A DOP alarm is generated whenever a DOP header, DOP order, or a supplying order will not be able to be delivered at the right time or with the right quantity. A DOP alarm is also generated if a configuration is used to create the DOP structure and if it does not match the configuration of a customer order line to which the DOP header is pegged.
DOP alarms can be viewed either on the DOP order itself or as component alarms on the parent order if there are any. The component alarms concern the fact that the necessary components for the DOP order are not available on time and/or in the right quantity. If an alarm exists, the Alarm Exists flag is displayed on the Details tab on the DOP Header page and/or on the Details tab on the DOP Order page. In addition, the alarms are displayed on the Alarms tabs on the DOP Header page and DOP Order page as well as on the DOP Alarms page.
The alarms are created in the Not Acknowledged status. When the alarm has been noticed, the status can be changed to Acknowledged using the Acknowledge command.
There are different types and sources of DOP alarms. Table below explains each combination, and possible ways to solve the alarm:
| Alarm Type | Source | Explanation | Solution |
| Time | DOP Header | The DOP header Due Date is early or late relative
to the Due Date of a customer order line to which it is pegged. When a DOP header is connected to multiple customer order lines, the alarm is generated for the customer order line with the earliest planned shipping date. When a customer order line is connected to multiple DOP headers, an alarm is generated for each date mismatch that exists between the customer order line and a DOP header. |
Use the Update DOP Header Due Date command available from the DOP alarm to align the date of the DOP header and top DOP order with the customer order line, or use the Update Customer Order Line Due Date command to align the customer order lines date with the DOP header. |
| Time | DOP Order | The Due Date for a top DOP order is early, or late relative to the Due Date of the DOP header. | Use the Update Top Level Date command available from the DOP header align the top DOP order date with the DOP header, or use the Propagate Date Downstream command from the top DOP order to align the date of the DOP header with the top DOP order. |
| Time | Parent DOP Order | The Due Date for a DOP order is early, or late relative to the Start Date of its parent DOP order. | Use the Propagate Date Upstream command available from the DOP order to align the dates of the sub level DOP orders, or use the Propagate Date Downstream command to align the dates of parent level DOP orders. |
| Time | Purchase Requisition | The Wanted Receipt Date for a pegged purchase requisition is early, or late relative to the Start Date of the DOP order to which it is pegged. | Use the Adjust Date command available from the alarm to align the date of the purchase requisition with the DOP order, or use the Update Dates from Supply command to align the date of the DOP order with the purchase requisition. |
| Time | Purchase Order | The Planned Receipt Date for a pegged purchase order is early, or late relative to the Start Date of the DOP order to which it is pegged. | Use the Adjust Date command available from the alarm to align the date of the purchase order with the DOP order, or use the Update Dates from Supply function to align the date of the DOP order with the purchase order. |
| Time | Shop Order | The Finish Date for a pegged shop order is early, or late relative to the Start Date of the DOP order to which it is pegged. | Use the Adjust Date command available from the alarm to align the date of the shop order with the DOP order, or use the Update Dates from Supply command to align the date of the DOP order with the shop order. |
| Quantity | Customer Order Demand | The sum of Qty Pegged pegged to a
customer order line for the DOP header is lower or higher than the
Inventory Qty on the customer order line. If multiple DOP headers are connected to the customer order line, DOP header with the lowest status gets the alarm. |
Use the Update DOP Header Qty Demand command available from the DOP alarm to adjust the quantity of the DOP header and top DOP order with the customer order line, or use the Update Customer Order Line Qty to align the customer order line quantity with the DOP header. |
| Quantity | Customer Order Supply | The Qty Demand for a DOP header is lower or higher than the sum of Qty Pegged to customer order lines for the DOP Header. | Use the Update DOP Header Qty Demand command available from the DOP alarm to adjust the quantity of the DOP header and top DOP order to align with the customer order line. |
| Quantity | DOP Header | The Order Qty for the top DOP order is lower or higher than the Demand Qty of the DOP header | Use the Update Top Level Quantity command available from the DOP header align the top DOP order quantity with the DOP header, or manually update the Demand Qty of the DOP header to align with the Order Qty of the top DOP order. |
| Quantity | Parent DOP Order | The Order Qty for a DOP order is
lower or higher than the demand quantity of its parent DOP Order expects
to receive from this DOP Order. For a parent DOP order without supply order, demand quantity is calculated based on the parent order quantity to multiplied with quantity per assembly plus planned scrap. For a parent DOP order with supply order(s), demand quantity is primarily fetched from the quantity required for the material line of the pegged shop order(s). If a shop order supplies several parent DOP orders, the total quantity required of the shop order material line is split between the parent DOP orders based on the quantity pegged to each DOP order. Secondarily, the demand for any remaining un-supplied quantity for the parent DOP order is calculated as the un-supplied quantity multiplied with the quantity per assembly plus planned scrap. |
Use the Propagate Quantity Upstream
command available from the DOP order
to align the quantity of the sub level DOP orders, or use the Propagate
Quantity Downstream command to
align the quantity of parent level DOP orders. When the quantity required on the shop order material line has increased or decreased as a result of scrap or operation quantity deviation it may be required to manually adjust the quantity of the supplying DOP order according to the excess/demand quantity stated on the DOP alarm. |
| Quantity | DOP Order | The sum of the remaining quantity expected
to be delivered from the supply orders pegged to the DOP order is lower
than or higher than the remaining, not already completed order quantity
of the DOP order. This may occur when:
When a purchase order or shop order is connected to more than one DOP order, the alarm is generated for the DOP order with the latest due date. If the DOP orders have the same due date, then the alarm is generated for the DOP order with the highest DOP ID. The quantity alarms are automatically removed when a reversal action for scrap, returns, or substitute receipts is done for the supply order |
Use the Adjust Quantity
command available from the alarm to
increase, or decrease the order quantity of a supply order according
to the shortage or excess quantity stated on the alarm.
You can also use the Manual Pegging of DOP Order page to manually increase/decrease the supply order peggings to align with the DOP demand. If a shortage exists, but there is no supply orders that can be adjusted, use the Create New Pegged Order command available from the DOP order to create a new supply order for the shortage quantity. |
| Structure Revision | DOP Order | Due date for a DOP order is not within the effective date range of its structure. This can occur if due date for a DOP is updated. | Use the Change Revision and/or Alternate command available from the DOP order. |
| Routing Revision | DOP Order | Due date for a DOP order is not within the effective date range of its routing. A change to the due date for a DOP order might cause this alarm to be generated. | Use the Change Routing Revision and/or Alternative command available from the DOP order. |
| Configuration | Customer Order Demand | A mismatch has occurred between the configuration defined for a customer order line and the configuration of the supplying DOP header. This can occur if the planned delivery date of the customer order line was changed in a way that the configuration must be reconfigured on the base of another part configuration revision than the original. If such reconfiguration is required, a mismatch occurs between the configuration defined for the customer order line and the DOP header configuration. Therefore, it is not possible to supply the customer order line with what is actually requested and the supply will deviate. | Use the Update Supply Configuration
command available from the DOP alarm. This will re-create the DOP structure
according to the new configuration. If flag Allow Configuration Changes for Started Supplies on the Site/Manufacturing page in the Configuration Change Management Settings section is Disabled: If any started supply order is affected by the configuration change, it may not be allowed to update supply configuration. Instead you will have to use the Unpeg Customer Order Line command available from the DOP alarm, then create a new DOP structure with the correct configuration and manually peg it to the customer order line. Note that it is not possible to acknowledge this Configuration alarm with source Customer Order Demand, it must be solved before processing the DOP header and connected DOP orders. If flag Allow Configuration Changes for Started Supplies on the Site/Manufacturing page in the Configuration Change Management Settings section is Enabled:
|
| Configuration | Demand Site Customer Order | A configuration change has been done on
the demand site customer order. This DOP alarm is created directly on
supply sites DOP headers as an information alarm to inform production
sites that a production change is soon going to be needed. This DOP alarm will be replaced by the DOP alarm Configuration/Customer Order Demand when created. |
Use of command Acknowledge can be
used if it is needed to continue to work with production orders on the
supply site until the DOP alarm of type Configuration / Customer Order
Demand has been created. This alarm is just a information alarm and can only be Acknowledged which will remove the alarm. |
Note: The quantity and configuration alarms are generated with alarm source related to the demand. Time, structure and/or routing revision alarms are generated with alarm source related to the supply.
The demand and supply relationships within a DOP structure are:
| Demand | Supply |
| CO line | DOP header |
| DOP header | DOP order |
| DOP order | Pegged supply order (shop order, purchase requisition/order); Inventory reservation |
DOP lead-time uses a manufacturing calendar, where as purchasing module uses the distribution calendar. In a situation where both these calendars differ, incorrect alarms could be created.
Alarms are automatically generated when date, quantity, configuration mismatches exist between demand orders and supply orders with a DOP structure, or if no valid structure- and/or routing revision exists for a part to be processed on an order in the DOP structure.