You use this program to establish which jobs need to be raised through several levels of a structure (providing a balanced supply of components and sub-assemblies) as well as the purchasing requirements required to complete the build.
This program provides an alternative to running the MRP Master Production Schedule program from within the Requirements Planning system and is an attempt to emulate the manual method used by a company to build a finished item. However, the Multi-level Trial Kitting program, as with other trial kitting machines, is designed to check supply and demand only for materials in the Bills of Materials. Therefore, if the requirement is to schedule subcontract operations (for example), then the Requirements Calculation program must be used.
Typically, the drawing office provides a list of components for each sub-assembly and component and the Kardex information is used to determine which jobs and purchase orders must be raised, taking into account the stock on hand.
All sub-assemblies and components are processed, multiplying the quantity per by the net requirement of the parent. This is then compared to the net quantities on hand to determine the shortages.
| Field | Description |
|---|---|
| Start Review |
Select this to generate the trial kit list and display the results in the Muti-level Trial Kit List listview (see Multi-level Trial Kitting routine). Processing is aborted if a structure is recursive, or has more than 15 levels. |
| Change Criteria | Select this to change the Selection criteria for the trial kit list. |
| Preferences | Select this to indicate the demand and supply factors required to determine the availability of stock. |
| Field | Description |
|---|---|
| Save Preferences | Save these preferences against your operator code and use them for future runs of the program until next you change them. |
| Close | Save the preferences for the current run of the program only. |
| Include in demand | |
| Sales order allocations | Select this to indicate that you require the availability of stock to be reduced by sales order allocations. |
| Work in progress allocations | Select this to indicate that you require the availability of stock to be reduced by work in progress allocations. |
| Safety stock | Select this to indicate that you require the availability of stock to be reduced by safety stock. |
| Include in supply | |
| Quantity on order | Select this to indicate that you require the availability of stock to be increased by the quantity on order. |
| Quantity in inspection | Select this to indicate that you require the availability of stock to be increased by the quantity in inspection. |
| Show negatives | Select this to display components with a negative net requirement quantity. |
The program uses the BOM to calculate the Required quantity for each component drilling down in the levels, taking into account what you selected to include as Demand and Supply for each sub-assembly or component.
The reason for having a Gross required and a Net required quantity for each sub-assembly and component, is that the Gross required quantity is the quantity calculated based on what is required (when applicable) in order to be able to build the specified quantity of the Main parent part. The Net required quantity is calculated as the Gross required quantity for the stock code minus any supply available for this component.
This section indicates the processing sequence applicable to the Multi-level Trial Kitting program:
The following are output to a temporary index file:
Depending on the selection criteria defined within the Preferences function, the following calculations are performed:
Quantity available
Stock on hand minus (sales order allocations plus safety stock pluswork in progress allocations plus quantity reserved for WIP allocations) plus (inventory quantity in inspection plus purchase/work in progress outstanding).
Exploded quantity
The exploded quantity is the quantity required if there is no stock available throughout the levels (i.e. there are no parent quantities available and you need to manufacture all the parents). This is calculated as follows:
((quantity per plus (quantity per multiplied by scrap percentage) multiplied by parent quantity) plus scrap quantity)
Gross required
The gross quantity indicates the quantity that is required based on the net quantity required for the parent. For example: If 10 parents are required for a structure, 3 of which are in stock, then you only need to manufacture 7).
If a sub-assembly has enough stock on hand or on supply coming in to build the specified amount of the main standard parent part, then the lower level components for that sub-assembly will have a Gross required quantity = 0.000, as they are not required to build the parent part in this scenario.
If a sub-assembly has only enough stock on hand or on supply coming in to satisfy a partial amount of the quantity specified for the standard parent part, then the Net quantity required for the sub-assembly is used to calculate the Gross quantity required for the lower level components for that sub-assembly.
Net quantity required
The net quantity required is calculated as: Gross requirement less quantity available
If the net required is greater than zero, then it is saved as the parent quantity for any components. If the shortage is zero, then the components are assigned a zero net requirement and a zero shortage.
ECC considerations
The Quantity available and Net required quantity are based on the quantities across all revision/releases for an ECC controlled component with an ECC consumption method of Deplete oldest when exploding the Bill of Material for a stocked parent part.
| Field | Description | ||||||
|---|---|---|---|---|---|---|---|
| Trial kitting selections | |||||||
| Stock code | Indicate the parent item for which to generate a trial kit list. | ||||||
| Description | This indicates the description of the Stock code. | ||||||
| Route | Indicate the route number of the structure that must be
processed. This applies only when the option: Alternate routings (Bill of Materials Setup) is enabled. |
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| Revision | Indicate the revision if the Stock code is ECC-controlled item. | ||||||
| Release | Indicate the release if the Stock code is ECC-controlled item. | ||||||
| Lead time | |||||||
| Quantity | Indicate the quantity to make of the parent Stock code. | ||||||
| Due date | The entry made here is used for documentation purposes only. | ||||||
| Warehouse selections | Indicate the warehouse(s) for which to generate the trial kit list. | ||||||
| Warehouse type |
|
The results of the trial kitting calculation (based on the Selections specified) are displayed in this listview when you select the Start Review function.
| Field | Description |
|---|---|
| Create | Select this create a supply for the line currently
highlighted in the listview. The Job Entry program is loaded if the item is made-in and the PO Creation program is loaded if the item is bought out. |
| Options | Select this to indicate the type of query you want to perform and the display options according to which you want to present information in the listview (see Options). |
| Select this to indicate the report you want to generate (see Print). |
This screen is displayed when you select the Options function.
| Field | Description |
|---|---|
| Close | Select this to display the information for the Query type and Display options you selected in the listview. |
| Query options | |
| Multi level trial kitting | Select this to display the information by required date and by level within the Bill of Materials. |
| Trial kitting for made in items | Select this to view the information for made-in items only. |
| Trial kitting for bought out items | Select this to view the information for bought out items only. |
| Display options | |
| Display shortage lines only | Select this to display only those components that have a net required quantity greater than zero (i.e. only those components where a shortage occurs). |
This screen is displayed when you select the Print icon.
| Field | Description | ||||||||
|---|---|---|---|---|---|---|---|---|---|
| Select this to generate a report according to the options you selected. | |||||||||
| Close | Select this to return to the previous screen without generating a report. | ||||||||
| Report options | |||||||||
| Report type |
|
||||||||
| Print options | The Print options available depend on the Report type you selected. | ||||||||
| Shortage lines only | Select this to print the only those components for which a shortage exists. | ||||||||
| Alternate stock on shortage lines | Select this to print the alternate stock codes for components for which a shortage exists. | ||||||||
| New page on change of supplier |
Select this to print the information for each supplier on a separate page. This option is only available if you selected the Report type: Trial kit list for bought out items. |