Finished Good Work Order Processing (WWOR)

Purpose: A finished good is an item, comprised of one or more component items, that requires assembly prior to picking and packing. Work order processing is the ability to reserve component items while you assemble a finished good. A work order builds a finished good item by increasing the inventory of the finished good and decreasing the inventory of its component items.

The work order process:

• identifies the finished good to create

• suggests where to pick the component items to make up the finished good

• prints a finished good work order ticket

• creates a make up finished good inventory transaction (transaction code = M)

• writes inventory transaction history for the finished good and its component items

Note: You cannot add a new component to a finished good if it has an open work order. See Entering Finished Goods Information (WFGD) and Importing Set Components (WCUP).

In this chapter:

Related System Control Values (Work Order Processing)

Work with Work Orders Screen

Create Work Orders Screen

- Work Order Validations

Create Work Order Details Screen

Work with Work Order Detail Locations Screen

Change Work Order Location Window

Change Work Orders Screen

Processing Work Orders

- Select Location Window

Work with Kit Makeup Screen

Create Kit Makeup Location Screen

Work Order Error Listing

Work Order Ticket

For more information:

• finished goods: Entering Finished Goods Information (WFGD)

• reviewing inventory transaction history for finished goods and their component items: Display Inventory Transaction History (DITH)

Related System Control Values (Work Order Processing)

System Control Value

Description

Use Work Order Processing (E37)

Select this field to use work order processing. The Protected qty (Protected quantity) field in the Item Warehouse table is used as a system-updated field for the component items of a finished good created through the work order process. The quantity in the Protected quantity field is increased for each component item when you create a work order and is decreased when you process the work order. The following message at the bottom of a menu screen indicates that you tried to enter the Work with Work Orders function and this system control value is unselected:

SCV: E37 must be set to 'Y' to perform Work Order Processing.

First Location Type (E42)

This field defines the location type the system searches first to fill the quantity of the component item needed to make up the finished good. Valid values are: *PRIMARY, *SECONDARY and *BULK. If the component quantity needed for this work order cannot be filled from the locations found in this location type, the system searches the location type from the Second Location Type (E43) system control value.

Second Location Type (E43)

This field defines the location type the system searches second to fill the quantity of the component item needed to make up the finished good. Valid values are: *PRIMARY, *SECONDARY and *BULK. If the component quantity needed for this work order cannot be filled from the locations found in this location type, the system searches the location type from the Third Location Type (E44) in the System Control table.

Third Location Type (E44)

This field defines the location type the system searches third to fill the quantity of the component item needed to make up the finished good. Valid values are: *PRIMARY, *SECONDARY and *BULK. If the component quantity needed for this work order cannot be filled from the locations found in this location type, the system splits the quantity needed between location types.

Work with Work Orders Screen

Purpose: Use this screen to:

• create a work order

• change, delete or display an existing work order

• print a work order ticket

• process a work order

How to display this screen: Enter WWOR in the Fast path field at the top of any menu or select Work with Work Orders from a menu.

Field

Description

Work # (Work order number)

The number used to identify the work order.

The system assigns work order numbers from the Purchase Order Header field in the Number Assignment table.

Numeric, 7 positions; optional.

Item number

The finished good to be produced.

Alphanumeric, 12 positions; optional.

COLR SIZE OTHR

The SKU of the finished good item to be produced.

Alphanumeric, three 4-position fields; optional.

Created on

The date the work order was created.

Numeric, 8 positions (user date format); optional.

Due date

The date the finished good item is scheduled to be available for sale. This date is indicated in Order Entry, Order Maintenance, standard or streamlined Order Inquiry, and in Item Availability.

Numeric, 8 positions (user date format); optional.

Vendor

The code for the vendor who is responsible for producing the finished good item.

Numeric, 7 positions, display-only.

Screen Option

Procedure

Change a work order

Select Change for a work order to advance to the Change Work Orders Screen.

Delete a work order

Select Delete for a work order to delete it. When you delete a work order:

• The Protected qty (Protected quantity) field for each component item in the Item Warehouse table is reduced by the amount specified in the work order

• The Pending transfer quantity field for each component item in the Item Location table is reduced by the amount specified in the work order

• The On order field for the finished good in the Item Warehouse table is reduced by the quantity deleted in this work order

Display a work order

Select Display for a work order to advance to the Display Work Order Screen.

Process a work order

Select Process for a work order to advance to the Select Location pop-up window. See Processing Work Orders.

Print a work order ticket

Select Print Ticket for a work order to print a Work Order Ticket.

Create a work order

Select Create to advance to the Create Work Orders Screen.

Create Work Orders Screen

Purpose: Use this screen to create the header information for a finished good work order. The header information includes:

• the work order number

• the warehouse where the finished good and its component items are located

• the quantity of the finished good to be produced

• the date the finished good is expected to be available for sale

How to display this screen: Select Create at the Work with Work Orders Screen.

Field

Description

Work order #

The number used to identify the work order. The system assigns work order numbers from the Purchase Order Header field in the Number Assignment table.

Numeric, 7 positions; display-only if system-assigned; required if manually entered.

Warehouse

The warehouse code and description where the finished good and its component items are stored. The warehouse code defaults from the Default Warehouse (A04) system control value. Warehouse codes are defined in and validated against the Warehouse table; see Creating and Maintaining Warehouses (WWHS).

Warehouse code: Numeric, 3 positions; required.

Warehouse description: Alphanumeric, 30 positions; display-only.

Item and SKU

The item code and SKU of the finished good to be produced. You define an item as a finished good by entering an F in the Kit type field in the Item table. The following message indicates that the item entered is not a finished good item:

Item is not Finished Good

A message similar to the following indicates that an Item Warehouse record does not exist for the item and warehouse you have entered:

Item/SKU (DOLL KIT/) does not exist for this warehouse (10)

Item: Alphanumeric, 12 positions; required.

SKU: Alphanumeric, three 4-position fields; required if the item has SKUs.

Qty (Quantity)

The quantity of the finished good to be produced.

Numeric, 7 positions; required.

Due date

The date the finished good is scheduled to be available for sale. This date is indicated in Order Entry, Order Maintenance, standard or streamlined Order Inquiry, and in Item Availability.

Numeric, 8 positions (user date format); required.

Vendor

The code for the vendor who is responsible for producing the finished good. Vendor codes are defined in and validated against the Vendor table; see Working with Vendors (WVEN).

Numeric, 7 positions; required.

Completing this screen: The message 'Suggesting locations, please wait' is displayed at the bottom of the screen. The system checks the available on-hand quantity of each component item in the warehouse and determines the locations from which each component item is picked to make up the finished good before advancing to the Create Work Order Details Screen. See Work Order Validations.

System updates: When a work order header is created:

• The Protected qty (Protected quantity)field in the Item Warehouse table for each component item is increased by the quantity needed to make up the finished good.

• The On order field in the Item Warehouse table for the finished good is increased by the amount being assembled for the work order.

• The Pending transfer quantity field in the Item Location table for each component item is increased by the quantity needed to make up the finished good. This quantity is a negative quantity since the component items will be transferred from their locations to the location for the finished good.

Work Order Validations

The system performs the following validations when a work order is created:

1.

Determines the available on-hand quantity of the component items in the warehouse entered on the Create Work Orders Screen, using the following calculation:

Component quantity < on-hand - (reserved + protected) = available on-hand quantity

An error message similar to the following indicates if the component quantity is greater than the available on-hand quantity:

Component FNHCMP34 - Warehouse qty (9) less than the requested qty (12)

2.

Determines the available on-hand quantity of the component items in the warehouse locations using the location type sequence from the Use Work Order Processing (E37) system control value. The system uses the following calculation:

On-hand - (printed - negative pending transfer quantity) = available on-hand location quantity

An error message similar to the following indicates if the system cannot find one or more locations that can fulfill the entire quantity needed to make up the finished good:

Component FNHCMP36 - Warehouse qty (9) less than requested qty (12)

3.

Checks that the locations are not frozen.

4.

Checks that the item locations are not frozen.

Create Work Order Details Screen

Purpose: This screen displays all of the component items needed to make up the finished good you have entered on the Create Work Orders Screen. Use this screen to accept, reject or change the locations the system has suggested to pick each component item.

How to display this screen: Select OK to accept the work order you have created on the Create Work Orders Screen.

Note: Component items are highlighted if an error occurred while the system was suggesting component locations to pick. The system will not accept the work order until you correct all items in error.

Field

Description

Work order #

The work order number assigned to this work order.

Numeric, 7 positions; display-only.

Warehouse (Warehouse and description)

The warehouse code and warehouse description where the finished good and its component items are stored. Warehouse codes are defined in and validated against the Warehouse table; see Creating and Maintaining Warehouses (WWHS).

Warehouse code: Numeric, 3 positions; required.

Warehouse description: Alphanumeric, 30 positions; display-only.

Kit

The item, SKU and description of the finished good entered on the Create Work Orders Screen.

Item: Alphanumeric, 12 positions; display-only. SKU: Alphanumeric, three 4-position fields; display-only.

Description: Alphanumeric, 30 positions; display-only.

Quantity

The quantity of the finished good to be produced. The quantity defaults from the Create Work Orders Screen. If you change the amount in the Quantity field, the system recalculates the available quantities in each location.

Numeric, 7 positions; required.

Component

The item/SKU of the component items that make up the finished good item. The component items default from the Kit Detail table.

Item: Alphanumeric, 12 positions; display-only.

SKU: Alphanumeric, three 4-position fields; display-only.

Description

The description of the component item.

Alphanumeric, 25 positions; display-only.

Kit qty (Kit quantity)

The quantity of the component item used to make up one finished good item. The kit quantity defaults from the Quantity field in the Kit Detail table.

Numeric, 5 positions; display-only.

Tot qty (Total quantity)

The total quantity of the component item needed to make up the total quantity of finished goods. The system determines the total quantity of component items needed using the following calculation:

kit quantity x total quantity of finished good = total quantity of component items needed

Example:

Kit quantity = 2

Total quantity of finished goods = 10

kit quantity (2) x total quantity (10) = total quantity of components needed (20)

Numeric, 7 positions; display-only.

Location

The location where the system suggests to pick the component items. If more than one location has been suggested, the location field appears blank and a plus (+) sign is displayed.

If you change the location for a component item, the system checks that:

• the item exists in that location

• the item/location reservation freeze flag = Unselected

• the location freeze flag = Unselected

• the available quantity in the location is equal to or greater than the quantity needed to make up the finished good

The system determines the available on-hand quantity in a location using the following calculation:

On-hand - (printed - negative pending transfer quantity) = available on-hand quantity

You can also add locations to a component item by selecting Locations for the component you wish to change. See Work with Work Order Detail Locations Screen.

Alphanumeric, 7 positions; required.

Instructions:

1. Optionally, you can change the Quantity and/or Location fields. The system recalculates the quantities in each location to determine if each component item needed is available.

2. Optionally, you can add locations to a component item by selecting Locations for the item. See the Work with Work Order Detail Locations Screen.

3. Select Accept to accept the work order details or select Reject to reject them. You return to the Create Work Orders Screen, where you can enter another work order.

4. If you rejected the work order because of errors, you can review the errors that occurred for each work order detail line on the Work Order Error Listing.

System updates: When you select Accept to accept the work order details:

• The system creates the details of a work order (this work order is displayed on the Work with Work Orders Screen).

• The Protected qty (Protected quantity) field in the Item Warehouse table for each component item is increased by the amount needed to make up the finished good.

• The Pending transfer quantity field in the Item Warehouse table for each component item is increased by the quantity needed to make up the finished good. This quantity is a negative quantity since the component items are transferred from their locations to the location for the finished good.

• The On order field in the Item Warehouse table for the finished good is increased by the quantity being assembled.

Screen Option

Procedure

Add locations to a component item

Select Locations for a component item to advance to the Work with Work Order Detail Locations Screen.

Accept the work order details

Select Accept to accept the work order details.

Reject the work order details

Select Reject to reject the work order details.

Print the Work Order Error Listing

Select Print Errors.

Work with Work Order Detail Locations Screen

Purpose: This screen is used to pick component items from more than one location, or to display, change or delete the system-recommended locations.

How to display this screen: Select Locations for a component at the Create Work Order Details Screen.

The system-recommended locations display in the lower half of the screen.

Field

Description

Work order #

The work order number for this component item.

Numeric, 7 positions; display-only.

Ln. (Line number)

The line number where this component item is located on the work order.

Numeric, 3 positions; display-only.

Item (Item/SKU and description)

The item number, SKU and item description for this component item.

Item: Alphanumeric, 12 positions; display-only.

SKU: Alphanumeric, three 4-position fields; display-only.

Item description: Alphanumeric, 120 positions; display-only.

Qty needed

The quantity of this component item needed to make up the finished goods. This amount defaults from the Create Work Order Details Screen.

Numeric, 7 positions; display-only.

Qty selected

The total quantity of this component item selected for the finished good across all locations. This field is updated as you add, change or delete locations to pick this component item in order to make up the finished good. The total quantity selected must equal the amount in the Quantity needed field or the following error message indicates:

Qty needed (1) must equal Qty selected (2)

Numeric, 7 positions; display-only.

Qty

The quantity of this component item to be picked from the associated location.

The total quantity entered for all locations must equal the amount in the Quantity needed field.

Numeric, 7 positions; optional.

Whs

The code for the warehouse where the component items are picked for the finished good. The warehouse code entered on the Create Work Orders Screen defaults and cannot be overridden. Warehouse codes are defined in and validated against the Warehouse table.

Alphanumeric, 3 positions; display-only.

Location

The location from which the associated quantity is picked.

Alphanumeric, 7 positions; optional.

Screen Option

Procedure

Change a detail location

Select Change for a location to advance to the Change Work Order Location Window.

Delete a detail location

Select Delete for the location you want to delete. The location and its associated quantity clears from the screen.

Accept the detail locations

Select Accept to accept the locations and their associated quantities.

Reject the detail locations

Select Reject to reject the locations and their associated quantities.

Instructions:

1. Review the system-suggested locations. See Change Work Order Location Window for more information on changing or deleting detail locations.

2. Enter the quantity of the component item you want to pick in the Quantity field.

3. In the Location field, enter the location code where the quantity will be picked. You must enter a valid warehouse location for the component item. A message similar to the following indicates if the location you enter is invalid: Item Location does not exist for Item (DRAWING PAD).

4. The system displays the quantity, warehouse and location at the bottom of the screen and increases the amount in the Quantity selected field in the top of the screen.

5. Select Accept to accept the locations you have created. The system verifies that the Quantity needed field equals the Quantity selected field. The following message indicates if the quantities are not the same: Qty needed (1) must equal Qty selected (2)

6. Select Reject to reject the changes you have made.

System updates: When you select Accept to accept the locations you have created, the Pending transfer quantity field in the Item Location table is increased by the quantity you entered. This quantity is a negative quantity since the component item is transferred from this location to the location for the finished good.

See Work Order Validations for a list of validations the system performs before accepting a work order detail location.

Change Work Order Location Window

Changing detail locations: To change a work order detail location for a component item, select Change for the location at the Work with Work Order Detail Locations Screen. Enter an amount in the Quantity field to change the amount picked from the location to make up the finished good item. See Work Order Validations for more information on the validations the system performs when you change a work order detail location.

Change Work Orders Screen

To change a work order: Select Change for a work order on the Work with Work Orders Screen to advance to the Change Work Orders screen. You can change only the Due date field on this screen. See Create Work Orders Screen for field descriptions. The following message indicates if the date you entered is less than today's date:

Due date must be Greater than or equal to today’s date

Change the due date if necessary and select Accept to accept the change. You return to the Work with Work Orders Screen.

Display Work Order Screen

To display a work order: Select Display for a work order on the Work with Work Orders Screen to advance to the Display Work Order screen. The Display Work Order screen indicates the details of a finished good work order including:

• the work order number

• the warehouse where the finished good and its component items are located

• the vendor who is responsible for producing the finished good

• the quantity of the finished good to be assembled

• the date the finished good is available for sale

• the component items that make up the finished good

• the locations the component items are taken from to make up the finished good

See Create Work Order Details Screen for a description of the fields on this screen.

You can also display a component's locations from this screen by selecting a component item. You advance to the Display Work Order Locations screen.

An error message similar to the following indicates if you select Locations for a component item that is not taken from more than one location:

This record does not have multiple locations to display

See Work with Work Order Detail Locations Screen for a description of the fields on this screen.

Processing Work Orders

Purpose: Once you have assembled all of the finished goods for a work order, you can process it. Processing work orders increases the inventory of the finished good and decreases the inventory of its component items through the make up finished good inventory transaction (transaction code = M).

To perform the make up finished good inventory transaction you must:

• define the location where the finished good is stored

• define the location or locations from which the component items are picked from to make up the finished good

Select Location Window

You can process a work order on the Work with Work Orders Screen by selecting Process for a work order. The Select Location pop-up window opens.

Field

Description

Work order #

The number of the work order you are processing.

Numeric, 7 positions; display-only.

Kit

The item, SKU and description of the finished good you are processing.

Item: Alphanumeric, 12 positions; display-only.

SKU: Alphanumeric, three 4-position fields; display-only.

Warehouse

The warehouse code and description in which the finished good you are processing is stored. Warehouse codes are defined in and validated against the Warehouse table.

Warehouse code: Numeric, 3 positions; display-only.

Warehouse description: Alphanumeric, 3o positions; display-only.

Quantity

The total quantity of finished goods to be produced on this work order. The quantity you entered when you created the work order defaults, but can be overridden.

You can process a portion of the finished goods that are ready on the work order by entering a quantity less than the total quantity available. The finished goods that are not processed, remain open on the work order until you process them.

Numeric, 7 positions; required.

Location

The location where the finished good will be placed once it is processed. The primary location for this finished good defaults if you have selected the Default Primary Location (C05) system control value.

You can prompt on this field to advance to the Select Item Location screen, where you can select an item location to default to the Location field on the Select Location window. If you do not select a location at the Select Item Location screen, you return to the Select Location window and the Location field updates to blank.

Alphanumeric, 7 positions; required.

Instructions: Use the following steps to select the quantity of the finished good you want to process and the location where the finished goods will be placed once they are assembled.

1. Review the quantity of the finished goods to assemble for this work order. To change the amount, enter a different quantity in the Quantity field. The following message indicates if you enter a quantity that is greater than the original quantity: Quantity entered cannot be greater than original quantity.

2. Enter the location where you want the finished goods to be placed once they are assembled.

3. Select OK to accept the quantity and location you entered. You advance to the Work with Kit Makeup Screen, where you can arrange the component items on the work order and process a make up finished good inventory transaction (transaction code = M).

System validations: When you select OK, the system checks that;

• The location you entered exists. A message similar to the following indicates if the location you entered does not exist:

Location (K010104) does not exist.

 

• The location you entered is not frozen. A message similar to the following indicates if the location you entered is frozen:

Location K010104 frozen

 

• The item/location you entered is not frozen. A message similar to the following indicates if the item/location you entered is frozen:

Location K010104 frozen

 

• If the location you entered is a primary location, the Allow Multiple Primary Item Locations (D12) system control value is set to ALLOW.

• The location class for the location matches the location class for the item if the Allow Location Class Edit in Inventory Transaction (F86) system control value is selected. An error message similar to the following indicates if the location's location class does not match the item's location class:

Item is not compatible with Location.

 

• The quantity you entered in the Quantity field is not greater than the original quantity. An error message similar to the following indicates if you enter a quantity that is greater than the original quantity:

Quantity entered cannot be greater than original quantity.

 

• The Default Primary Location (C05) system control value is selected. An error message similar to the following indicates if you have not selected this field:

No Default Location was found. Please enter a location.

Work with Kit Makeup Screen

Purpose: Use this screen to arrange the component items on a finished good work order and process a make up finished good inventory transaction (transaction code = M).

How to display this screen: Select OK on the Select Location Window. You can also display this screen by entering valid information for a finished good at the Work with Inventory Transactions Screen.

Field

Description

Batch #

The number of the batch assigned to this work order. The batch number is used to keep track of the component items that make up the finished good.

Numeric, 7 positions; display-only.

Work order #

The number used to identify the work order that this finished good is assigned to.

Numeric, 7 positions; display-only.

Kit

The item, SKU and description of the finished good on this work order.

Item: Alphanumeric, 12 positions; display-only.

SKU: Alphanumeric, three 4-position fields; display-only.

Description: Alphanumeric, 30 positions; display-only.

Component

The item, SKU and description of a component item that makes up the finished good.

Item: Alphanumeric, 12 positions; display-only.

SKU: Alphanumeric, three 4-position fields; display-only.

Description: Alphanumeric, 30 positions; display-only.

Control quantity

The quantity of the component that is needed to make up the finished good.

Numeric, 7 positions; display-only.

Actual quantity

The quantity of the component that is taken from a location. If you are taking a component from more than one location, be sure the actual quantity matches the control quantity.

Numeric, 7 positions; required.

Whs (Warehouse)

A code for the warehouse that contains the component item. Warehouse codes are defined in and validated against the Warehouse table. The warehouse code for this work order defaults.

Numeric, 3 positions; display-only.

Location

The location from which the system suggests to pick the component items. If more than one location has been suggested, the Location field is blank and a plus (+) sign is displayed.

If you change the location for a component item, the system checks that:

• the item exists in that location

• the item/location freeze flag = Unselected

• the available quantity in the location is equal to or greater than the quantity needed to make up the finished good

You can add locations to a component item by selecting Locations for the component item you wish to change. See Select Location Window.

Alphanumeric, 7 positions; required.

Instructions:

1. Complete the necessary fields.

2. Select Accept.

3. You return to the Work with Work Orders Screen, where you can process another finished good work order.

System validations: When you select Accept to process a work order, the system checks that:

• The component items exist in the locations specified. A message similar to the following indicates if a component item does not exist in the location specified:

The system could not reserve the entire Qty required. Qty available (0)

 

• There is enough available on-hand quantity in each location for each component item to make up the finished good. If the on-hand quantity is not enough, the system will not process the work order and displays the following message: Trans qty (-100) will cause on hand quantity in item location to be negative. The system uses the following calculation to determine the amount available in each location:

On-hand - [printed - (pending quantity - pending work order quantity) = available on-hand

 

• The amount of component items taken from each location will not reduce the on-hand quantity below the reserved quantity.

• The locations are not frozen.

• The item locations are not frozen.

System updates: When you select Accept to process a work order:

• The make up finished good inventory transaction is processed (this increases the amount of finished goods and decreases the amount of each component item).

• Inventory transaction history records are created for the finished good and its component items. See Display Inventory Transaction History (DITH).

• The Pending transfer quantity field in the Item Location table for each component item is reduced by the quantity processed.

• The work order record is deleted if the entire quantity of finished goods on the work order has been processed; if not, the quantity in the Work Order Header table is reduced by the quantity processed.

• The Protected qty (Protected quantity) field in the Item Warehouse table for each component item is reduced by the quantity processed.

• The On order field in the Item Warehouse table for the finished good is reduced by the quantity processed.

Screen Option

Procedure

Add a component location

Select Add location for the component to advance to the Create Kit Makeup Location Screen.

Accept the kit

Select Accept. You return to the Work with Work Orders Screen.

Create Kit Makeup Location Screen

Purpose: Use this screen to add locations to component items. Adding locations allows you to take a component item from more than one location to make up the finished good. There must be a quantity in each location before you can perform this transaction.

How to display this screen: Select Add location for the component item at the Work with Kit Makeup Screen.

Field

Description

Actual quantity

The quantity of the component item that is taken from a location. If you are taking a component item from more that one location, be sure the actual quantity matches the control quantity.

Alphanumeric, 7 positions; required.

Location

The location from which the system suggests to pick the component items. If more than one location has been suggested, the Location field is blank and a plus (+) sign is displayed.

If you change the location for a component item, the system checks that:

• the item exists in that location

• the item/location freeze flag = Unselected

• the available quantity in the location is equal to or greater than the quantity needed to make up the finished good

Alphanumeric, 7 positions; required.

System validations: When you add a location to a component item, the system checks that:

• The item location exists. A message similar to the following indicates if the item location you enter does not exist:

Location (K010105) does not exist.

 

• The item location Reservation freeze flag is unselected. A message similar to the following indicates if the Reservation freeze flag in the item location table is selected:

The system could not reserve the entire Qty required. Qty available (0)

 

• the location Freeze field is unselected. The following message indicates if the Freeze field in the location table is selected:

No available location found for component item

 

• the Cls (Location class) for the location matches the Loc class (Location class) for the item if the Allow Location Class Edit in Inventory Transaction (F86) system control value is selected. An error message similar to the following indicates if the location's location class does not match the item's location class:

Item is not compatible with Location.

 

• There is enough available on-hand quantity in the location for each component item to make up the finished good. The system uses the following calculation to determine the amount available in a location:

On-hand - (printed - negative pending transfer quantity) = available on-hand

WWOR OMSCS 19.0 December 2019 OHC