A disassembly component is a component derived from the disassembly process of a product. Disassembly components can be added to below structure types:
A disassembly component is technically included in the Bill of Material (BOM) of the main product with a negative quantity per assembly. In IFS/Manufacturing Standards disassembly components are defined with a positive quantity per assembly separately from the components on the Produced Parts tab on the Product Structure and Configuration Structure pages. When a shop order is created for the main part, disassembly components are copied to the Shop Order/Produced Parts tab according to the selected structure revision and alternate.
Disassembly components can be connected to the operation where they are produced and should be received to stock. If not connected, the system assumes it is produced and received in the last routing step.
IFS/Dynamic Order Processing (DOP) does not support the use of disassembly components.
By selecting the Use as Supply in MRP option for the given disassembly component, it is possible to define it as a supply to be used in MRP. Furthermore, by enabling Use as Supply in MRP, MRP will use that component supply for future demands that comes for the part which was defined as a disassembly component.
After creating the shop order from the shop order requisition (created for the parent part by MRP), by enabling or disabling the Use as Supply in MRP option the planner has the option to consider using the disassembly component supply from the shop order in the next MRP run. By default the Use as Supply in MRP option is getting the enabled status from the structure disassembly component line.
Note: Use as Supply in MRP option cannot be enabled in the Product Structure page Produced Parts tab if this part has a structure and the parent part is already defined as a disassembly component at a lower level. For example, in the structure of Part A , Part B is defined as a disassembly component and in the structure of the Part B, Part A defined as a disassembly component, and therefore it is not possible to enable the Use as Supply in MRP option in such a situation. This can be sorted out in a way such that once the shop order is created for the parent part (in the example for part A) planner can enable Use as Supply in MRP on the Product Structure page Produced Parts tab for the disassembly component (in the example part B) so that in the next MRP run it will be considered as a supply. Here, planner should carefully create shop orders and should enable or not Use as Supply in MRP option to have a good use of disassembly component being produced.
The valuation of manufactured products can be determined by using cost distribution factors. The cost distribution factors provide a means of distributing costs of materials, operations and general overhead cost between the by-products and the main product. When not using cost distribution, the valuation of the main product is determined by removing the standard cost of the by-products from the sum of the material, operation, and general overhead costs.
For Structure Type Disassembly, the disassembled main product will not be received when processing the shop order. The main product can be both purchased or manufactured, if the part type is purchased there is a need of a cost template that consist of both material, machine and labor cost buckets.
The cost distribution method requires identification of a portion of costs for material, operation, and general overhead to be allocated for each disassembly component on a disassembly structure or a disassembly shop order. The disassembly components should together absorb 100% of the cost. Separate factors are used for material, operation, and general overhead costs.
The disassembled main product itself is used when distributing its material cost to the disassembled components. The disassembled main product is displayed on the Component Cost Distribution tab on the Product Structure page, as well as on the Product Structure Alternate tab.
It is strongly recommended to use cost distribution method if the Structure Type is Disassembly.
If cost distribution is enabled for a main product structure alternate, then the shop order estimated cost and the weighted average cost for the disassembled components will be calculated using the cost distribution as mentioned above.
The cost distribution is enabled by enabling the Use Cost Distribution option for the relevant alternate on the Product Structure, Configuration Structure of Recipe Structure pages.
The value to determine how much operation cost or general overhead production cost should be allocated is decided by entering the value in the Operation Cost Distribution Factor field or General OH Cost Distribution Factor field on the Produced Parts tab of the Product Structure and Configuration Structure pages, and By-Product tab of the Recipe Structure page.
The value to determine how much component material cost should be allocated is decided by entering the value in the Cost Distribution Factor field on the Component Cost Distribution tab on of the Product Structure and Configuration Structure pages.
The value to determine how much component material cost should be allocated is decided by entering the value in the Cost Distribution Factor field on the By-Product Cost Distribution tab on of the Recipe Structure page.
The cost distribution factors can allocate more or less than 100% of the cost. It is strongly recommended that the sum of each distribution factor should be 100%. The badges Total Operation Cost Distribution, Total General OH Cost Distribution and Total Cost Distribution Factor (per component), summarizes the allocation factors of each type. This gives a clear indication if more or less than 100% is allocated.
During shop order cost calculations for estimated cost or weighted average actual cost, each of the shop order costs (component, operation, or general overhead) is multiplied by the appropriate cost distribution factor to determine the allocation for each disassemble components. Any remaining cost is allocated to the main product.
For example, suppose that product A has two disassemble components, B and C, and a component X. The cost distribution factors are as follows:
If Use Cost Distribution is enabled (recommended), then during the shop order cost calculations, the costs would be calculated as follows:
If Use Cost Distribution is not enabled, then during the shop order cost calculations, the costs would be calculated as follows: