Bill of Materials > Reports > Advanced Trial Kitting

Advanced Trial Kitting

You use this program to establish the jobs and purchasing requirements needed to complete the build of a parent part.

The program provides an alternative to running the Requirements Calculation and related MRP reports, but its purpose is not to replace MRP and give you a total requirement. The program purely indicates the quantity required to satisfy the demand you select (i.e. sales orders, jobs, quotations). See Comparison to MRP.

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Field Description
Generate Trial Kit List

When you select this function, the quantities required for all components of the selected standard and/or non-standard parts, jobs, quotations and sales order lines on back order are calculated.

The results of the calculation are displayed in the Advanced Multi-level Trial Kit List listview.

Processing is aborted if the Bill of Materials structure is recursive or has more than 15 levels.

When generating a trial kit list for co-products:

  • the quantity to make for each co-product is accumulated per notional part on the selected route.
  • if the planning weight for a co-product is not greater than zero (BOM Co-products) the co-product is ignored. For multi-grade co-products, this implies that only demand for the principal part applies.
  • the highest quantity to make for the notional part is calculated as:

    (Co-product Quantity to Make x Co-product Planning Weight) / Co-product Quantity Per

    The bill of materials for the notional part is then exploded to generate the list of required components for the co-products.

  • For standard parts, each co-product's due date is calculated as:

    Due date entered on Standard parts tab less dock to stock days for the co-product (Stock Code Maintenance) less the number of days after stock arrives that it can be used (Requirements Planning Setup - General 1 tab).

  • For sales orders and quotations, each co-product's due date is calculated as:

    Sales order/qupotation ship date less co-product dock to stock days less the number of days after stock arrives that it can be used.

  • Refer to Example 1 Calculations for Co-products.

When exploding a bill of materials for a made-in parent item (either from a standard part or from a sales order/quotation line) ) where a co-product is a component of the made-in parent part and the co-product is attached to a notional part on the specified route, the co-product ‘inherits’ the BOM structure from the notional part. Refer to Example 2 Calculations for Co-products.

Only those warehouses to which you have access (Operator Maintenance - Security tab - Warehouses) are included in the trial kit list, irrespective of the warehouses you selected to include in the list. If you do not have access to all warehouses, then the results of the advanced trial kitting list could be affected.

Change Criteria Select this to change the Options according to which the Trial Kit list must be generated. All listviews are cleared.
Preference Select this to configure the default sources of supply/demand that must apply when determining the availability of stock and the unit of measure in which the quantities in the trial kit list are displayed. See Preferences.

Preferences

Field Description
Save and Exit Select this to save the preferences against your operator code.
Include in demand

Each Include in demand option you select theoretically reduces the availability of stock when the netting off calculation is performed.

These options enable you to select the sources of demand to include in the trial kitting calculation.

Sales order allocations

Select this to include all open sales orders that have a back order quantity greater than zero and meet the ship date criteria when calculating demand for standard parts.

The requested ship date of the sales order determines whether the sales order allocation is considered as a demand for the component. If the ship date is before the date entered in the Due date field (Advanced Trial Kitting - Standard Parts tab), then the sales order is included as a demand.

Work in progress allocations

The date of material demand is calculated by using either the days from the job delivery date or the planned queue date for the operation number depending on which is defined.

If the material demand date is before the date entered in the Due date field (Advanced Trial Kitting - Standard Parts tab), then the material allocation is included as a demand for the component.

Quotations allocations

The default offer for each detail quotation line is used to determine the demand created by the quote. Quotation lines that do not have a default offer defined are ignored.

If the ship/delivery date required is before the date entered in the Due date field (Advanced Trial Kitting - Standard Parts tab), then the quote is included as a demand for the component.

Other selections
  • Safety stock

    Select this to include the safety stock level defined against the stock item (Warehouses for Stock Code), as part of the demand.

    If you select this preference, then the Available and On Hand quantities are reduced by the Safety stock quantity (Stock Code Maintenance) before applying the supplies and demands to calculate the required quantity of components to satisfy the specific parent requirement (i.e. Standard part, job, sales order or quote) only.

    The purpose of including safety stock in the Advanced Trial Kitting is merely to reduce the quantity available when netting off.

    If the Quantity Available is calculated as positive, then the Net Required is calculated as (Gross Required - Qty Available). However if the Quantity Available is calculated as negative then the Gross Required = Net Required and no supply is suggested to account for the shortfall in safety stock.

  • Minimum quantity

    Select this to include the minimum quantity level defined against the stock item (Warehouses for Stock Code), as part of the demand.

    If you select this preference, then the Available and On Hand quantities are reduced by the Minimum quantity (Stock Code Maintenance) before applying the supplies and demands to calculate the required quantity of components to satisfy the specific parent requirement (i.e. Standard part, job, sales order or quote) only.

  • None

    Select this to exclude safety stock and minimum quantity from the trial kitting calculation.

Include in supply

Each Include in supply option you select theoretically increases the availability of stock when the netting off calculation is performed.

These options enable you to select the sources of supply to include to offset the required demand.

Outstanding purchase orders

Select this to include outstanding purchase orders as a source of supply.

The order quantity for outstanding purchase orders is included as a source of supply if:

The purchase order due date + the number of days after stock arrives that it can be used (Requirements Planning Setup - General 1 tab) + the dock to stock for the stock code (Stock Code Maintenance) is before the date entered in the Due date field (Advanced Trial Kitting - Standard Parts tab).

Outstanding jobs

Select this to include outstanding jobs as a source of supply.

The job is included as a source of supply if:

The delivery date of the job + the number of days after stock arrives that it can be used (Requirements Planning Setup - General 1 tab) + the dock to stock for the stock code (Stock Code Maintenance) is before the date entered in the Due date field (Advanced Trial Kitting - Standard Parts tab).

Outstanding SCT orders

Select this if you want to include outstanding Supply Chain Transfers as a source of supply.

This option is only enabled if the setup option: Use full Goods in Transit transfers facility is selected (Inventory Setup - General tab).

Quantity in p/order inspection

Select this if you want to include quantities in purchase order inspection as a source of supply.

The quantity in P/O inspection is calculated from the quantities left in the Purchase Order inspection file.

Inspection quantities received into Purchase Order inspection after the date required for the build of the parent item (or job delivery date if jobs are included as a source) are excluded. If the GRN receipt date is after the required date for the component, then the inspection quantity cannot serve as a supply for the particular build (or job).

Quantity in WIP inspection

Select this to include quantities in work in progress inspection as a source of supply.

The quantity in Work in Progress inspection is calculated from the quantities left in the WIP inspection file.

Inspection quantities received into WIP inspection after the date required for the build of the parent item (or job delivery date if jobs are included as a source) are excluded. If the receipt date is after the required date for the component, it cannot serve as a supply for the particular build (or job).

This option is only enabled if the setup option: Work in Progress inspection required is selected (WIP Setup - General 1 tab).

Show negative allocations

Select this to display components with a negative net requirement quantity.

This option only applies when you are viewing the generated Trial Kitting list for all items.

Unit of measure options  
Unit of measure selection Indicate the unit of measure in which to display the quantities in the Trial Kit list.
As per supplier/stock code cross reference uom

Select this to use the purchase order quantity unit of measure defined in the supplier/stock code cross reference, (see Browse on Supplier Stock Code Cross Ref), for bought out items.

If no supplier/stock code cross reference is defined for the component and supplier combination, then the unit of measure option selected above is used (i.e. stocking, alternate, manufacturing or other).

As per supplier/stock code cross references uom

Select this to use the default purchase order price unit of measure defined in the supplier/stock code cross reference (see Browse on Supplier Stock Code Cross Ref), for bought out items.

If no supplier/stock code cross reference is defined for the component and supplier combination, then the unit of measure option selected above is used (i.e. stocking, alternate, manufacturing or other).

If the purchase order price unit of measure is not equal to the stocking or alternate unit of measure, then a valid conversion factor for the stocking unit of measure must be defined using the Browse on Price Unit of Measure program, otherwise the unit of measure option selected above is used (i.e. stocking, alternate, manufacturing or other).

Options

You use this pane to indicate the warehouses and sources to include in the trial kitting list. In addition, you can specify your preferences for the default sources of supply/demand that must apply when running the Advanced Trial Kitting program.

For supply/demand to be taken into account, it must occur before or on the due date of a component requirement.

[Note]

The program allows multiple selections of Standard Parts (stocked and non-stocked), Jobs, Sales Orders and Quotations to be included in the Advanced Trial Kitting calculation.

The selections you make on this pane therefore affect the options available on these other panes.

Field Description
Component warehouse selection  
Warehouse selection for components

Specify which warehouse(s) must be used to establish the component quantity on hand and which warehouse(s) to use to establish the supply and demand of components.

If you defined a warehouse to use against the component bill of materials for a stocked standard part, then that warehouse is used, irrespective of your selection at this option.

If you defined a warehouse against a stocked component in an estimate for a non-stocked part, then that warehouse is used, irrespective of your selection at this option.

Only those warehouses to which you have access (Operator Maintenance - Security) are included in the trial kit list, irrespective of your selections at these options. If you do not have access to all warehouses, then the results of the advanced trial kitting list could be affected.

Field Description
Warehouse to use Select this to base the component quantity on hand according to the warehouse to use defined against the stock item (Stock Code Maintenance) subject to the following:
  • For standard parts, quotations for stocked parent items and sales orders with no jobs attached to them:

    If a warehouse is defined for a component in the Bill of Materials, then that warehouse is used, else the warehouse to use defined against the component (Stock Code Maintenance) is used.

  • When processing quotations for non-stocked parent items, the warehouse defined against the stocked components in the quotation structure is used. If not defined, the warehouse against the component (Stock Code Maintenance) is used.

  • When processing jobs and sales orders with jobs attached to them, the material allocation warehouse defined in the job is the warehouse to use.

Specify warehouses

Select this to specify the warehouses to use to establish the component quantity and the supply and demand for components.

If you run the Advanced Trial Kitting program for selected warehouses only, then the results returned differ as follows:

  • Standard Part

    If the warehouse defined against the component bill of materials is not in the range of warehouses you specified, then the component is still displayed in the list. The quantity which is required is displayed in the Net required column, but the quantity available is zero because the component is not stocked in the warehouse(s) you selected for the trial kitting list.

    If the component is for a sub-assembly, then all components of the sub-assembly are also included in the trial kit list.

    This also applies when expanding the structure for a stocked sales order line (where the sales order is not attached to a job) and when expanding the structure for a stocked quotation line.

    If the warehouse defined against a stocked component in an estimate for a non-stocked part is not in the range of warehouses specified, then the requirement for that component for that estimate is still displayed in the trial kit list.

  • Jobs

    If the warehouse defined against the job allocation is not in the range of warehouses you specified, then the component is excluded from the trial kitting list.

    If the component is for a sub-assembly, then all components of the sub-assembly are also excluded from the trial kit list.

    If the warehouse defined against a stocked component in an estimate for a non-stocked part is not in the range of warehouses specified, then the requirement for that component for that estimate is excluded from the trial kit list.

By parent warehouse

Select this to use the component's warehouse defined against the parent's warehouse.

When you select this option:

  • if the source is for a stocked standard part, then you must make a selection at the Parent warehouse selection option (Standard Parts tab).
  • the component warehouse defined against the warehouse control record for the sales order line or stocked quotation line is used when exploding the bill. If the component warehouse is not defined against the warehouse control record for the sales order or quotation warehouse, then the warehouse to use against the component (Stock Code Maintenance) is used to retrieve the supply/demand for the components while exploding the bill of materials.
  • if the source is for a non-stocked standard part or a non-stocked quotation line, then the warehouse to use against the component (Stock Code Maintenance) is used for stocked components.
Warehouse selection These options apply if you selected the Specify warehouses option.

Indicate the warehouse(s) to use to generate the Trial Kit list.

If you select All, then quantities are calculated based on the warehouse quantities in all the warehouses.

When a Single warehouse is specified, the program validates that the stock code is stocked against that warehouse. If not, then the Inventory warehouse to use is used for the component to calculate the quantity on hand and the supply and demand records.

Route selection

Indicate the route to use for all source selections (i.e. stocked standard parts, sales orders and stocked quotation lines).

This applies the option: Alternate routings required is enabled (Bill of Materials Setup - General).

Use route defined against warehouse control

Select this to use the route defined against the parent warehouse control for all source selections (i.e. stocked standard parts, sales orders and stocked quotation lines).

If you select this option and the source is for a stocked standard part, then you must make a selection at the Parent warehouse selection option (Standard Parts tab). If a warehouse control record does not exist for the selected parent warehouse, then Route 0 is used.

If you select this option, then the route defined against the warehouse control record for the sales order or stocked quotation line is used when exploding the bill. For no-stocked quotation lines, the route defined against the quotation offer is used. However, if you selected a route against the quotation offer C- lowest cost or L - shortest lead and you have not performed a cost roll up, then route 0 is used.

Routing

If you did not select to use the route defined against warehouse control, then you use this field to indicate the factory routing to use for all source selections.

Include source options
[Note]

You must select at least one source option to generate the trial kitting list.

Include stocked standard parts

Select this to establish the quantities and components required to make all or a specified range of stocked standard parts by a specified date.

The supply and demand are determined from the Bills of Material and the value entered in the Quantity to make field on the Standard Parts tab of the Advanced Trial Kitting (Legacy) program.

If you do not select this option, then the options for Stocked standard parts on the Standard part tab are disabled.

Include non-stocked standard parts

Select this to establish the quantities and components required to make all or a specified range of non-stocked standard parts by a defined date.

The supply and demand are determined from Quotations and the value entered in the Quantity to make field on the Standard Parts tab of the Advanced Trial Kitting program.

This option is only enabled if you selected the option: Include non-stocked parts under Other options below.

If you do not select this option, then the options relating to non-stocked standard parts in the Standard Parts pane are disabled.

Include job selection

Select this to establish what is required to satisfy the demand for all or a specified range of jobs.

The WIP Material allocations records are used to determine the requirements based on the quantity to issue minus the quantity already issued.

If you do not select this option, then all options on the Jobs tab are disabled.

Include sales order selection

Select this to establish what is required to satisfy the demand for the range of sales orders you select on the Sales Orders tab.

If you select this option, then Order and Billing sales order types are included in the calculation. Orders are included if they are in a status of Open order (1), Open backorder (2), Released backorder (3) or In warehouse (4). Billings are included if they are in a status of Open backorder (2). Released backorder (3) or Ready to invoice (8).

If the sales order is linked to a job, then the WIP Material allocations records are used to determine the requirements based on the quantity to issue minus the quantity already issued.

If the sales order is not linked to a job, then all levels of the Bill of Materials are exploded to determine the requirements.

If you do not select this option, then the options on the Sales Orders tab are disabled.

Include quotation selection

Select this to establish what is required to satisfy the demand for all or a specified range of unconfirmed quotations.

The Quotations Detail records are used to determine the requirements.

If you do not select this option, then the options on the Quotations tab are disabled.

Other options  
Explode bought out items with structures Select this to include bought out parent items and bought out sub-assemblies when generating the trial kitting list.
Include non-stocked parts

Select this to include all non-stocked standard parts and any associated non-stocked jobs, sales orders, quotations and standard parts when generating the trial kitting list.

[Note]

This option applies to all source selections.

Use non-current Revision/Release

If you select this option, then archived bills of material are used when applicable.

This option is only enabled if ECC (Engineering Change Control) is used (see Stock Code Maintenance - Tracking) and the Stock control level is not set to Stock code (Bill of Materials Setup - Engineering Change Control tab).

[Note]

Selecting this option can slow the calculation process down if you are running SYSPRO in a SQL environment.

Include supply due in number of days

These options enable you to include supply within a period of days after the component is required. For example, you may have raised a purchase order for an item that has a long lead time and that will arrive the following week. The demand, therefore, need only be postponed until the following week and an additional purchase order need not be raised.

If you do not specify one of these options, then supply is only considered up to the time that the item is required for use. If there is no supply at that time, then a shortage is assumed.

Field Description
Demand time fence days Select this to include the number of days defined in the Demand time fence (days) field for the component (Stock Code Maintenance) in the calculation of supply for the component.
Lead time days Select this to include the number of days defined in the Lead time (days) field for the component (Stock Code Maintenance) in the calculation of supply for the component.
Enter number of days Select this to manually specify the number of days for which you want to include supply in the calculation of the net required quantity for components.
Number of days Specify the number of days for which you want to include supply in the calculation of the net required quantity for components.
Use lot expiry date

Select this to take the lot expire date into account when the quantity on hand for a stock code is calculated.

If the lot has expired before the required date for the component, then the lot quantity on hand is subtracted from the warehouse quantity on hand for the stock code.

In effect, this excludes expired lots based on component required date.

Standard Parts

This enables you to specify the stocked and/or non-stocked parent parts for which you want to generate components.

This pane is only enabled if you selected to include either stocked or non-stocked standard parts under Include source options in the Options pane.

Field Description
Standard part selection  
Stock code selection

Indicate the stock code for which you want to include components in the trial kit list.

If you select all, a range or a list of stocked codes and some of these are ECC controlled, then the current version and release is used for these items if ECC is not controlled at stock level (Bill of Materials Setup - Engineering Change Control tab).

If you selected the option: Explode bought out items with structures, (Advanced Trial Kitting - Options tab), and your stock code selection includes bought out items, then the components for the bought out items that have structures defined are included in the trial kit list. The selected bought out items that have no structures defined against them are ignored, together with any jobs, sales orders and quotations that are linked to them.

A stock item which is manufactured as a co-product on a specific route cannot be selected if it is also manufactured via a notional part on the same route. Items defined as notional parts can only be selected individually or as part of a list of stock items and not as part of a range of items or of all items.

Items defined as notional parts (Stock Code Maintenance) are excluded.

List of stock codes

Indicate a list of stock codes for which you want to include components in the trial kit list.

Field Description
Stock code Enter the stock code to add to the list.
Description Indicates the stock code description.
Use EBQ

Select this to use the economic batch quantity defined against each stock item (Stock Code Maintenance) as the quantity to make.

If the Economic batch quantity defined against the stock item is zero, then the quantity to make defaults to one.

If you selected the option: Progressive scrap required (Bill of Materials Setup - General tab), then the economic batch quantity is taken as the net quantity. If the standard part is not stocked in the warehouse specified, or the re-order quantity against the warehouse is zero, then the EBQ defined against the standard part (Stock Code Maintenance) is used. If this is EBQ is zero, then a quantity of one is used.

Quantity to make

Enter the quantity to make for all standard items.

If you did not select to use the economic batch quantity, then you must enter a quantity to make which is greater than one.

The number of decimals you enter for the quantity must not exceed the number of decimals defined against a stock item (Stock Code Maintenance).

Gross

Select this if the Quantity to make you entered represents the gross quantity.

If this is not enabled, then the Quantity to make is the net quantity.

This option only applies if you selected the option: Progressive scrap required (Bill of Materials Setup - General tab).

Revision Indicate the revision of the stock item to use if it is ECC controlled.
Release Indicate the revision of the stock item to use if it is ECC controlled.
Standard part quantity selection Indicate the quantity to make for the selected standard parts.
Use economic batch quantity

Select this to use the economic batch quantity defined against each stock item (Stock Code Maintenance) as the quantity to make.

If the Economic batch quantity defined against the stock item is zero, then the quantity to make defaults to one.

If you selected the setup option: Progressive scrap required (Bill of Materials Setup - General tab), then the economic batch quantity is taken as the net quantity.

If you selected the option: Use route defined against warehouse control (Options tab) then quantity used as the EBQ for the standard part is the re-order quantity defined against the stock code/warehouse.

Stocking quantity to make

Enter the quantity to make for all standard items.

If you did not select to use the economic batch quantity, then you must enter a quantity to make which is greater than one.

The number of decimals you enter for the quantity to make must not exceed the number of decimals defined against a stock item (Stock Code Maintenance ).

Stock gross quantity

Select this if the quantify to make you entered represents the gross quantity.

By default, this option is not selected which indicates that the quantity to make is the net quantity.

This option is only enabled if you selected the setup option: Progressive scrap required (Bill of Materials Setup - General).

Parent warehouse  
Parent warehouse selection

If you selected the option: Use route defined against warehouse control (Options tab), then you must make a selection at this option.

  • Use standard part - Warehouse to use

    Select this to use the warehouse to use defined against the standard part when exploding the bill of materials.

    If the component warehouse is not defined against any of the standard part warehouse control records, then the warehouse to use defined against the component (Stock Code Maintenance) is used to retrieve the supply/demand for the components while exploding that bill of materials.

  • Enter parent warehouse

    Enter the parent warehouse to use when exploding the bill of materials.

    If a warehouse control record does not exist for the selected parent warehouse, then Route 0 is used.

Non-stocked code  
Non-stocked code selection Indicate the non-stocked code(s) to include in the trial kitting list.

This option only applies if you selected the option: Include non-stocked parts on the Options tab page.

The estimate defined for a non-stocked item is used to generate the list of required components and quantities.

Non-stocked bought out items are ignored.

List of non-stocked codes

Indicate a list of stock codes for which you want to include components in the trial kit list.

Field Description
Non-stock code Enter the non-stocked item you want to add to the list.
Description This indicates the description of the non-stocked code.
Quantity to make Enter the quantity to make for the non-stocked item.
Gross

Select this if the Quantity to make you entered represents the gross quantity.

If this is not enabled, then the Quantity to make is the net quantity.

This option only applies if you selected the option: Progressive scrap required (Bill of Materials Setup - General tab).

Route If the route selected for non-stocked standard parts is not required for a non-stocked item, then the non-stocked item is ignored.
Quantity to make If you selected the Include non-stocked standard partsoption (Options tab), then you must enter a quantity to make greater than zero for the non-stocked parent parts.
Gross quantity

Select this if the quantity to make you entered represents the gross quantity.

By default, this option is not selected which indicates that the quantity to make is the net quantity.

This option is only enabled if you selected the setup option: Progressive scrap required (Bill of Materials Setup - General tab).

When you select this option, the program calculates the resultant net quantity for each top level parent part based on the operations defined in the estimate.

For example:

The quantity to make for an estimate is 200. There is one operation with a scrap percentage of 50%.

If you select the Gross option, the resultant net quantity to make is 100 (i.e. 50% of 200).

If you do not select the Gross option, then the gross quantity to make is 400 (i.e. you require 200, but due to the 50% scrap rate, 400 need to be made). The material allocations linked to the operation are inflated accordingly, allowing for the 50% scrap of total parent parts made.

Due date selection This applies only if you selected to include stocked standard parts or non-stocked standard parts on the Options pane.
Due date

Enter the date on which you require the stocked and/or non-stocked items.

[Note]

This defaults to the current system date, but can be changed.

The date you enter in this field determines which sources of supply and demand are included when calculating the net requirements for the components.

The quantity on hand for a component at each required date includes only the supply and demand quantities that could serve as a supply or demand at the required date.

The required date for each standard item is calculated as the Due date entered less the Dock to stock days for the item, (Stock Code Maintenance - Replenishment tab), less the number of days after stock arrives that it can be used, (Requirements Planning Setup - General 1 tab).

The required date for each component is calculated using either the offset days from the parent required date or the operation queue date, depending on which is defined. The calculation of the total number of days required to complete all operations (i.e. queue time, elapsed time, start time, complete time and move time) is affected by your selection at the setup option: Allow operation to end earlier than prior operation (WIP Setup).

Jobs

This enables you to specify the jobs for which you want to generate components.

If you selected the option: Include non-stocked parts (Options tab), then jobs for non-stocked parent items are included in the trial kit list.

This pane is only enabled if you selected to Include job selection under Include source options in the Options pane.

Field Description
Job selection Indicate the job(s) you want to include in the trial kitting list.

The warehouse selection influences the job selection as follows:

  • If you selected the option: Warehouse to use, then the warehouse against the allocation must be the same as the warehouse to use against the stock code, otherwise the allocation is ignored.

    The quantity on hand and the supply and demand is taken only for the warehouse to use.

  • If you specified a Single warehouse, then the allocation must be for the warehouse specified, otherwise the allocation is ignored.

    The quantity on hand and the supply and demand is taken only for the warehouse specified

  • If you specified All, a Range or a List of warehouses, then the quantity on hand and the supply and demand are the consolidated quantities from the selected warehouses.
List of jobs

Indicate the list of jobs to include in the Trial kit list.

Field Description
Job Enter the job code of the job to add to the list.
Description This indicates the job description.
Balance outstanding

Select this to use the outstanding balance against the job in the calculation.

If you select this option, then the required quantity for each component is calculated as:

(Quantity per of the component x Quantity to manufacture) - Quantity already issued to the job for the component.

Quantity to make

Enter the quantity to make for each job selected.

If you did not select to use the Balance outstanding option, then you must enter a quantity to make greater than zero. Your entry here cannot exceed the quantity outstanding for the job.

If you define a quantity to make, then the gross required quantity for each component allocation for the job is calculated as:

Quantity to make x Quantity per for the allocation.

If you select to generate the trial kit list for All or a Range of jobs and the quantity to make exceeds the quantity outstanding for a job within the range selected, then the outstanding quantity for the job is used instead.

Job classification selection

Indicate the jobs to include in the trial kitting list according to the job classification assigned to the jobs.

Jobs with a job classification to which you do not have access (Operator Maintenance) are ignored.

This applies when the option Job classification required is enabled (WIP Setup).

Job start date selection

Indicate the job start date(s) for which you want to include jobs in the trial kitting list.

The required date for the allocations for the jobs selected is either the number of days from the job delivery date or the operation queue date, depending on which is defined against the job.

Quantity selection Indicate the component quantity for each job selected.
Balance outstanding

Select this to use the outstanding balance against the job for the calculation.

If you select this option, then the required quantity for each component is calculated as:

(Quantity per of the component x Quantity to manufacture) - Quantity already issued to the job for the component.

Quantity to make

Enter the quantity to make for each job selected.

If you did not select to use the Balance outstanding option, then you must enter a quantity to make greater than zero. Your entry here cannot exceed the quantity outstanding for the job.

If you enter a quantity to make, then the gross required quantity for each component allocation for the job is calculated as: Quantity to make x Quantity per for the allocation.

If you select to generate the trial kit list for All or a Range of jobs and the Quantity to make exceeds the Quantity outstanding for a job within the range selected, then the Quantity outstanding for the job is used instead.

Include options  
Include confirmed jobs

Select this to include confirmed jobs in the trial kitting list.

Confirmed jobs within this selection are ignored if you do not select this option and you select either All or a Range of jobs.

Sales Orders

This enables you to specify a selection of stocked Sales order lines that are currently on back order for which you want to generate a list of components.

The stock items on the sales orders you select are used as the parent parts for which to generate the trial kit list.

This pane is only enabled if you selected to Include sales order selection under Include source options in the Options pane.

Field Description
Sales order selection Indicate the sales order(s) you want to include in the trial kitting list.

For a sales order to be included, the order type must either be 'Order' (O) or 'Billing' (B).

For order type 'Order' (O) the order status must be one of the following:

  • Open order (status 1)
  • Open backorder (status 2)
  • Released backorder (status 3)
  • In warehouse (status 4)

For order type 'Billing' (B) the order status must be one of the following:

  • Open backorder (status 2)
  • Released backorder (status 3)
  • Ready to Invoice (status 8)

Only sales order lines with a back order quantity greater than zero are included.

Orders for salespersons to which you have been denied access (Operator Maintenance - Security tab) are ignored.

Orders for Accounts Receivable branches to which you have been denied access (Operator Maintenance - Security tab - A/R Branches), are ignored.

For sales order lines that are not attached to a job, the back order quantity and the Bill of Materials is used to generate the trial kit list. The required date for each component is calculated by using either the offset days from the parent required date, or the operation queue date, depending on which is defined.

If you selected the setup option: Progressive scrap required (Bill of Materials Setup - General tab), then the sales order quantity is taken as the Net quantity. Factory Route 0 is always used.

For sales orders attached to a job, the quantity to issue per job allocation is used to generate the trial kit list.

Sales orders that are linked to a purchase order are ignored.

[Note]

Sales order lines for the following items are ignored:

  • Non-stocked codes
  • Items on full or partial hold
  • ECC controlled items when either the stock code or the version and release is held by ECC for sales orders
  • Kit items
  • Bought out items; if you have not selected the option: Explode bought out items with structures (Advanced Trial Kitting Options tab).
Sales orders ship date

Indicate the ship date(s) for which you want to include sales orders in the trial kitting list.

The required date for each sales order is calculated as:

Sales order ship date less the Dock to stock days for the stock code (Stock Code Maintenance), less the Number of days after stock arrives that it can be used (Requirements Planning Setup ).

Sales orders customer Indicate the customer(s) for whom you want to include sales orders in the trial kitting list.

Quotations

This enables you to specify the quotation lines for which you want to generate a list of components.

This pane is only enabled if you selected to Include quotation selection under Include source options in the Options pane.

Field Description
Quotations selection Indicate the quotation(s) you want to include in the trial kitting list.

Quotation lines for bought out items are ignored if you do not select the option: Explode bought out items with structures (Options tab).

If you selected the option: Include non-stocked parts (Options tab), then the estimate of non-stocked items is used to generate a list of required components and quantities per component for non-stocked quotation lines.

Confirmed quotations are ignored.

Quotations ship date selection Indicate the ship date(s) for which you want to include quotations in the trial kitting list.
Quotations customer selection Indicate the customer(s) for whom you want to include quotations in the trial kitting list.
Offers selection

The offer quantity of the Offer selection indicated is used as the demand quantity for each quotation line.

If you selected the setup option: Progressive scrap required (Bill of Materials Setup - General tab), then the offer quantity is taken as the Net quantity.

Offer selection

Indicate the offer to use as the demand quantity for each quotation.

Only merchandise lines for the offer you select are included in the calculation.

Quotation lines that do not have an offer defined for the selected offer are ignored.

If you select Default offer, then the default offer for each quotation line is used to determine the demand for that quotation line. If a Default offer is not defined against a quotation line, then that line is ignored.

Include quotations  
Probability greater than

Indicate the offer probability for which quotations must be included in the trial kit list.

Only quotations with a probability greater than the value you select are included.

Advanced Multi-level Trial Kit List

When you select the Generate Trial Kit List function the results of the trial kitting calculation are displayed in this listview.

Field Description
Include Indicate the lines to include when using the Create function.

The Status column indicates why an item cannot be included when it is excluded by the system.

Exclude Indicate the lines to exclude when using the Create function.
Create See Create.
Create Selected Select this to create a Purchase order, Requisition, Supply Chain Transfer or Job for the included item(s).
Create Multi-line

Select this to create a multi-line purchase order.

Options  
Options Indicate the types of components to display in the listview. See Options.
Defaults Indicate the default information for creating Purchase orders, Requisitions, Jobs and Supply Chain Transfers for the run of the program. See Defaults.
Query  
Query Stock See Inventory Query.
Alternate stock See Alternate Stock Codes.
Print Select this to generate a report of the Trial kit list. See Reports.
Include A tick in this column indicates that the line is included when creating Purchase orders, Requisitions, Supply Chain Transfers or Jobs.
Required date

This indicates the ship or delivery date or due date of the source of the component.

If you select the Query type: Trial kitting for made in items or Trial kitting for bought out items, (Options menu), then the required date is not displayed. This is because these queries are summaries of the requirements for the items and multiple requirements over multiple dates can exist. As these requirements are summarized into single lines, the required date cannot be displayed.

Warehouse If you selected to Specify warehouses and at the Warehouse Selection option you included more than one warehouse, then '--' is displayed in this column, to indicate that this is a consolidated warehouse view.

'**'' is displayed for non-stocked standard parts.

Uom This indicates the unit of measure for the item.
Net required

This indicates the net quantity required.

If you selected the setup option: Progressive scrap required (Bill of Materials Setup - General tab) and you defined a scrap quantity or percentage, then the net quantity includes progressive scrap.

Quantity available Indicates the quantity of the item currently available.
Quantity on order Indicates the quantity of the item currently on order.
Part category This is defined against the item (Stock Code Maintenance) and determines the type of supply you can create when using the Create function.
Status Indicates when an item cannot be included as it is excluded by the system.

Examples are that you can only include lines for made-in, bought out and subcontract items or an ECC item is held by ECC control.

EBQ Indicates the Economic Batch Quantity for the item.

Options

This screen is displayed when you select Options from the Options menu.

Field Description
Query options Indicate the information to display in the listview.
Multi level trial kitting

Select this to display the information by required date and by level within the Bill of Materials.

When you create a job for the requirement, the route is passed to the job creation program so that material allocations can be picked up for the correct route.

Trial kitting for made in items

Select this to view the total gross and total net required quantities for each component for made-in items only.

The required dates, routes and levels within the structure are ignored, so supply/demand details and source details are not displayed. If more than one route occurs, the route is displayed as '-' indicating a consolidation of routes. If a job is created for a component where the routes were consolidated, then route 0 is passed to the job creation program.

Trial kitting for bought out items

Select this to view the total gross and total net required quantities for each component for bought out items only.

The required dates, routes and levels within the structure are ignored for this view, so no supply/demand details or source details are displayed. If more than one route occurs, the route is displayed as '-' indicating a consolidation of routes. If a job is created for a component where the routes were consolidated, then route 0 is passed to the job creation program.

Accumulate required quantity by date

If you select this option, then the quantities required for the same component on the same required date are accumulated.

If more than one route occurs, the route is displayed as '-' indicating a consolidation of routes. If a job is created for a component which is not a co-product, where the routes were consolidated, then route 0 is passed to the job creation program.

In this view, the level within the Bill of Materials is ignored.

Trial kitting for co-products only

Select this to display the total quantity required per co-product where the co-products are used in a bill of material for a normal made-in parent.

The required dates, routes and levels within the structure are ignored for this view. If more than one route occurs, the route is displayed as '-' indicating a consolidation of routes. You will be unable to create a job for a co-product if the routes were consolidated.

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).

Defaults

Indicate the default information for the creation of Purchase orders, Requisitions, Jobs and Supply Chain Transfers for the run of the program.

Field Description
Customer purchase order Enter the default customer purchase order reference or number for the creation of purchase orders for the run of the program.
Due date

Indicates the default Purchase order due date, SCT ship date or Requisition due date to use when you create a purchase order, SCT or Requisition for the highlighted line.

This field defaults to the Due date for the component, but can be changed.

You can enter a different date and then select the Default date option to use the date you enter in this field as the default date.

Alternatively, you can set the default date to be the Required date for the component by selecting the Required date for component option below.

[Note]

If the required date or the due date for the component is before the current system's date, then the purchase order line due date and the job due date will default to the current system date. This is irrespective of the Due date you enter in this field. This is because it does not make sense to create a purchase order or a job with a due date that is in the past.

Job description Enter the default job description to use for the creation of jobs for the run of the program.
Job delivery date

This indicates the default job delivery date to use when you create a job for the highlighted line.

This field defaults to the Due date for the component, but can be changed.

You can enter a different date and then select the Default date option below to use the date you enter in this field as the default date.

Alternatively, you can set the default date to be the Required date for the component by selecting the Required date for component option below.

[Note]

If the required date or the due date for the component is before the current system's date, then the job due date will default to the current system date. This is because it does not make sense to create a job with a due date that is in the past.

Default date to

Indicate the date to use for creating the supply for the item.

Field Description
Required date for component Select this to use the required date for the component as the default purchase order due date, SCT ship date or requisition due date to use when you create a purchase order, SCT or requisition for the highlighted line.
Due date for component Select this to use the due date for the component as the default purchase order due date, SCT ship date or requisition due date to use when you create a purchase order, SCT or requisition for the highlighted line.
Default date

Select this to use the dates you entered in the Due date and Job delivery date fields as the default Purchase order line date, SCT ship date, Requisition due date or Job delivery date.

[Note]

If the required date or the due date for the component is before the current system's date, then the Purchase order line due date and the Job due date default to the current system date.

This is irrespective of the Due date and Job delivery date entered, because it does not make sense to create a Purchase order or Job with a due date that is in the past.

Reports

This screen is displayed when you select the List option from the File menu.

Field Value
Print

Select this to generate a report according to the options you selected.

Report type The Print options available are dependent on the Report type you selected.
Multi-level trial kitting list

Select this to print a report of all components for all levels of the structure.

The report lists the information by required date, level within the bill of materials and route.

List for made in and sub contract items

Select this to print a report of only the made-in components.

The report lists the total gross and total net required quantities per component for made-in items.

The required dates, routes and levels within the structure are ignored, so supply/demand details and source details are not printed on this report. If more than one route occurs, the route is listed as '-' indicating a consolidation of routes. If a job is created for a component where the routes were consolidated, then route 0 is passed to the job creation program.

Trial kitting for bought out items

Select this to print a report of only the bought out component items.

The report lists the total gross and total net required quantities per component for bought out items.

The unit cost of bought out items is printed if you have not been denied access to the Field: Show costs in Inventory/WIP queries (Operator Maintenance - Security tab).

The required dates, routes and levels within the structure are ignored, so supply/demand details and source details are not printed on this report. If more than one route occurs, the route is listed as '-' indicating a consolidation of routes. If a job is created for a component where the routes were consolidated, then route 0 is passed to the job creation program.

Accumulate required quantity by date

Select this to generate a report where the quantities required for the same component on the same required date are accumulated.

If more than one route occurs, the route is listed as '-' indicating a consolidation of routes. If a job is created for a component which is not a co-product, where the routes were consolidated, then route 0 is passed to the job creation program. You will be unable to create a job for a co-product if the routes were consolidated.

The level within the Bill of Materials is ignored for this report.

Print options Select this to print the only those components for which a shortage exists.
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.

The quantity available for the alternate stock item is calculated as:

Quantity on hand for the component in the warehouse required

Less

  • Warehouse quantity allocated to sales orders (if you selected sales order allocations in the demand)
  • Warehouse quantity allocated to WIP (if you selected to include work in progress allocations in the demand)
  • Safety stock for the warehouse (if you selected to include safety stock in the demand)
  • Minimum quantity for the warehouse (if you selected to include minimum quantity in the demand)

Plus

  • Warehouse quantity in inspection (if you selected to include either Purchase order or WIP inspection in the supply)
  • Warehouse quantity on order (if you selected to include outstanding purchase orders and/or outstanding SCT orders in the supply)
Supply and demand details Select this if you want to print the supply and demand details on the report.
Source details Select this if you want to print the details of the sources of the gross requirements for the components on the report.
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.

Create

Once the trial kitting list is generated you can optionally select to create a supply for the lines against which the Include option is enabled in the Advanced Multi-level Trial Kit List.

The type of supply you can create depends on whether the lines are for Made in, Bought out or Supply Chain Transfer items.

Job/SCT

This screen is displayed when you select the Create Selected option from the Create menu against a Made-in or Supply chain Transferred item and enables you to create a Job or a Supply Chain Transfer to satisfy the shortage of the component.

Field Description
OK Select this to create the Supply Chain Transfer or the Job for the component.
Cancel Select this abandon the creation process and return to the previous screen.
Create Supply Chain Transfer Select this to use the Create Supply Chain Transfer program create a supply chain transfer for the highlighted component.
Create Job

Select this to use the Job Entry program to create a job for the highlighted component.

You may only create a job for a component when:

  • The component is a made-in or sub-contracted item.
  • The component is not on partial or full hold (see Browse on Stock Codes).
  • The quantity required is for a single warehouse.
  • Neither the component, nor its revision or release are held by ECC for jobs, if the component is an ECC controlled item (see Change Orders).

You may create a job for a co-product but, this is created via a notional part if the co product is attached to a notional part on the selected route, unless the co-product is a Multi-grade co-product. The notional part is sent to the job creation program with a quantity to make equal to the co product qty required divided by the qty per for the co product.

Since creating the job for the notional part results in manufacturing stock for all co products attached to that notional part, after the job has been created ATK will check through all the component requirements in the generated trial kit list and update the Net required quantity for all co products attached to that notional part on the route to reflect the new supply.

For Multi-grade co-products, you may only create a job for the principal part.

Purchase Order/SCT/Requisition

This screen is displayed when you select the Create Selected option from the Create menu against a Bought out or Supply chain Transferred item and enables you to create Purchase order, Requisition or SCT to satisfy the shortage of the component.

Field Description
OK Select this to create the Supply Chain Transfer, Purchase order or Requisition for the component.
Cancel Select this to return to the previous screen.
Create Supply Chain Transfer Select this to use the Create Supply Chain Transfer program create a supply chain transfer for the highlighted component.
Create Purchase Order

Select this to use the PO Creation program to create a purchase order for the highlighted component.

You may only create a purchase order for a component when:

  • The component is a bought out item
  • The component is not on partial or full hold (see Browse on Stock Codes).
  • The quantity required is for a single warehouse (i.e. not consolidated)
  • Neither the component, nor its revision or release are held by ECC for purchase orders, if the component is an ECC controlled item (see Change Orders).

If you select to create a purchase order against a supplier that is defined as using blanket purchase orders (Stock Code Maintenance), then the line is excluded from the purchase order if:

  • Blanket purchase orders exist for the component
  • The option: Manual entry of a normal P/o line when BPO contract exists (Purchase Orders Setup - Options tab), is set to Not allowed or Base on contract.

If the setup option: Restrict order to single warehouse and use for delivery address is selected (Purchase Orders Setup - Options tab), then you must enter a warehouse code for the purchase order header.

Create Requisition

Select this to use the Requisition Maintenance program to create a requisition for the highlighted component.

You may only create a requisition for a component when:

  • The component is a bought out item
  • The component is not on partial or full hold (see Browse on Stock Codes).
  • The quantity required is for a single warehouse (i.e. not consolidated)
  • Neither the component, nor its revision or release are held by ECC for purchase orders, if the component is an ECC controlled item (see Change Orders).
Requisition user

Enter your requisition user code to create a requisition.

You can only create a requisition if the option: Allow creation of reqn from sales order review (Browse on Requisition Users ) is selected against your requisition user code.

Create Multi-line Purchase Order

You use the Create Multi-line P/order option from the Create menu to create a single purchase order for all bought out items linked to the same supplier.

Create Purchase Order for Supplier

This screen is displayed when you select the Create P/order option from the Create Multi-line option from the Create menu.

You may only create a multi-line purchase order for a component when:

  • The component is a bought out item
  • The component is not on partial or full hold (see Browse on Stock Codes).
  • The quantity required is for a single warehouse (i.e. not consolidated)
  • Neither the component, nor its revision or release are held by ECC for purchase orders, if the component is an ECC controlled item (see Change Orders).
Field Description
OK Select this to use the PO Creation program to create the purchase order.

The message: There are no lines with a valid supplier to create a purchase order is displayed when the system cannot create any purchase order lines for your selections. For example if no lines have been included in the Advanced Multi-level Trial Kit List listview. Note that after this message is displayed, all lines in the listview are set to included. You use the Exclude function to exclude lines from the creation of a multi-line purchase order.

When you create a multi-line purchase order, the job number is attached to the purchase order lines only if that job is the only source of demand (i.e. if you create a multi-line purchase order for multiple jobs, then the job number is not attached to the order lines).

Cancel Select this to return to the previous screen without creating a purchase order.
Supplier

Indicate the supplier to use to create the multi-line purchase order.

This field is populated if the supplier is the same for all the included lines.

All selected bought out items for the supplier you enter in this field are displayed in sequence, to enable you to enter the purchase order line information for each item.

If the supplier is defined as using blanket purchase orders (Supplier Maintenance), then the line is excluded from the purchase order if:

  • Blanket purchase orders exist for the component
  • The option: Manual entry of a normal P/o line when BPO contract exists (Purchase Orders Setup - Options tab), is set to Not allowed or Base on contract.
Delivery warehouse

Indicate the warehouse to which the items must be delivered.

If the option: Restrict order to single warehouse and use for delivery address is selected (Purchase Orders Setup - Options), then you must enter a warehouse code for the purchase order header. Only lines for the warehouse specified on the purchase order header are included in the purchase order.

Delivery warehouse

Indicate the warehouse to which the items must be delivered.

If the option: Restrict order to single warehouse and use for delivery address is selected (Purchase Orders Setup - Options), then you must enter a warehouse code for the purchase order header. Only lines for the warehouse specified on the purchase order header are included in the purchase order.

Delivery wh description

This indicates the description of the Delivery warehouse.

Change Supplier

This screen is displayed when you select the Change Supplier option from the Create Multi-line option from the Create menu.

You use this screen to change the supplier for whom you want to create a multi-line purchase order.

Field Description
Alternative Suppliers Select this to use the Alternate Suppliers program to view and assign alternate suppliers to selected stock items.
OK Select this to accept the supplier code you entered and to return to the previous screen.
Supplier Enter the supplier for whom you want to create a multi-line purchase order.
Supplier description This indicates the name of the Supplier.

Supply and Demand Details for Component

This displays the cause of the supply and demand quantities, per required date, for the currently highlighted component in the Advanced Multi-trial Kit List listview.

Field Description
Include Select this to indicate the sources of supply and demand to display in the Supply and Demand Details for Component listview.
Required date Indicates the ship or delivery or due date of the highlighted component.
Warehouse Indicates the warehouse for the supply or demand of the component.
Source Indicates a short description of the source of the demand or supply. The descriptions include: Safety stock, Job allocation, Sales order, Quotation, Purchase order and Job.
Source ID Indicates the reference for the source or demand. Source IDs include: Job number, Sales order number and line number, Quotation number and line number, Purchase order number and line number.
Supply quantity Indicates the quantity that will be received from purchase orders, jobs, SCT orders, purchase order inspection or WIP inspection to satisfy the required demand.
Demand quantity Indicates the quantity required to satisfy the demand created by safety stock, job allocations, sales order lines and quotation lines.
Parent part Indicates the parent part of the component for which the trial kitting list was generated (i.e. the stock code defined in the selection of standard parts, jobs or sales orders).
Parent Rev Indicates the revision number of the parent part if the parent part is defined as being ECC controlled (Stock Code Maintenance - Tracking).
Parent Rel Indicates the release number of the parent part if the parent part is defined as being ECC controlled (Stock Code Maintenance - Tracking).

Source Details for Component

This displays the source(s) of the gross requirement details for the component (i.e. the stocked standard part, non-stocked part, job or sales order) for the currently highlighted component in the Advanced Multi-trial Kit List listview.

Column Description
Include Select this to indicate the sources of demand to display in the Source Details for Component listview.
 
Required date Indicates the ship or delivery or due date of the highlighted component.
Warehouse  
Source Indicates a short description of the source of the demand or supply. The descriptions include: Safety stock, Job allocation, Sales order, Quotation, Purchase order and Job.
Source ID Indicates the reference for the source of demand. Source IDs include: Job number, Sales order number and line number, Quotation number and line number, Purchase order number and line number.
Quantity Indicates the quantity required.
Parent part Indicates the parent part of the component for which the trial kitting list was generated (i.e. the stock code defined in the selection of standard parts, jobs or sales orders).
Parent Rev

the revision number of the parent part if the parent part is ECC controlled (Stock Code Maintenance - Tracking).

Parent Rel

Indicates the release number of the parent part if the parent part is ECC controlled (Stock Code Maintenance - Tracking).

Netting Off Calculation

When you select the Generate Trial Kit List function, the Advanced Trial Kitting program performs a netting off calculation, which determines the gross and net requirements of components, based on the sources of demand and the options you selected. The calculation is based on the requirement dates for each component which, in turn are based on the requirement dates of the demand sources.

Standard parts, Quotations and Sales order sources are processed as follows:

  • All sub-assemblies and components for parent items are processed.

    The quantity per of each component is multiplied by the net requirement for the parent item.

    The result is compared to the net quantities on hand to determine the shortages for the stocked components.

For standard items and sales orders not linked to a job, the Advanced Trial Kitting program uses the bill of materials defined for the item to generate a requirement for each component in the bill of materials. Components at all levels of the bill of materials are included in the calculation. Sub-assemblies are included if sub jobs are defined for them.

Jobs and Sales orders attached to jobs are processed as follows:

  • All allocations are processed.

    The quantities already issued are subtracted from the quantities required.

    The result is compared to the net quantity on hand to determine the shortages for stocked allocations.

For jobs, the Advanced Trial Kitting program uses the material allocations for the job to generate requirements based on the quantity to issue for the material allocation, less the quantity already issued for that allocation. The bills of materials are ignored. This also applies to jobs linked to a sales order.

If several demands occur on the same day for the same component, then the demands are prioritised in the following order:

  • Safety stock and minimum quantity
  • Existing Supply Chain Transfers
  • Existing purchase order inspections
  • Existing outstanding jobs
  • Existing work in progress inspection references
  • Existing outstanding purchase orders
  • Existing quotations
  • Existing sales order allocations
  • Existing work in progress allocations
  • Demand created by stocked standard parts
  • Demand created by non-stocked standard parts
  • Demand created by job source
  • Demand created by sales order source
  • Demand created by quotation source

Calculations for Co-products

Example 1:

  • You have a notional part N with co-products A, B, C for route 0.

    All relationships are 1 to 1 for ease of use.

    Number of days after stock arrives that it can be used = 2

  • Co-product setup:

    Co-product EBQ Dock to Stock
    A 3 1
    B 2 0
    C 5 2
  • There is a sales order for co-product B with a back order quantity of 4. Ship date: 23/08/2006

  • There is a quote for co-product C for a quantity of 2. Ship date: 18/08/2006

  • Run ATK for:

    • Route for all source options – route 0

    • Select ‘Include stocked standard parts’ and select a range of standard parts From: A To: C.

      Select ‘Use economic batch quantity’ and Due date 25/08/2006

    • Select ‘Include sales order selection’ and select the Single sales order mentioned above.

    • Select ‘Include quotation selection’ and select the Single quotation mentioned above.

  • ATK works through the range of standard parts, the sales order and quotation and calculates that you need the following quantities for the co-products and for notional part N:

    Co-product Due date Qty to make Notional qty to make Comment
    C 14/08/06 2 2/1 = 2 Quote
    B 21/08/06 4 4/1 = 4 Sales order
    C 21/08/06 5 5/1 = 5 Standard part
    A 22/08/06 3 3/1 = 3 Standard part
    B 23/08/06 2 2/1 = 2 Standard part

    The earliest requirement for the notional part is on the 14/08/06. ATK explodes the Bill for the notional part generating component requirements for a qty to make of 2 for the notional part for the due date 14/08/06.

    Thus we will also have 2 of co-product B and 2 of co-product A available on the 14/08/06.

    The remaining requirements for co-products will now be:

    Co-product Due date Qty to make Notional qty to make Comment
    B 21/08/06 4 - 2 = 2 2/1 = 2 Sales order
    C 21/08/06 5 5/1 = 5 Standard part
    A 22/08/06 3 - 2 = 1 1/1 = 1 Standard part
    B 23/08/06 2 2/1 = 2 Standard part

    The next earliest requirement for the notional part is on the 21/08/06 and highest notional qty to make of 5. ATK explodes the Bill for the notional part generating component requirements for a qty to make of 5 for the notional part for the due date 21/08/06.

    Thus we will also have 5 of co-product B and 5 of co-product A available on the 21/08/06.

    The remaining requirements for co-products will now be satisfied as well:

    Co-product Due date Qty to make Notional qty to make Comment
    A 22/08/06 4 still available   Standard part
    B 23/08/06 1 still available   Standard part

Example 2:

  • You have a notional part N with co-products Co1 and Co2 for route 0.

  • Co1 has a qty of 1 per notional part and Co2 has a qty of 2 per notional part.

  • Thus your bill for Notional part N is as follows, with one operation for all components of 1 day: Co1 (1) Co2 (2)

    |_____________| | N ______|______ | | D (1) K(2)

  • You have a bill for a made-in parent A as follows, with one operation for all components of 1 day:

    A ________|______ | | | F (1) H(1) Co1(2)

  • You have a bill for a made-in parent B as follows, with one operation for all components of 1 day:

    B ________|______ | | F (1) Co2(2)

  • Run ATK for:

    • Route for all source options – route 0

    • Select ‘Include stocked standard parts’ and select a range of standard parts

      From: A To: B. Quantity to make = 2. Due date 25/08/2006

  • ATK explodes the bill for parent A. When it gets to component Co1, it checks if the co-product is attached to a Notional part on the current route. Since Co1 is attached to notional part N, ATK records that a quantity of 4 is required for co-product Co1 on 24/08/2006.

  • ATK explodes the bill for parent B. When it gets to component Co2, it checks if the co-product is attached to a Notional part on the current route. Since Co2 is attached to notional part N, ATK records that a quantity of 4 is required for co-product Co2 on 24/08/2006.

  • Thus we need the following quantities for the co-products and for notional part N:

    Co-product Due date Qty to make Notional qty to make
    Co1 24/08/06 4 4/1 = 4
    Co2 24/08/06 4 4/2 = 2
  • ATK explodes the bill for the notional part N for a quantity of 4 for the required date of 24/08/06.

    The final trial kit list is as follows:

    Component Required date Qty required
    F 24/08/06 4
    H 24/08/06 2
    Co1 24/08/06 4
    Co2 24/08/06 4
    D 23/08/06 4
    K 23/08/06 8

Comparison to MRP

The Advanced Trial Kitting program provides an alternative to running the Requirements Calculation and related reports from within the Requirements Planning system and is an attempt to emulate the manual method used by a company to build a finished item.

Unlike Requirements Calculation, the Advanced Trial Kitting program enables you to include or exclude supply which is yet to arrive.

The Advanced Trial Kitting program is not designed to schedule supply according to demand. It is designed to display shortages on the dates components are required, regardless of whether or not a supply is attached to the material allocation or whether the supply is associated with other demand.

The Advanced Trial Kitting program ignores all batching rules (Stock Code Maintenance).

Following are some of the differences between MRP and Advanced Trial Kitting:

Advanced Trial Kitting Material Requirements Planning
Calculations are always based on the current data at the time the Advanced Trial Kitting program is run (i.e. the listview and reports reflect information based on current data). Calculations are based on snapshots taken of the data at the time the Requirements Calculation program is run (i.e. reports and suggestions are based on the data at the time the snapshot was taken).
Calculations can be performed for a range, list or single sales order, job or quotation. This enables you to perform a mini-MRP calculation for the specific source(s) of demand you require. Calculations are based on ALL items selected on the Planning 1 tab of the Requirements Planning Setup program (i.e. no ranges, lists or single demand sources can be specified).
A what-if calculation can be performed based on the bill of materials or estimate of a parent part, where no demand exists as yet. Calculations are made only according to existing demand within the system. If no demand exists for an item, it is ignored.
No calculations are performed for demand quantities on parent parts. Only the net requirement quantities for components are calculated. The net required quantity for a parent part is calculated. i.e. when a demand exists for a parent part, then all existing sources of supply are netted against the demand and a job suggested for the remaining demand on the parent part.
A list of requirements is generated. The creation of jobs, purchase order and requisitions is done manually. Suggested jobs and purchase orders are created by the system where a demand exists.
The requirements for components only is displayed by the Advanced Trial Kitting program, based on the source selections made. The supply and demand information for both the parent part and its lower level components can be displayed using the Requirements Planning Query program.
You use the Supply/Demand and the Source options from the listview of the Advanced Trial Kitting program to view the sources of supply and demand. You use the Pegging function of the Requirements Planning Query program to view the sources of supply and demand.

Notes and warnings

Processing considerations

  • The Advanced Trial Kitting program is date-sensitive. It uses the delivery/due date when calculating the gross requirements and the sources of supply and demand. This means that sources of supply or demand that do not fall within the selected time frame are excluded from the calculations.

Perform a what-if calculation

You can use the Advanced Trial Kitting program to establish the components required to make selected standard items. The requirement is based on the quantity to make and the earliest possible delivery date according to the Due date you enter on the Standard Parts tab.

You would perform a what-if calculation to establish the soonest possible date on which you can make a standard item, without including existing sources of supply or demand.

  1. From the Options tab of the Advanced Trial Kitting program, select the following options:

    • Warehouse to use
    • Include stocked standard parts

    • Optionally select the option: Explode bought out items with structures, if you want to include bought out parent items and bought out sub-assemblies when generating the trial kitting list.

  2. From the Standard Parts tab, select the following options:

    • Stock code selection: Single.

      Enter the single stock code in the From field.

    • Routing: 0 - Factory Main Routing
    • Quantity to make: Enter the quantity of the parent part you want to make.
    • Due date: Enter the date on which you require the standard part.
  3. Select the Generate Trial Kit List function.

    The Advanced Trial Kitting program uses the Bill of Materials for the standard stock code you selected. The gross requirement is calculated only for the components of the selected stock item.

    The setup option: Number of days after stock arrives that it can be used (Requirements Planning Setup - General 1 tab) and the Calendar (Company Calendar) are included in determining the date on which the components are required in your factory.

  4. Optionally use the List option from the File menu to generate reports from the results of the advanced trial kitting calculation.