Maintaining Component Lists

This chapter provides an overview of component lists and discusses how to maintain component list information.

Understanding Component Lists

When the system releases production to the shop floor, it creates a component list for the production quantity specified and associates it with the production ID or production schedule. With the creation of a component list, PeopleSoft Manufacturing provides you with the ability to alter the bill of material (BOM) to accommodate item substitutions or configuration changes. You can also associate attachments with each component on the component list.

Once you define a production area/item combination and create a production ID or production schedule for an item, you can verify and change the production requirements before or after releasing production to the shop floor.

You can create a component list by:

• Manually changing a production ID or production schedule status from Entered to Firmed or Released or running the batch release process for a range of production IDs or production schedules.

  When the production status is changed to Firmed or Released for:

  • Regular production: The system copies the valid BOM in effect on the production due date or for the specified revision into the component list for the production ID or production schedule.

    For a configured end item, the component list comprises standard items, as well as the options and features selected for the particular configuration. For this type of production, a component cannot be the same item ID as the item ID being produced. Floor stock and expensed items appear for informational purposes only.

  • Rework production for an item without a rework BOM: The system creates a component list with the reworked end item as the only component and assigns the Kit issue method.

    The scheduled quantity is the same as the production quantity. If additional material is needed to complete the rework, manually add the items to the component list using the Edit/Issue Components page. Additionally, if component requirements are known prior to the start of rework, you can specify those components using the Update Component List pages. This enables you to issue the additional components, along with the end item being reworked, using the Material Pick Plan. The system issues any additional components required for rework production using the issue method set for each item at the production area/item level.

  • Rework production for an item with a rework BOM: The system bases the component list on the rework BOM and automatically adds the reworked end item as a component and assigns the Kit issue method.

    For the reworked end item, the scheduled quantity is the same as the production quantity. For additional components on the rework component list, the system calculates the scheduled quantity based on the quantity per component and the rework production quantity.

  • Teardown production: The system automatically adds the end item to be torn down as a component when the production is released and assigns the Kit issue method.

    You can't change or delete the end item, but you can add additional components if necessary. The scheduled quantity is the same as the production quantity. The system issues any additional components required for teardown production using the issue method set for each item at the production area/item level. These additional components can't be substituted. The scheduled quantity is the same as the production quantity.

• Processing new production recommendations for production IDs and production schedules from PeopleSoft Supply Planning in PeopleSoft Manufacturing.

• Recording an end item or production completion.

  If you specify a production schedule quantity or production ID quantity that still has a status of Entered or Firmed during the completions and scrap reporting process, the system prompts to release the production and creates the component list. The ability to release production during the completion process is dependent on the manufacturing business unit options.

• Adding a production schedule after you have completed manufacturing an item.

  When you add a production schedule quantity at the same time that you record operation completions and scrap, the system automatically creates the production schedule, releases production, and creates the component list. After backflushing, components are consumed and costs are posted for the completed quantity.

• Running the production configuration process for a configured order.

  When the production ID for the configured item is created, the status is automatically set to Released, and the component list is created based on the options and features selected during the configuration process.

The component lists created differ depending on whether the component list is for regular, teardown, or rework production or for a configured item. For regular production, the system uses the end item's BOM to create the component list. For teardown production, the component list consists of the item that you are tearing down, which is automatically issued using the Kit issue method. For rework production, the system bases the component list on the rework BOM if there is one and automatically adds the reworked end item as a component and assigns it the kit issue method. If a rework BOM doesn't exist, the system creates a component list with only the reworked end item as a component.

For a configured item, the component list is created using the options and features selected during sales order entry. You can modify either component list by adding new components, deleting existing components, or changing the quantity per assembly or per order, scheduled quantity, or component yield. You can't specify configured items as a component on a component list for a non-configured end item. Configured items can have other configured items as components. You can't change the rework or teardown end item on the component list.

This section discusses how to:

• Create component lists for regular production.

• Create component lists for rework production.

• Create component lists for teardown production.

• Modify the component list during the production process.

Creating Component Lists for Regular Production

To create a component list for regular production, the system copies the item's BOM. The component list defines the required components for the production quantity. You define which BOM to use for production by selecting the appropriate revision of the BOM or using the BOM in effect at the time production is due.

Note. Components that are supplied by an outside vendor aren't included when creating the component list. These components are marked as subcontractor-supplied on the item's BOM.

Note. Floor stock and expensed items are included on the component list for informational purposes only. Although the system calculates and displays a scheduled quantity, these items aren't included in any pick plan and therefore won't be issued to production during the material release process.

When creating the component list, the system determines the scheduled quantities and current scheduled quantities for each of the end item's components. Scheduled quantity is based on this formula:

[(operation start quantity x quantity per assembly) / component yield]

The scheduled quantity is calculated based on the quantity of the end item started at the operation where the component is used. In addition, the system also initializes the components operation sequence and quantity per assembly or per order with information from the BOM. The components issue method defined for the end item within the production area is also defined at this time.

If you're adding a new component, the scheduled quantity is calculated the same as when a production ID is created (operation start qty * qty per assy)/component yield.

If you're changing the scheduled quantity, then the system calculates the quantity per assembly: QPA = (current component scheduled qty * component yield) /operation start qty. The operation start quantity factors in any planned yield loss or actual scrap that has occurred at prior operation sequences.

If you're changing the QPA, then the current scheduled quantity is recalculated using the operation start quantity at the operation sequence where the component is required.

See Also

Maintaining Bills of Material

Creating Component Lists for Rework Production

PeopleSoft Manufacturing creates the component list for rework production somewhat differently than for regular production. When the rework production ID is released, the system adds the end item being reworked to the component list, with a scheduled quantity the same as the production quantity. The system assigns the kit issue method to the end item being reworked. Additionally, if the end item being reworked has a rework BOM associated with the rework production ID, the system calculates the additional component requirements and adds them to the component list on the rework BOM. The system issues any additional components required for rework production using the issue method set for each item on the production area/item level. The issue method defaults from the Define Business Unit Item - Manufacturing page; you can override it on the Production Area - Item Detail page. The operation sequence of the reworked end item is automatically set to 0. The operation sequence of the additional components reflects the operation sequence specified on the rework BOM. If you haven't predefined a rework BOM, you can add other components to the component list as needed to repair or rework the end item.

Creating Component Lists for Teardown Production

PeopleSoft Manufacturing creates the component list for teardown production by copying the item that you are tearing down into the component list with a scheduled quantity the same as the order quantity. If additional material is needed to tear down the item, manually add those components to the component list. The issue method for the end item being torn down is automatically set to Kit. The system issues any additional components required for teardown production using the issue method set for each item at the Production Area/Item level. The issue method defaults from the Define Business Unit Item - Manufacturing page; you can override it on the Production Area - Item Detail page.

Modifying the Component List

You can modify the component list after the release of the production ID—even if production is in process. If you have already consumed or issued components on the component list, you can't delete those components from the production ID. However, you can:

• Add, change, or delete other components.

  However, for teardown or rework production, you can't delete the teardown or reworked end item from the component list. Additionally, you can only add a configured item as a component if the end item is also a configured item.

• Change the operation sequence.

• Change component quantities.

• Indicate whether the component is issued per assembly or per order.

• Change the component yield.

When you modify a component list and if you are integrating to a third-party Manufacturing Execution System (MES), PeopleSoft Manufacturing uses the Production Order Update Enterprise Integration Point (EIP) to publish a message to the MES with the transaction information. The MES then subscribes to that message and updates the MES information.

In addition, you can also view and edit a limited number of components associated with a production ID or production schedule. Select a subset of components by using various filters. Use this when you do not want to select all the components associated with the production ID or production schedule.

See Also

Integrating with Third-Party Systems

Manufacturing Execution System Integration

Common Elements Used in This Chapter

Maintaining Component List Information

This section discusses how to:

• Define component selection criteria.

• Select specific components.

• Maintain the component list summary.

• Make item substitutions.

• Maintain component detail.

• View component status information.

• Associate component documents.

• Specify component attachments.

• Delete components from component lists.

Pages Used to Maintain Component List Information

See Also

SFS2006 - Component Where Used in Production Report

Defining Component Selection Criteria

Access the Update Component List - Production Selection page (Production Control, Define Production, Production IDs/Schedules, Update Component List, Production Selection).

Production ID	Select to view or maintain the component list for a specific production ID.
Production Area and Item	Enter values in both fields to view or maintain the component list for production schedules. The production schedule information is based on the start date of production or when production is due to be completed.
Select Components	Click this link to access the Component List Selection page, where you can retrieve specific components.

Date Type

Selecting Specific Components

Access the Component List Selection page (Click the Select Components link on the Update Component List - Production Selection page).

Op Sequence Range

Component Range

Select one of these options:

• All Components

• Range

• Description: Enter the words or strings included in the component's description. The system retrieves any component whose description contains the words or string that you enter in this field.

  Note. The values for this field are case sensitive.

• List of Components: Select specific components to retrieve.

Note. You can use both the Op Sequence Range and Component Range options to further filter the selection criteria.

Click OK to retrieve the selected components and access the Summary page.

Click Cancel to return to the Production Selection page.

Maintaining the Component List Summary

Access the Update Component List - Summary: Summary page (Production Control, Define Production, Production IDs/Schedules, Update Component List, Summary, Summary).

Print at Save	Select this check box if you want to print production documents at save time.
Setup Print Options	Click this link to access the Process/Output Options page to select different print criteria for the production documents.

Component Summary

Quantity Per Calculations

You can calculate the quantity per assembly or per order.

• To calculate the quantity per assembly with a known scheduled quantity:

  Quantity Per Assembly = [(Scheduled Quantity / operation start quantity) x (Component Yield / 100)] + .00005*

  *.00005 is used for rounding

• To calculate the quantity per order with a known scheduled quantity:

  Quantity Per Order = Scheduled Quantity

Important! To provide greater accuracy when modifying component data, we don't require the Quantity field to follow the quantity precision rules defined for the item. A warning is issued if you define a decimal quantity value for an item whose quantity precision value is a whole number.

Scheduled Quantity Calculations

You can calculate the scheduled quantity per assembly or per order.

• To calculate the scheduled quantity with a known quantity per assembly:

  Scheduled Quantity = Production Start Quantity x [Quantity Per Assembly / (Component Yield / 100)]

  Note. The production start quantity in this calculation denotes the starting quantity required at the operation sequence associated with the component. If there is no operation sequence, then the production start quantity is the starting quantity of the production ID or production schedule.

• To calculate the scheduled quantity with a known quantity per order:

  Scheduled Quantity = Quantity Per Order

Note. The format for the Scheduled Quantity on this page may be determined by the item's unit of measure and quantity precision combination that was defined in PeopleSoft Inventory.

Other tab

Issue Method

When you set the component issue method to Issue, material is delivered to the work center WIP location. When you record end item completions for the operation, the components associated with that operation sequence are consumed from the work center's WIP location. At that point, the system decrements the quantity on hand in the WIP location and updates the issue quantity on the component list.

Components using the Replenishment method are handled in a manner similar to those using the Issue method. Material is delivered to the WIP location using the production replenishment pages as a result of a worklist notification.

When you record end item completions, the components associated with that operation sequence are consumed from the work center's WIP location. At that point, the system decrements the quantity on hand in the WIP location and updates the issue quantity on the component list.

If you are using PeopleSoft Flow Production, you can also replenish the WIP locations directly from an inventory location, feeder line, or vendor using Kanban Cards or online replenishment requests.

When you use the Kit component issue method, the operation sequence is only a reference for the material handler. Kitted material is delivered to the work center tied to the operation sequence, but the system charges the material directly to the production ID upon issue. The material isn't issued to the work center's WIP location, nor consumed when the operation is completed. The system updates the issue quantity on the component list when the material is released to production.

When you add a new component to the component list, the operation sequence defaults to zero. A component with an operation sequence of zero means that the component will be used at the first operation. If an invalid operation sequence has been specified on the end item's BOM, the system assumes that it will be used at the first operation.

For the phantom item's components, the system assigns the phantom's operation sequence to all of its components.

If an invalid operation sequence has been specified on the end item's BOM, or the operation sequence is set to zero, the system issues the components to the production area's WIP location. Owned components are issued only to owned WIP locations. Likewise, non-owned components are issued only to non-owned WIP locations.

Serial Control

The Serial Controlcheck box is a display-only field that indicates if the component is serial-controlled.

Teardown

The Teardown check box designates the component as a potential teardown output. This value is copied from the BOM Component Detail page. If a production ID is selected as the basis for a teardown order, the components designated as teardown are considered the outputs from the teardown production.

Substitute

The Substitute check box designates that a substitution has already taken place. This value is copied from the Component List Substitution detail page.

MES and Component Lists

When you modify a component list, if you are integrating to a third-party MES, PeopleSoft Manufacturing uses the Production Order Update EIP to publish a message to the MES with the transaction information. The MES then subscribes to that message and updates the MES information.

See Also

SFS2003 - Production Documents

Maintaining Production Orders and Production Schedules

Managing Inventory by Item Status

Understanding the Flow Production Process

Making Item Substitutions

Access the Item Substitution page (Production Control, Define Production, Production IDs/Schedules, Update Component List, Summary, Summary. Click the Item Search button next to the Component ID).

Maintaining Component Detail

Access the Update Component List - Detail: Detail page (Production Control, Define Production, Production IDs/Schedules, Update Component List, Detail, Detail).

Component Details	Summarizes the activity of the component for the production ID or production schedule.
Orig Comp ID (original component ID)	Displays the original component ID, if this component is a substitute, as well as the issue method for the component. There are several component issue methods: Production Issue, Production Kit, and Production Replenishment.
Source Cd (source code)	Values are Make, Buy, Expenses,or Floor Stock.
Sched Qty (current scheduled quantity) and Yield	Fields are display only, but you can change this information.
Quantity	Displays the calculated quantity per assembly or per order. The system calculates the quantity per by dividing the quantity per assembly by the BOM's BOM quantity. You designate the level of precision for the calculated quantity per in the manufacturing installation options page.
Config Code (configuration code)	Displays a code if the item is configured. If you add a configured item to the component list, you must add the configuration code here. Note. For serial-controlled items, values in the Quantity Per and Scheduled Quantity fields must be whole numbers.
Non-Owned Item	Indicates that the component is supplied by the customer or is a consigned item. Approved consigned items can be added to component lists.
Teardown	Designates the component as a potential teardown output. This value is copied from the BOM Component Detail page.

See Also

Working With Configuration Codes

Managing Consigned Purchases Inventory

Viewing Component Status Information

Access the Component Details page (On the Update Component List - Detail: Detail page, select the Detail icon.)

Pending Issue Qty (pending issue quantity)	Displays the quantity used based on the quantity completed at the operation multiplied by the quantity per assembly. If the component's quantity is expressed as per order, this is the per order quantity. The per order quantity is completely consumed at the first backflush. This quantity hasn't yet been consumed from the WIP location due to material shortages.
Yield Loss Qty (yield loss quantity)	Displays the quantity that was scrapped during the end item process and consumed from the WIP location.
Issue Qty (issue quantity)	For components using the Issue or Replenishment material issue method, this is the quantity that was consumed from the WIP location for the component and that was charged to work in process. For components using the Kit method, this is the quantity issued directly to the production ID.
Pending Yield Loss Qty (pending yield loss quantity)	Displays the quantity of components that was scrapped during the end item process but that has not yet been consumed from the WIP location due to material shortages.
Pending Pick Quantity	Displays the quantity that is awaiting issue to the WIP location or to the production ID to satisfy the scheduled component requirement. The pick plan has already been generated for these components but they haven't yet been reviewed and released to production.

Associating Component Documents

Access the Update Component List - Detail: Documents page (Production Control, Define Production, Production IDs/Schedules, Update Component List, Detail, Documents).

Note. You must have PeopleSoft Engineering installed before you can access this page.

Using the Documentum Component Options page, you control the document management buttons that appear on this page.

Component Details and Documents

The system displays all the documents associated with this component list, including the document name and title, and whether the document is fixed or not. When you fix an associated document to a page, a specific version of the document is "permanently" associated with the page.

See Also

Managing Documents

Specifying Component Attachments

Access the Update Component List - Detail: Attachments page (Production Control, Define Production, Production IDs/Schedules, Update Component List, Detail, Attachments).

Deleting Components from the Component List

When deleting components, the system checks to see if material was issued to the location associated with the component's operation sequence, if material was consumed during a backflush or if material was issued using a production kit. A warning message appears if material was issued to the location. If material was consumed during a backflush, issued directly to the production ID, or an inventory picking plan has already been created for the component, the system won't allow you to delete the component. To delete the component, reverse the backflush, unconsume or debit the component, and then delete it.