Implementation of ECOs on Jobs and Schedules
You can indicate whether to update work in process requirements when you implement an ECO revised item. When you implement the revised item that is set to update work in process, the bill of material is automatically re-exploded and updated for all unreleased discrete jobs and repetitive schedules for the item.
If you have updated component material requirements for the unreleased job or schedule, you lose these updates after you implement the revised item.
Released, Complete, and On hold Repetitive Schedules
For repetitive schedules, if you have not moved assemblies beyond the Queue intraoperation step of the first operation, Work in Process automatically regenerates the bill and component requirements for the repetitive schedule to include the effects of the ECO.
If you have moved assemblies beyond the Queue intraoperation step of the first operation, when you implement the ECO, Work in Process splits the schedule into two schedules that take the place of the original schedule. The first schedule uses the original bill and the second new schedule uses the revised bill that includes any revised item or component changes. Work in Process assigns the two new schedules a status of Released, Complete, or On hold, depending on the status of the original schedule.
The schedule splits based on the number of assemblies in process (moved past the Queue intraoperation step of the first operation if you are using routings) on the original routing. That number is rounded up to the nearest day so that you can finish your day's work using the original bill. The next day production starts using the revised bill and a new schedule.
The following example best illustrates this procedure.
Example
Released Schedule:
- Production rate = 50 per day
- Total quantity of schedule = 200 units
The following diagram illustrates the original schedule:
Shop floor distribution of assemblies before the implementation of the ECO for the original schedule:
- 80 units spread in the routing beyond queue of the first operation
- 120 units in queue of the first operation
Original schedule dates:
- First unit start date = Day 1
- First unit complete date = Day 2
- Last unit start date = Day 4
- Last unit complete date = Day 5
Since the daily quantity is 50, this means that production is in its second day. Therefore, if you implement the ECO now, the schedule splits after the second day's work is completed.
If you implement a change order for the item on Day 3 (Today), the shop floor distribution of assemblies following the implementation of the ECO are:
New Schedule 1 = 100 total units
- 20 units in queue of the first operation
- 80 units spread in the routing beyond queue of the first operation. These 80 units are located exactly where they were before the implementation of the ECO.
New Schedule 2 = 100 total units
- 100 units in queue of the first operation. The reason that there are only 100 assemblies and not 120 assemblies is that only two process days remain in the schedule; therefore, only two process days worth of assemblies can be put into new schedule 2.
Schedule dates following the implementation of the ECO:
New Schedule 1:
- First unit start date = Day 1
- First unit complete date = Day 2
- Last unit start date = Day 2
- Last unit complete date = Day 3
New Schedule 2:
- First unit start date = Day 3
- First unit complete date = Day 4
- Last unit start date = Day 4
- Last unit complete date = Day 5
The following diagram illustrates the split schedule:
All material that you issued to the original schedule remains with new schedule 1. Material requirements for new schedule 1 are changed to match the new number of assemblies to complete. Material requirements for the altered assembly are exploded for new schedule 2 for the number of assemblies assigned to the new schedule 2.
See Also
Overview of Discrete Manufacturing
Overview of Repetitive Manufacturing
