Stockroom Module
11.1.1
Overview of the Stock Transaction Module
The
Stock Room Module allows users to: receive parts from receiving, issue parts
and sub-assemblies to manufacturing, receive parts from manufacturing as
completed assemblies, backflush piece parts, issue parts and assemblies to
shipping, issue parts from one inventory area to another, and adjust the onhand
quantities.
11.2.1
Issue parts/sub-assemblies to a sales or work order Step 1 – Press New
By
Selecting Modules, Stockroom, and New pc/MRP will display a list
of all of the stockroom transactions available for users to enter. Simply click
on the radio button or press the key of the letter you want. 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.
11.2.2
Issue parts/sub-assemblies to a sales or work order Step 2 – Select
Issue
Select
the "I" transaction to
issue a top-level assembly(s) infinite levels deep for a sales/work order. You must use this function once and only
once to issue parts for every sales/work order that is issued to manufacturing.
All
manufacturing jobs start with the I
(for issue) type transaction and end with the R (for receive) type transaction.
Users can only use the L, M, F,
B, U, and T type
transactions after performing the I
transaction and before performing the R
transaction.
Select
the stock room area you wish to issue the parts from. pc/MRP cannot issue from multiple areas
during the I type transaction. If a
users wishes to issue part of the build from one inventory area and other parts
from a different inventory area, users will have to issue the I transaction
short, and perform make up transactions, M,
F, and B, transactions to issue from the alternate area.
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.
Please Note:
You must enter an existing Sales or Work Order Number; otherwise pc/MRP will
not be able to decrement the WIP quantities correctly when the Sales/Work Order
is received as assemblies from manufacturing.
11.2.3 Issue parts/sub-assemblies to a sales or work order Step 3 – Select
Issue Methods
pc/MRP
must be told how you want to issue the items. You can issue component parts
only, sub-assemblies only or both part and sub-assemblies.
- Select Assembly (IF available) then parts
if you want pc/MRP to issue sub-assemblies, if available, then parts when
there are no more sub-assemblies available.
- Select Parts Only if you wish to issue
parts only and no completed sub-assemblies.
- If you Select Subassemblies Only the following
options are available:
- Never Ask, will issue sub-assemblies only.
- Ask When Short, will ask to issue
parts or subassemblies if subassemblies are short.
- Always ask, will ask, parts or subassemblies when
it comes to a subassembly.
By default, pc/MRP will
automatically issue items. If you prefer to verify each item or record
serial/lot numbers using pc/MRP's standard serial/lot number features, uncheck
the "Issue parts automatically" check box. If “Issue Parts Automatically’ is checked and Option
11.2.4 Issue parts/sub-assemblies to a sales or work order Step 4 – Select Line Items
Select the line items on this sales order you wish
to include on the issue. Line items
that can not be issued and the reason they can not be issued will be displayed in
the scrollable list box below the line item list.
11.2.4 Issue parts/sub-assemblies to a sales or work order Step 5 – Handle any
Shortages
If you issue the parts one at a time instead of automatically
or pc/MRP detects a shortage the screen shown above will be displayed. Option 45 can be set to default the Qty
Issued Field to the quantity required or the quantity available. We recommend you set Option 45 to the
Quantity Available and always inset the actual quantity issued (this will keep
your WIP straight). If you set Option
45 to Required, you do not answer ‘Yes’ to track serial numbers, and you have
checked Automatic issue, the screen below will not appear and part quantities
can be driven negative.
Always enter the correct quantity issued to the
manufacturing floor. pc/MRP will create
an issue to manufacturing stock room record decreasing the stock room quantity
and increasing the WIP quantity. If you
count the quantity left in the bin, it is different from the displayed quantity
left, and you enter the correct quantity left in the bin, pc/MRP will make an
additional adjusting stock room record.
Whenever users enter an "I" type
transaction, pc/MRP creates a stock transaction record for each part or
sub-assembly issued. Each stock transaction record created contains the
following fields:
- The stock transaction
number (stktrano)
- The sales/work order
number (sono)
- The part or assembly
number being issued (partno)
- The quantity required
(qtyreq)
- The quantity issued
(qtyissued)
- The quantity returned
(returnqty) is left at 0, as this field is filled in when the sales order
is received back as completed assemblies.
11.2.5 Issue parts/sub-assemblies to a sales or work order Step 5 – Record
Serial Numbers
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.
Furthermore, if you have changed the QTY Left in the
Bin field on the Issue Stock to Manufacturing
screen, the serial lot number module has been activated, and the part is
serialized, the Adjust Serial/Lot button will appear.
If you want to adjust serial/lot number, click the Adjust Serial/Lot button. You will get a list of the existing serial lot numbers from the master serial lot number table for that part as shown on the Serial/Lot Number List Screen. If you would like to enter a new serial lot number, click on the New button, you will get a screen similar to the Serial Lot Number Adjustment Screen. Enter the necessary fields for the serial/lot number and click Ok to save. If you would like to adjust the serial lot quantity for an existing serial lot number, select the serial lot number, and click the Edit button, you will get the Serial Lot Number Adjustment Screen. Entering a negative number into the Adjust QTY field will bring the serial/lot quantity down and entering a positive number into the Adjust QTY field will bring the serial/lot quantity up. Click the Ok button to save the adjusted serial lot number. When you are done with entering and adjusting the serial lot numbers, click Ok on the Serial/Lot Number List screen. All of the newly entered serial numbers will be saved into the master serial lot number table, and the adjusted serial lot numbers’ SNLOTQTY field in the master serial lot number table will be replaced by the value in the NEWSNLOTQTY field of the cursor. An adjustment entry will be created in the detail serial/lot number table for each adjusted serial lot number.
11.2.5
Issue parts/sub-assemblies
to a sales or work order Step 6 – Print PIC List/Labels
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.
In
versions 7.50 and higher users can create a flag file allowing labels to be
created for the items being issued to manufacturing. The flag file is isstklab.flg.
If
this file is present in the pcmrpw directory the screen shown above will
appear.
This
option allows users to select various criteria, a specified work order, and
multiple output types for the labels to be created.
11.3.1
L - Issue Part(s) and/or Assemblies one Level Deep to
Manufacturing
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 or 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.
11.3.2 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.
- Please Note: You must enter an existing
Sales/Work Order number; otherwise, pc/MRP will not be able to decrement
the WIP quantities correctly when the Sales/Work Order is received as
assemblies from manufacturing.
·
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-Assemblies?” Answer G if you wish to issue the sub-assembly as completed
sub-assemblies. Answer B if you wish
to issue the sub-assembly as parts on another lower level "L" type
transaction that you will enter after you have finished issuing parts at this
level.
·
Creating a text file, LISSUPWO.FLG, with notepad in the pcmrpw
directory will force pc/MRP to insert a ‘Y’ into the Sales/Work Order ISSTMFG
field. This is not recommended, as pc/MRP will not allow an ‘I’ type issue
transaction to that Sales/Work Order afterwards.
11.3.3
Importing Part Number and Quantity information
Importing creates a series of "L" type
Stockroom transactions from a comma separated ASCII file. This file may be
generated by a barcode reader or produced by another program. The ASCII file
must contain the Part number and Quantity information and may contain other
optional information.
The
data structure of the ASCII file is shown below:
|
DATA |
TYPE |
|
Part Number |
6-15 Character
Numeric |
The following screen allows configuration of the
import process.
·
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.
- The Automatic setting will draw the
sales/work order number from the import file. If the sale/work order
number does not exist in the import file or it is invalid, the program
will halt at each item and prompt the user to enter the correct sales/work
order for that part.
·
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.
·
- Automatic pulls the information from the source
file.
Manual stops at each issue item and prompts the user to enter the Lot Number.
Off turns off lot number tracking
·
Any of the eleven 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.
11.4.1
M - Issue Makeup or Shortage Parts to Mfg
We
strongly recommend using the stockroom’s P option instead of the M or F option
to issue makeup shortages to sales and work orders.
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.
For
stockroom transactions P, M, and F if option
With
versions 7.71B and higher, pc/MRP will create a new issue transaction for
makeup transactions where the quantity issued and the quantity required will
equal the quantity being fulfilled, inventory will be decreased and WIP will be
increased. In the original transaction,
the quantity required will be deducted by the quantity being issued in the make
up issue. Thus, the original transaction
will carry forward any subsequent shortage.
If the sales order is closed, pc/MRP will not allow you to issue a
makeup issue against the order.
11.5.1
F - Issue Multiple Makeup Shortages to Manufacturing
Automatically
We
strongly recommend using the stockroom’s P option instead of the M or F option
to issue makeup shortages to sales and work orders.
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.
For
stockroom transactions P, M, and F if option
11.6.1
P - Issue Multiple Makeup Shortages from a Single Inventory
Area
The
P option allows users to fill stock
room shortages from a list of possible stockroom transactions that were issued
short. When users select this option, pc/MRP will create the screen above. This
screen allows users to select the criteria to generate the list of shortages to
be filled.
- First, select the area
where the parts will be issued from.
- Second, select the desired
sort order.
·
The Issue Shortage Make-ups screen allows users to choose from a list
of shortages that can be filled and fulfill them by entering the desired
quantity to be issued.
- Highlight the shortage
that you wish to issue and enter the quantity in the Issue Qty field.
- Continue this process
until you have selected all of the shortages you wish to fulfill.
- Users can also select
to have the Issue Shortage option generate a report. This report can be
sent to several output types.
- If the serial lot
number module is being utilized, once the item(s) has been selected and
the user presses OK, the
user will be prompted to track serial numbers as needed.
·
For stockroom transactions P, M,
and F if option
·
NOTE: The ‘P’ type transaction must have a positive quantity on hand in
the chosen inventory area in order for the shortage to be displayed.
11.7.1
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. (Do not use this transaction if you are set to Inventory
Adjustment method A, see Settings and Utilities option 4.)
11.7.2
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.
11.7.3
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.
11.7.4
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.
11.7.5
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.
11.7.6 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.
11.8.1 B - Issue Transfer Parts
Between Inventory Areas
This
transaction allows users to transfer inventory parts and assemblies between
inventory areas. You can rename the alternate storage areas using the configuration menu, option 34. Transferring inventory from area 1 (Stores)
into an alternate area creates an ISSTB record.
Transferring inventory from an alternate area into area 1 (Stores)
creates a RECFB record. Transferring
inventory from an alternate storage area into another alternate storage area
creates both an ISSTB and RECFB record.
11.9.1
R - Receive Completed Assemblies from Manufacturing
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:
- Find the stock transactions records for that
sales/work order number
- Reduce the quantity in WIP by the quantity
issued to the sales/work order based on the BOM and the parts and
sub-assemblies issued. The return quantity field contains the quantity WIP
was reduced by.
- When the final assembly is returned pc/MRP
reduces WIP by the difference of the quantity issued and the returned
quantity. It also increases the quantity returned to match the quantity
issued. pc/MRP versions 7.00 and lower do not alter the original quantity
required. Jobs that are received back in full with shortages still
outstanding will still show up as short as the quantity required is still
greater than the quantity issued. The stockroom record can be edited so
that the quantity issued equals the quantity required. pc/MRP versions
7.01 and higher decrease the quantity required to match the quantity
issued. As such, versions 7.01 and higher will not leave shortages in the
stock room records for sales/work order that were completed and returned
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 is
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 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:
- Not all parts for all
10 of the original assemblies have to be issued to the manufacturing,
before any completed assemblies can be turned in.
- If you plan to turn in completed
sub-assemblies for a sales order, issue the sub-assemblies under their own
work order numbers.
- If you are utilizing
the Serial Lot Number Module, you can also issue serial numbers to
returned assemblies with this transaction.
·
In pc/MRP versions 7.73 and higher, when performing the R type
transaction, users will be presented with the additional screen below:
11.9.2
Receive Back Completed Assemblies Shortage Warning
If pc/MRP determines
that the work order or sales order you are receiving back can not be received
back in full, it displays the following screen.
This
screen allows users to quickly determine the status of the build. Users can see the quantity required, quantity
already received from manufacturing, the quantity the user has requested
returned back from manufacturing, and the calculated quantity that can be
returned based on the material issued thus far.
Users can also view the shortage report for this build and print the
shortage report. If users choose to view
the shortage report, once they are finished viewing the report, they will be
returned to this status window.
After
entering R type transaction pc/MRP
will ask for the number of labor hours required to complete this assembly. With
versions 7.73 and higher, you can populate the labor hours from the Employee
Time Tracking module by setting option 79 within the Settings and Utilities
menu. The average labor cost entered
into the transaction can be set to be derived from the employee pay rates or
Option 6 from within the Settings and Utilities menu. If you select the average labor cost to be
derived from the employee pay rates, the following formula will be used:
SUM of different employees
(employee pay rate * work hour + employee pay rate *
overtime * overtime pay rate
factor)
total hours of employees
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
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 quantity of completed assemblies is turned in,
pc/MRP reduces the quantity in WIP as described above.
The
Onhand quantity of the assemblies or
parts will increase in inventory.
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.
11.10.1 U - Receive Unused
Returned Parts from Manufacturing
This option allows users to return unused parts back into inventory.
When users select this option, the choices above will appear. This selection
screen allows users to enter the criteria for the jobs to be returned. The next
screen will generate a list of all material allowing the user to choose which
items and the quantity to be returned.
- Select the storage area
that will receive the returned parts.
- Sort the data as
needed.
- Select the Include
field to add additional information to help you make the decision on what
to return.
- Select Multiple work
orders/sales orders or select a specific order.
- Click the OK Button and
the screen shown below will appear
- Highlight the part
number that you wish to return and enter the quantity in the Un-issue Qty field.
- Continue this process
until all of the items to be returned have been selected.
- Users can select to Reduce Requirement and Issued
Quantities or simply Reduce the
Quantity Issued only.
- Users can also select
to have the Un-issue option generate a report. This report can be sent to
several output types.
- If the serial lot
number module is being utilized, once the item(s) has been selected and
the user presses OK, the
user will be prompted to track serial numbers as needed.
- This type of
transaction must be done before the final return of completed assemblies
is transacted.
11.11.1
V - Receive Parts from Receiving
Enter
a "V" to receive parts
from receiving. pc/MRP will display the
next available stock transaction number. Press OK to accept the number. If
there is a receiver for this transaction, enter Yes, and enter the receiver number.
pc/MRP will ask if you wish to track
Do
not use this transaction if you are set to Inventory Adjustment method A, see
Settings and Utilities option 4.
11.12.1
A - Adjust Onhand Quantities
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.
11.13.1
T - Return all Parts/Assemblies Issued to a Sales/Work
Order
This
option allows users to un-issue sales or work orders from manufacturing. This option subtracts the quantity issued
into WIP for each part and or subassembly to a specific sales or work order and
increments inventory in the issuing area.
Pc/MRP will prevent users from using this if they have already performed
the R type transaction (qty assembled > 0).
11.14.1
S- Issue Parts or Assemblies to Shipping
This
option was created for companies that do
not use pc/MRP’s Invoice module. If you use this option, set the inventory
Adjustment method, Option 4, to ‘S’.
Do
not use this option if you are using pc/MRP’s Invoice module, as you will get a
double decrement on your invoice movement report.
11.15.1
Scroll Inventory
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. A more complete
search feature is available in the Queried
Search feature in the Inventory module.
11.16.1
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.
11.17.1
Edit/View (Delete/Undelete A Stock Transaction)
This
option allows users to scroll, edit, delete, undelete, or run queries on
Stockroom records.
Selecting
an Indexed Search allows users to
search on indexed fields. This allows
pc/MRP to find the information much faster.
To perform an Indexed Search
select the:
·
Indexed Search tab
·
Desired Sort Order, Document
Number, Sales and Work order Number, Part Number, or Model Number
·
Enter the applicable data in the Begin
Scrolling At: field
·
Select the desired Action, View or Edit
·
Press Search
pc/MRP
will automatically scroll to the desired record or the nearest match. Select the correct record by scrolling and
press Ok to proceed to the edit
screen for that record.
Selecting
to run a Queried Search allows users
to build, run, save, and load queries for the Stockroom table. For further details, see chapter 15.14.
Every
field in the Stockroom table is editable.
Users however need to understand several key concepts before editing
stockroom records.
·
There are three key fields in most stockroom transaction, REQUIRED QTY, ISSUED QTY, and RETURNED QTY. The REQUIRED
QTY is the quantity required for this transaction. ISSUED
QTY is the quantity actually issued for this transaction. If applicable to the transaction there may
also be the RETURNED QTY, this is
the quantity returned or backflushed for this transaction.
·
When the REQUIRED QTY does
not equal the ISSUED QTY, pc/MRP
will flag this as a shortage in the stockroom shortage report. To correct a shortage where none exists, the
job is already complete and returned from manufacturing; users must research to
see what has happened. When performing
the R type transaction pc/MRP will
not warn users if a shortage still exists.
Thus, in some instances, can make inventory be incorrect by not
fulfilling makeup shortage transactions before the R type transaction. Users must research to see if the shortage
needed to be fulfilled or if the job was completed with the shortage.
·
If the shortage needs to be fulfilled, edit the ISSUED QTY to equal the REQUIRED
QTY and manually deduct the difference from inventory.
·
If the shortage does not need to be fulfilled, edit the REQUIRED QTY to equal the ISSUED QTY.
·
There is a key of TRANSACTION
TYPES in the edit screen of each stockroom transaction.
·
Use the delete and undelete buttons to mark and unmark records for
deletion. Once the record has been
marked for deletion, return to the menu and select REMOVE ALL DELETED RECORDS FROM DISK AND REINDEX. Removing stockroom transactions will not
automatically change inventory. It is
not recommended to delete stockroom transactions. If users choose to delete stockroom
transactions and they wish to adjust inventory, they must manually accomplish
each task.
11.18.1
Reports (Printout/Display Stock Transaction Reports)
Selecting
Modules, Stockroom, Reports will display the screen shown below.
The above screen will
allow you to display/print all manner of stockroom reports.
11.19.1
Convert Parts To Assemblies
Provides
a short cut method that automatically converts 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 PICK 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 inventory will go negative.
pc/MRP
versions 8.01 and higher will create records of these transactions. Without
these transaction records, the Inventory Movement report will not be
accurate. pc/MRP versions 7.92G and
higher will disable this option if a file named ‘NOCONVERTPARTSTOASSY.FLG’
exists in the pcmrpw directory.
11.20.1
Index
Re-indexes
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,
re-indexing the index file is usually the cure.
11.21.1
Remove Marked Records
Removes
all stock transaction records marked for deletion from the disk. The records
will no longer be recoverable.
11.22.1
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.
11.23.1 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:
- Let pc/MRP issue the
required amount but physically issue the reel. Consider the reel as part
of the stock room stock even though the reel(s) are on the manufacturing
floor. If extra parts were issued from the reel, enter an L type stockroom
transaction to cover the extra quantity issued.
- Let pc/MRP issue the required amount (automatically or manually). Once you are finished with your 'I' type issue for that sales/work order number, Enter an L type stockroom transaction and issue the remaining quantity on the reel. When the sales/work order is returned from manufacturing as finished assemblies to the stock room along with the reels. Enter the quantity remaining on the reels using the stockroom’s "U" type transaction ("Returned unused parts from manufacturing to stock"). Select "Over issue to an L type transactions" as the reason for the return. Once you have returned all the reel quantities with "U" type transactions, you can return the sales/work order as completed assemblies using the stockroom's "R" type transaction.
11.24.1 Handling Scrap Parts
You have used the Stockroom’s ‘I’ Transaction Type to issue all the parts for 200 bicycles for a sale or work order. Part of the issue included 200 inner tubes. Two of the inner tubes are defective.
Use the Stockroom’s ‘L’ Transaction Type to issue two more inner tubes to the sales or work order.
OR
Use the Stockroom’s ‘U’ Transaction Type to return the two defective inner tubes to an area designated as scrap. Select ‘Reduce the Quantity Issued’ but not the ‘Quantity Required’. Use the Stockroom’s ‘P’ Transaction Type to issue two more inner tubes when they become available.
Once the bicycles are built, use the Stockroom’s ‘R’ Transaction Type to receive back the 200 completed bicycles.
Please note that pc/MRP’s Serial/Lot Number module will record the serial numbers for ‘I’, ‘R’, ‘A’, ‘U’, and ‘L’ the stockroom transactions.
11.25.1 Handling Finished Assembly Yields
You have used the Stockroom’s ‘I’ Transaction Type to issue all the parts for 200 circuit boards for a sale or work order.
Use the Stockroom’s ‘R’ Transaction Type to receive back the 200 completed circuit boards into a stores area.
Inspection rejects five of the finished circuit boards ‘A’ (This must occur after the Stockroom’s ‘R’ Transaction Type).
Use the Stockroom’s ‘B’ Transaction Type to move the 5 finished/rejected Circuit Boards from a stores area to a scrap area.
OR
Use the Stockroom’ ‘A’ Transaction Type to decrement the quantity in the stores area by 5.
Please note that pc/MRP’s Inspection Module provides a record of the inspection, and the quantity rejected but does not adjust any on hand quantities.
Accounting should be notified of any ‘A’ type adjustments to inventory so they can adjust their inventory asset and COG account values.