Shop Order and Shop Order Operation Split

There can be several reasons as to why you need to split a shop order or only an operation on a shop order.

There are different alternatives to perform split of a shop order or a shop order operation:

Shop order split
Comprehensive shop order split
Shop order operation split

Shop order split can be performed for shop orders in the status of Planned or Released. Comprehensive shop order split and shop order operation split can be performed for shop orders in the status of Planned, Released, Reserved and Started. Shop order type can be any of Manufacturing, Repair, Prototype, Disassembly and Remanufacturing. It is not possible to perform Shop Order Split or Comprehensive Shop Order Split if any of the shop order operations has Manual Operation Qty enabled. It is not possible to perform shop order operation split if the operation has Manual Operation Qty enabled.

It is only possible to split the remaining quantity to report and it is independent of how the split is performed as well.

A split reason must always be entered.

If there is an outside operation there are some delimitation related to the operation status if a split can be performed or not. Those will be described later in this document.

There are some scenarios where the shop order split will not be allowed:

If the shop order has an automatic pegging against a customer order.
If a material line is manually pegged against a purchase order line or a shop order, the pegging has to be removed first.
If the parent part is manually pegged against a customer order line or a shop order, the pegging has to be removed first.
If the shop order has split operations.

Split Shop Order

This split functionality is possible if the shop order is in the status of Planned or Released. When you use the functionality Split Shop Order to perform the split, new shop order in the status of Planned will be created.

Comprehensive Split Shop Order

This split functionality is performed by using an assistant. The assistant gives you an opportunity to manually select how the reserved/issued material and reported operations can be split between the original and the new shop order. This determines how the actual cost is split between the shop orders.

For component material selected to be incorporated in the new shop order created by the split process, transactions will be created to un-issue material from the original shop order and to issue material to the new shop order.

For machine and labor work selected to be incorporated in the new shop order created by the split process, transactions will be created to remove machine and labor work from the original shop order and to report it on the new shop order.

If operation time reported through shop floor workbench clockings has got split, the particular clocking records will be deleted.

If there are transactions on the shop order you intend to split and you can use Apply Excess to Split. Only transactions that are for quantities higher than what is required for the original shop order new lot size, will be proposed to be moved to the new split shop order. The intention is to always keep transactions on the original shop order.

Split Shop Order Operation

This split functionality is useful if there is only one or some of the shop order operations that needs to be split. You can split the operation from the Shop Order/Operations, Shop Order Operations and the Shop Floor Workbench pages as well as the Machine Load and Machine Operations Scheduling charts.

If the operation is an internal operation then it is possible to split the operation to:

Internal operation on the same work center (another resource)
Internal operation on a different work center
Outside operation

If the operation is an outside operation it is possible to split the operation to:

Outside operation with the same supplier
Outside operation with another supplier
Internal operation

It is only possible to split to one new operation at a time, but an operation can be split to more than once. When an operation is split the new operation will get the same operation sequence number as the original operation. Transactions performed before the split will remain on the original operation. Split operation will be handled as parallel operations.

Operation linked material will not be included in the split and also the split operations are considered as a group that consumes the operation linked material.

Note: Material which is operation linked appears on the pick list just as a record for the original operation, not for any split operation. This means that all material is picked and delivered to the work center where the original operation is to be performed independent of if the split operations are performed on the same work center or not. If it is necessary to divide the material between the split operations then is this something that needs to be handled without support of the shop order pick lists.

By-products will not be split. Split operations will be considered as a group that all contributes to the expected quantity of by-products.

If the shop order head lot size is updated then it has an effect on the split operations. The original operation will primarily be updated, if it isn't possible then the first available operation will be updated. If there are split operations with complete quantities those will be taken into consideration when shop order lot size is increased or decreased to calculate the new split operation quantities.

If there is a need to adjust the quantities between split operation you can do this by using Adjust Split Shop Order Operations. It is also possible to perform adjustments of the quantities between the split operations by using the same dialog. It also allows to set the quantity to zero, but you can never remove the original operation. This dialog box also provides the option to change the operation sequence for all the split operations at the same time. Since it is a condition, split operations that are parallel with all split operations receive the same operation sequence and it is independent of which the operation you try to perform the update from.

If there are split operations which has overlapped with the previous or next operations each of the those will be calculated individually and not as a group when start and finish times are re-calculated for the operations. As a result of this lead-time of the shop order can also increase. If there are split operations with overlap, adjust the overlap for the split operations if needed.

Delimitations

An operation split can only be performed on a shop order. It is not possible to split an operation already on the routing as a planned split in order to divide the work between different work centers and/or resources.

Neither is it possible to split operations on a DOP order. It is however possible to split operations on a shop order pegged as supply for a DOP order. If an operation is split on a shop order pegged to a DOP order then are not the split operations replicated to the DOP order. To be noticed is hence that replication from a DOP pegged shop order includes just date and quantity changes, not replication of operations added due to split. This is in line with how it works when adding an operation manually to a DOP pegged shop order.

Split Shop Order/Shop Order Operation including Outside Operation

If the shop order includes an outside operation there are some delimitations where it allows to perform the split.

If WIP is shipped to the supplier and you want to perform a split for an operation, you have to reverse the quantity to split from the supplier before it is possible to perform the split.

WIP is shipped to a supplier:

Split shop order - not allowed
Comprehensive shop order split - new purchase requisition/order will be created for the new shop order with the same supplier. If the purchase order for the original shop order has status equal with released or higher you must manually change the quantity for the connected purchase order line. The WIP at supplier for the created shop order is the product of the estimate cost for the new shop order and the WIP quantity that has been moved to the new shop order when the split was performed.
Split shop order operation - the quantity that you want to split must be reversed from the supplier before you can perform the split.

Outside operation is partially reported:

Comprehensive shop order split - only the remaining quantity to receive is available for split.
Split shop order operation - only the remaining quantity to receive is available for split and the quantity must be reversed from the supplier before you can perform the split.

Outside operation is complete reported:

Comprehensive shop order split - you can only split from a later operation, all costs and transactions related to previous operations will remain on the original shop order. The split can only be performed if the Adjust on Op Qty Deviation is not selected.
Split shop order operation - not allowed.

The table below is a summary about when to perform the different split functionalities depending on how far the outside operation has been processed.

Shop Order Data						Split functionality
Outside Operation Status	Purchase Order Status	Material Issued	Shipped WIP	Outside Operation Received	Outside Operation Invoiced		Split Shop Order	Comprehensive Shop Order Split	Shop Order Operation Split
Planned/Released	Planned	No	No	No	No		OK	OK	OK
Planned/Released	Released	No	No	No	No		OK	OK	OK
Released	Released	Yes	No	No	No		OK	OK	OK
In progress	Released	Yes	Yes	No	No		Not Allowed	OK	OK
Partially Reported	Partially Delivered	Yes	Yes	Partially	No		Not Allowed	Only available Qty	Only available Qty
Closed	Closed	Yes	Yes	Complete	No		Not Allowed	Only from next operation	Not Allowed
Closed	Closed	Yes	Yes	Complete	Yes		Not Allowed	Only from next operation	Not Allowed

Split a Shop Order with serials/lot batch number

If you perform the split by using Split Shop Order and the parent part is multilevel-tracked with an existing tracked structure, then the tracked structure of the serials and their lot batch numbers get assigned to the child shop order which has got lost. Not to lose the child shop order it has to be created in the Planned status.

If you perform the split by using Comprehensive Split Shop Order, the reserved serial numbers and lot/batch numbers will be distributed as indicated by you. Reserved tracked structures will belong to the shop order with the reserved lot/batch numbers.

When splitting a shop order that contains issued components which are selected as lot/batch origin, lot/batch numbers will be created when you perform the splitting.

Split a Shop Order connected to project

You can only perform split through the Split Shop Order. If the shop order is manually connected to a project activity or the shop order is connected via project delivery, the new shop order will be connected to the project/activity the same way as the original shop order which was before the split. The planned cost of the shop order is also split and the project activity is updated accordingly.