11.1.1
11.1.1 Overview Of The Stock Transaction Module
pc/MRP's Stock Room Module can be used to:
Receive parts from receiving
Issue parts and sub-assemblies to manufacturing
Receive those parts from manufacturing as completed assemblies
Issue parts and assemblies to shipping
Issue parts from the main stock area to an alternate area
Receive parts from an alternate area to the main stock area
Adjust, increase or decrease, the onhand quantity of any of the areas
11.1.2 New (Issue/Receive Parts)
By Selecting Modules, Stockroom, and New pc/MRP will display the following menu that will allow parts and assemblies to be issued and received. With the Windows version you must click on the radio button or press the key of the letter you want. Moving the cursor will not change the default radio button. The user name, date, and time will be stored in the Entered By field for every transaction made. Comments for each transaction are also available. Following is a description of each type of transaction.
11.1.2.1 I Issue parts for an assy(s) infinite levels deep to mfg
You must use this function once and once only to issue parts for every sales/work order that is issued to manufacturing.
Select the "I" transaction to issue a top level assembly(s) infinite levels deep for a sales/work order.
Select the stock room area you wish to issue the parts from.
Enter the account number to credit for these parts if required to do so by accounting, otherwise leave this space blank (pc/MRP's accounting package does not use this field).
pc/MRP will display the next available stock transaction number. Press OK to accept the number.
Answer Yes if there is a sales/work order number for this transaction. pc/MRP will then allow you to scroll by sales/work order number, part number, or account number for the correct sales/work order number.
pc/MRP will display the following screen:
pc/MRP must be told how you want issue the items. You can issue component
parts only, sub-assemblies only or both part and sub-assemblies.
In addition, pc/MRP will reduce the stores quantity (onhand) and increase the wip quantity (wipqty) in the partmaster file for each part and assembly issued.
If you have activated pc/MRP's Advanced Serial/Lot Number module, pc/MRP will ask if you wish to enter serial numbers. If the serial numbers entered are past their expiration date the user will be warned to cancel or continue.
pc/MRP will produce an "Issued PIC List" report containing the details of all items issued. The report can be displayed, printed or saved as a file.
11.1.2.2 L Issue part(s) and/or assy(s) one level deep to mfg
Only use this function to issue extra parts or parts that were not on the bill of materials.
Select an "L" transaction to issue a part, or combination of parts and completed sub-assemblies for a sales/work order to manufacturing.
You will be asked whether the information is to be manually entered or imported from an ASCII file. Manual entry is the most often used method and will be explained first.
pc/MRP will reduce the onhand quantities and increase the WIP quantities of the parts and finished sub-assemblies issued.
Manual Part Number and Quantity entry
Select the stock room area you wish to issue the parts from.
Enter the account number to credit for these parts if required to do so by accounting, otherwise leave this space blank.
pc/MRP will display the next available stock transaction number. Press OK to accept the number.
Answer Yes if there is a sales/work order number for this transaction.
Enter the Part or BOM number and the quantity you wish to issue.
Enter Yes if you wish to track lot numbers.
If the number entered was a BOM number pc/MRP will ask if you wish to issue the BOM to the floor as a completed assembly or as component parts.
If you choose to issue as a completed assembly, pc/MRP will issue the assembly(s) as a completed assembly(s).
If you choose to issue the assembly as component parts, pc/MRP will issue the component parts. Once again enter the date and quantity of the assembly you wish to issue (pc/MRP will not change the onhand quantity of the assembly at this time).
Answer Yes if you wish parts to be issued automatically.
When it comes to a sub-assembly for that kit, pc/MRP will ask "Issue parts or Sub-assys?". Answer G if you wish to issue the sub-assy as completed sub-assys. Answer B if you wish to issue the sub-assy as parts on another lower level "L" type transaction that you will enter after you have finished issuing parts at this level.
Importing Part Number and Quantity information
The data structure of the ASCII file is:
|
Part Number Quantity Issued SO/WO Number (leading zeros) SO/WO Item Number (leading zeros) Issue Area (same as area name) Lot Number Quantity Required |
6-15 Character Numeric 6 Character (optional) 4 Character (optional) 8 Character (optional) 6 Character (optional) Numeric (optional) |
Enter the location and name of the import file or use the FIND button to
pick it from the directory tree.
Configure the Sales/Work Order info to meet your situation.
If all the items to be issued are against the same sales/work order, selecting Manual allows a one time entry of the sales/work order number which is then applied to all items issued.
Lot tracking has three possible settings:
Any of the six storage areas can be manually selected as the issuing area or it can be set to automatically draw the issuing area from the import file.
Pressing OK will begin the import process.
If any errors are detected during the importation process. An error report will be available after completion.
11.1.2.3 M Issue Makeup or Shortage Parts to Mfg
Use this function to issue make up shortages for items that were short when the original "I" type transaction was issued for a sales/work order number.
Enter an "M" type transaction to issue make up or shortage parts for a sales/work order.
Enter the stock transaction number of the part that is short. The stock transaction number can be located on the stock transaction report for that sales/work order number.
pc/MRP will allow you to enter the lot number and the quantity required to fill the shortage. pc/MRP will then reduce the onhand quantities and increase the WIP quantities of the parts issued.
11.1.2.4 P Issue Multiple Makeup Shortages from a Single Inventory Area
pc/MRP Versions 7.02 and higher contain P option to fill stock room shortages from a list. The list will contain a list of shortages (qty required greater than qty issued) sorted by date required (of the sales/work order number).
11.1.2.5 F Issue Multiple Makeup Shortages to Mfg Automatically
Use this function to automatically issue make up shortages for items that were short when the original "I" type transaction was issued for a sales/work order number. It will fill as much of the shortage as the inventory level allows while giving priority to the sales/work orders by with the earliest date required. This function looks at shortages for open sales and work orders (complete does not equal Y) that have been issued (issuedtmf = Y) that now have stock available to be issued (onhand greater than 0).
The user may select the inventory area(s) to consider when issuing items. The user also has the ability to issue only to sales order transactions or work order transactions.
Two reports are available after completion. The Action report details all of the stockroom shortages that were filled. The Make-up shortage Pick list produces an inventory list of material from each inventory area to be transferred from inventory to WIP.
The user may elect to actually issue shortage make-ups or to simulate the shortage make-ups. Actually issuing will produce the reports described above while reducing the quantity of the parts from the issuing area and increasing the quantity in WIP. Simulating the shortage make-ups will produce the same reports as the actual issue without transferring inventory. This allows the user to check the shortage make-ups before they are transacted.
An example of a Make-up Shortage Pick List is shown below.
11.1.2.6 S Issue Parts or Assemblies to Shipping
Enter an "S" to issue parts or assemblies to shipping.
pc/MRP will issue each line item as you have configured it on this screen. The onhand quantity of each part shipped will be reduced if pc/MRP is configured to do so in the configuration menu.
In the upper left corner of the window:
The Sales Order number against which the material is to be issued can be manually entered or you may elect to pull the number in by scrolling the Sales database.
This is where the Inventory area from which the material is to be issued is selected.
Users who have purchased the optional Serial/Lot Number module can elect to track the serial or lot numbers of the material that is issued.
In the upper right corner of the window:
Displays the customer address so the user can verify that the correct Sales Order is to be processed.
In the center of the window:
Displays a scrollable list of all open items in the Sales Order with the order quantity and the quantity that you want to issue. Items will not be included on the list if the Complete field on the Sales Order contains a "Y" or if the quantity previously issued against the item equals or exceeds the order quantity.
If the quantity to be issued exceeds the quantity available in the selected inventory area, an exclamation point "!" will appear to the right of the issue quantity number. See Item 0001 on the example picture on the previous page.
In the lower left of the window:
The Full Fill button will automatically set the issue quantities for all the items to equal the order quantities.
The Limit Fill button will automatically set the issue quantities to issue as much of the item as is available in the selected Inventory area, up to the order quantity.
The Zero All button will reset all issue quantities to zero.
The More Detail button is not used when issuing to shipping.
In the lower center of the window:
This section displays information about the item currently highlighted in the center section. It also displays the quantity of this item currently available in the selected Inventory area.
At the bottom of this area, you can manually set the issue quantity and enter a serial or lot number to be associated with this item. The serial/lot number will be retained as part of the Stock transaction record.
The Full, Limit and Zero, buttons function just like the Full Fill, Limit Fill and Zero All buttons but affect only the highlighted item.
The Item Detail button, like the More Detail button, is not used when issuing to shipping.
In the lower right corner of the window:
The OK button begins the issue process for the items you have specified while the Cancel button exits the screen without making any changes.
The Default button opens a second window where some of the behavioral characteristics can be set.
The Default Settings window: (The initial default settings are shown.)
When a Sales Order is loaded into the first window for processing, the issue quantities for all items will be automatically entered based on the default Issue Quantities setting displayed in this window. The default Inventory issuing area can also be specified.
If the Update quantities when Area changes box is checked, changing the Inventory area on the first screen will automatically update the issue quantities based on the Issue Quantities setting.
If the Warn if over issuing against order box is checked, a warning message will appear before transaction processing begins if the issue quantity of any of the items exceeds the order quantity. You then have the option to continue with the over-issue condition or return to the window for further editing.
If the Warn if insufficient quantity in Area box is checked, a warning message will appear before transaction processing begins if the issue quantity of any of the items exceeds the quantity available in the selected Inventory area. You then have the option to continue with the over-issue condition (which will drive the Inventory quantity negative) or return to the window for further editing.
The Track Serial/Lot Numbers box will be activated for those users who have purchased the optional Serial/Lot Number module. When this box is selected, the Track SN/Lot check box on the first window will start in the checked condition.
11.1.2.7 B Issue Parts to Alternate Areas (MRB, R&D, etc.)
This module allows parts to be issued from onhand to alternate storage areas such as MRB, R&D, etc. You can rename the alternate storage areas using the configuration menu, option 34.
11.1.2.8 R Receive Completed Assemblies from Manufacturing
pc/MRP Versions 6.75 and Higher.
This module allows completed assemblies to be received from manufacturing back into the stock room. pc/MRP uses the following pseudo code when completed assemblies are returned from manufacturing to the stock room:
The above method allows overages and waste to be deducted from WIP. It also does not require all parts to be issued before part of the sales/work order are returned as finished assemblies.
pc/MRP will ask for the sales/work order number that you wish to turn in as completed assemblies. It will then locate the original sales/work order record to determine how many assemblies were originally ordered and issued. pc/MRP will ask for the quantity being received and then increment the onhand quantity of the assembly listed on the sales/work order. Next it will then search the stock transaction data base file and decrement the WIP quantities of all parts issued to manufacturing for that sales/work order. If you are turning in a partial order it will make a partial deduction of the parts issued to manufacturing for that sales/work. For example, if you are turning in 6 completed assemblies for a sales/work order for 10 assemblies. pc/MRP would decrement the exact quantity of bolts, nuts, wheels, etc. for six assemblies.
Please note:
pc/MRP Versions 6.74 and Lower.
This module allows completed assemblies to be received from manufacturing back into the stockroom. pc/MRP uses the following pseudo code when completed assemblies are returned from manufacturing to the stock room:
This method allows overages and waste to be deducted from WIP
This method requires all parts to be issued before any finished assemblies are returned
pc/MRP will ask for the sales/work order number that you wish to turn in as completed assemblies. It will then locate the original sales/work order record to determine how many assemblies were originally ordered and issued. pc/MRP will ask for the quantity being received and then increment the onhand quantity of the assembly listed on the sales/work order. Next it will then search the stock transaction data base file and decrement the WIP quantities of all parts issued to manufacturing for that sales/work order. If you are turning in a partial order it will make a partial deduction of the parts issued to manufacturing for that sales/work. For example, if you are turning in 6 completed assemblies for a sales/work order for 10 assemblies. pc/MRP would decrement 6/10 of all the bolts, nuts, wheels, etc. issued to that sales/work order number.
Please note:
All parts for all 10 of the original assemblies must be issued to the manufacturing, before any completed assemblies can be turned in.
For all pc/MRP Versions
After entering R type transaction pc/MRP will ask for the number of labor hours required to complete this assembly. The amount of hours entered will be multiplied by the average hourly labor rate, found in pc/MRP's Configuration Menu. This way of tracking labor is only utilized in the Stockroom Module reports.
pc/MRP will display the next available stock transaction number. Press OK to accept the number.
If there is a sales or work order number for this transaction enter Yes and enter the sales order number. pc/MRP will use the Sales/Work Order Number to determine which and how many part(s) or assembly(s) should be received.
pc/MRP will ask if you wish to track Lot Numbers.
Enter the Quantity of assemblies or parts being returned from manufacturing. If the quantity of assemblies being turned in matches the quantity of assemblies originally issued to manufacturing, all of the items issued to manufacturing for the sales/work order number will be deducted from WIP. If a partial qauntity of completed assemblies are turned in, pc/MRP reduces the quantity in WIP as described above.
The Onhand quantity of the assemblies or parts will increase in the Partmaster.
The Quantity Assembled will be increased in the Sales/Work Order.
If it is for a Work Order and the quantity assembled is equal to or greater than the original quantity required a "Y" will be placed in the Complete Field.
11.1.2.9 U Receive Unused Returned Parts from Mfg
11.1.2.10 V Receive Parts from Receiving
11.1.2.11 G Receive Parts from Alternate Areas (MRB, R&D, etc)
This module allows parts to be received from alternate storage areas such as MRB, R&D, etc) and place them back into the stock room increasing the onhand quantity in the partmaster. You can rename the alternate storage areas using the configuration menu, option 34.
11.1.2.12 A Adjust Onhand Qtys
This option allows the onhand quantity of parts to be adjusted (increased or decreased). It leaves a record of the adjustment, where as editing the part number would not leave a record of the adjustment. Increasing the onhand quantity in stores or in another area creates RECFA stock transaction record(s). Decreasing the onhand quantity in stores or in another area creates ISSFA stock transaction record(s). If you are utilizing the Serial Lot Number Module, this transaction will also automatically adjust quantities in the Serial Lot Number database.
11.1.2.13 T return all parts/assys issued to a sales/work order
This option returns all parts and or assemblies issued to a sales or work order from WIP back into the original issuing area.
11.1.3 Edit/View (Delete/Undelete A Stock Transaction)
Allows you to edit an individual stock transaction record.
Use the delete button to mark a record for deletion with the Windows version of pc/MRP. With pc/MRP for DOS once you have finished editing the record, pc/MRP will ask Do you wish to mark this record for deletion? Once the record has been marked for deletion, return to the menu and select REMOVE ALL DELETED RECORDS FROM DISK AND REINDEX.
11.1.4 Scroll Partmaster
Allows you to scroll or search for a part number. Select scroll if you know the first part of the part number, model number or description. Select search if you wish to find the part by entering a partial description. For example, entering "elb" would reveal all of the parts, such as elbow, that have the letters elb anywhere in their description.
11.1.5 Reports (Printout/Display Stock Transaction Reports)
Allows you to print out or display stock transactions reports using
the following options:
Any of the above (except Shippable sales orders) can include
Any of the above (except Shippable sales orders) can include:
The report output options include:
The report format options include:
11.1.6 Check Availability (Of Parts For A Specified Assembly)
Will print out the status (quantity on hand, quantity on order, and quantity required) for each part number in a specified assembly. pc/MRP will ask for the BOM number and the quantity required. Enter P to check for parts infinite levels deep or S for sub-assemblies and parts to one level deep. If any part is short the report will list it as, "SHORT". This report is not as thorough as the Consolidation Report in Purchasing as it only looks at what is currently on hand. A narrow carriage print out will include a purchasing history of parts that are short. A wide carriage printout will include reference designators. pc/MRP Version 7.01B and higher allow user to check availability from any area , all areas, quantity available and quantity available - on order quantity.
11.1.7 Convert Parts To Assemblies
Provides a short cut method that automatically converting parts into assemblies. This routine bypasses putting parts into WIP and using a work order number to record the transactions. If you select the print out option you will receive a printed record of the transaction that can double as a PIC list. If any of the parts are short, pc/MRP will stop and ask how parts you wish to issue? If you issue the full amount, the onhand quantity in the partmaster will go negative.
11.1.8 Index
Reindexes the Stock Transaction Index File. pc/MRP automatically updates its index files under normal operation. However, if you ever get a "record out of range" error message or can not find a stock transaction record, reindexing the index file is usually the cure.
11.1.9 Remove Marked Records
Removes all stock transaction records marked for deletion from the disk. The records will no longer be recoverable.
11.1.10 Remove Over X Years
Deletes and removes from the disk all Stock Transactions over a specified number of years old. Prior to running this command it is advisable to save the Stock Transaction Database File (stocktra.dbf) to disk and label it "Stock Transactions DBF as of MM-DD-YYYY". You should also generate a printout of the file prior to closing it out.
11.1.11 Special Cases - Issuing Reels
Reels containing thousands of electronic components that must be issued to an assembly vendor or the manufacturing floor present a special issuing and tracking problem as you must issue more than the quantity required to the machine picking off the required number of components. This can be resolved in one of the following ways: