88. Feature - Item Selection in Cost Master Maintenance
  89. Feature - Plus WO Operation Number Default Increment
  90. Feature - Print Totals on Material Production History Report
  91. Feature - Print Total Quantity Order/Completed on the Production Schedule Report
  92. Feature - Add Default for Material Pick List, "Print By Pick Sequence"
  93. Feature - Allow Password to be Required to Update Parent Cost in Inventory
  94. Feature - Production Time Not Captured Report
  95. Feature - Add "Related Quotes" Option to Where-Used Inquiry
  96. Feature - Allow Export to CSV File for End Item Where-Used Report
  97. Feature - Allow End Item Where-Used to Select Items Based on CSV File
  98. Feature - Limit Access to the Mass Replace Function in BOMP Product Structure File Maintenance
  99. Feature - Add Down Arrow Prompt when Using Material Work Order at the Quantity Field

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