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 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.
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.
The BOM Multi-level Trial Kitting (Legacy) 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.
- Multi-level Trial Kitting
- Preferences
- Warehouse Selection
- Multi-level Trial Kitting Enquiry
- Notes and warnings
| Field | Description | ||||
|---|---|---|---|---|---|
| Trial kitting selections | |||||
| Stock code | Indicate the parent item for which you want to generate a trial kit list. | ||||
| Rev/Rel | Indicate the revision and release for an ECC-controlled item. | ||||
| Routing | Indicate the route number of the structure that must be
processed. This applies only if the option: Alternate routings required (Bill of Materials Setup) is enabled. |
||||
| Quantity | Indicate the quantity to make of the parent stock item. | ||||
| Due date | The entry made here is used for documentation purposes only. | ||||
| Preferences | Select this to indicate the demand and supply factors required to determine the availability of stock. | ||||
| Specify Warehouses | Select this to indicate the warehouse(s) for which you require the trial kit list to be generated. | ||||
| Generate Trial Kit List | Select this to commence processing.
Refer to Multi-level Trial Kitting routine for additional details. |
||||
The following steps indicate the processing sequence applicable to the BOM Multi-level Trial Kitting (Legacy) program:
![[Note]](images/note.png)
|
|
|
Processing is aborted if a structure is recursive, or has more than 15 levels. |
|
-
The following are output to a temporary index file:
- on hand quantities
- detail records with the scrap quantities and percentages
- quantity per
-
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)
-
Net quantity 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).
The net quantity required is calculated as follows:
gross requirement less quantity available
If the net required is greater than zero, 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.
-
This screen is displayed when you select the Preferences option.
| Field | Description |
|---|---|
| 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. |
| Save Preferences | Select this to save your preferences against your operator code. |
| Close | Select this to save your preferences for the current run of the program only. |
You use the Specify Warehouses function to specify which warehouse(s) must be used when generating the multi-level trial kitting list.
| Field | Description |
|---|---|
| Warehouse | |
| Warehouse to use | Select this to use the Warehouse to use defined against BOM structure (Structures and Routings) for the review. If no warehouse to use is defined against the BOM structure, then the warehouse to use defined against the stock item (Stock Code Maintenance - Descriptive tab) is used to check supply and demand. |
| Specify warehouses | Select this to specify which warehouse(s) to use in the review to check supply and demand. You use the Warehouse selection options to indicate these warehouses. |
| Warehouse selection | Indicate the warehouse(s) to include when generating the trial kit list. These options are only enabled if you selected the Specify warehouses option above. |
| List |
Select this to indicate a list of warehouses to use for generating the trial kit list. You use the Define List function to define the list of warehouses. |
| Define list | Indicate the list of warehouses to include when generating the trial kit list. |
| OK | Select this to accept the warehouse options selected. |
You use the Define List function from the Warehouse selection option to define the list of warehouses to include when generating the trial kit list.
| Field | Description |
|---|---|
| Warehouse list selection | |
| Warehouse | You use this field to enter the warehouse code of the warehouse that you want to add to the list. |
| Add |
Select this to add the warehouse code in the previous field to the list. When you select this function, the warehouse code and description are displayed in a list on the screen. |
| Remove | You use this function to remove the highlighted warehouse from the list of warehouses to include. |
| Wh Description | This indicates the warehouse code(s) and description(s) currently included in the warehouse list. |
| Close | Select this to return to the previous screen. |
You use the Generate Trial Kit List function to generate a trial kitting list based on your trial kitting selections.
The results of the trial kitting calculation are displayed in a listview.
You can press Ctrl+Q from within the listview to use the Listview Styles program to customize the following items in the listview:
- Sufficient stock (lines for items where there is sufficient stock)
- Shortage (lines for items where there are shortages of stock)
Once lines are customized, you can press Ctrl+W to toggle the customization on or off.
You can sequence the data in the listview according to a specific column by moving your mouse pointer onto that column's heading and typically pressing your left mouse button.
| Field | Description |
|---|---|
| Parent details | The following details are displayed for information purposes: |
| Stock code | This indicates the parent item for which the trial kitting list is generated. |
| Routing | This indicates the routing you selected for the parent item. |
| Quantity | This indicates the quantity you selected to make of the parent stock item. |
| Rev/Rel | This indicates the revision and/or release for the item if it is defined as ECC controlled (Stock Code Maintenance - Tracking tab). |
| CLT | This field displays the cumulative lead time for the bill of material. |
| Due date | |
| 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 on the screen (see Options). |
| Select this to indicate the type of report you want to produce and the print options according to which the report must be printed (see Reports). | |
| Create | Select this to create a job (see Job Entry) or a Purchase order (see PO Creation), depending on the part category of the item (i.e. bought-out or made-in). |
| Alt Stock | Select this to use the Alternate Stock Codes program to select (or take on) a substitute item for the highlighted stock code. |
| Query | Select this to use the Inventory Query program to query detailed information for the highlighted stock code. |
| Close | Select this to return to the previous screen. |
This screen is displayed when you select the Options function.
| Field | Description |
|---|---|
| Query type | |
| 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). |
| Close | Select this to return to the listview and to display the information for the Query type and Display options you selected. |
This screen is displayed when you select the Print function.
| Field | Description |
|---|---|
| Report type | |
| Multi-level trial kitting list | Select this to print a report of all components for all levels of the structure. |
| Trial kit list for made in items | Select this to print a report of only the made-in components. |
| Trial kit list for bought out items | Select this to print a report of only the bought out component items. |
| Print options | The Print options available are dependent 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. |
| 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. |
-
When an ECC controlled item is found in the Bill of Material of the parent stock code that has been flagged as Deplete oldest Rev/Rel, the item will be displayed with a Gross Required quantity against the Current revision/release for that item.
The Net required quantity will be calculated based on the quantity available against all the revision/releases for that item.