Merge Shop Order Requisition into Shop Order
Explanation
This activity is used to merge one or several shop order requisitions into
either a new
shop order, or into an existing shop
order.
When shop orders and shop order requisitions are created by Material Requirement
Planning (MRP) and/or Project MRP (PMRP), they receive a planning method based
on the planning data of the part. This does not happen when orders or requisitions
are created from the next level demand calculations or customer order-controlled
production when demand determines the lot size. This means that many orders
and requisitions have a smaller lot size than the maximum and you can combine
them into one shop order with the correct quantity. This creates a relationship
between the requisition and the shop order. If the shop order requisition is
created by PMRP, the requisition will have project related information attached
to it.
To merge shop order requisition(s) into an existing shop order. Select
the relevant shop order requisition(s) and click Merge into Shop Order.
If you have selected more than one requisition, first select Merge into
Existing Shop Order. Finally select the required shop order number in
the Order No field.
To merge shop order requisitions into a new shop order. Select the
relevant shop order requisitions, click Merge into Shop Order and
then select Merge into New Shop Order.
Note: When merging several shop order requisitions,
the requisitions should be for the same part and should have the same
Program ID/Project ID/Sub Project ID/Activity ID (PPSA) if
it is related to a project.
If a shop order is generated from a requisition where
the Requisition Source is set to Direct Supply,
but no shop order is created for the direct demand requisition, it could
lead to the master scheduling/MRP generating another direct supply
requisition in the subsequent run, potentially causing an oversupply.
Prerequisites
- At least one shop order requisition in status Proposal Created
must exist.
- The shop order requisitions that will be combined must be of the same
part and requisition type. If merged into a shop order, the order must
be for the same part and type as the requisition(s).
- The shop order requisition must not have any shop order requisitions
pegged as direct supply.
- You must select more than one shop order requisition if you want to
merge requisitions into a new shop order.
- The shop order with which you want to combine the requisition cannot
originate from a customer order. This is because the completed parts must
be reserved for that order at receipt.
- The shop order with which you want to combine the requisition must not
have reached the Reserved, Started, or Closed statuses.
- Shop order requisitions created by PMRP can be merged into one shop
order only if the parts are identical and the PPSA are the same for the requisitions.
- If the parent part is manually pegged against a customer order line
or a shop order, the pegging has to be removed first.
System Effects
- If Merge into New Shop Order is selected, one or more shop orders with
Order Type set to the same as the Requisition Type
of the selected shop order requisitions are created.
- If the Requisition Type is
Manufacturing, the maximum lot size of the part and quantity on the shop order requisitions
dictate how many new shop orders are created.
- If the Requisition Type is
Remanufacturing or Disassembly, one shop
order is created regardless of the maximum lot size of the part.
- If Merge into Existing Shop Order is selected, the quantity
of the selected shop order requisitions is added to the lot size of the
selected shop order. The lead time for the new shop order increases as a result
of the new lot size. This affects the start and finish date of the shop
order.
- If the requisitions are connected to a project activity, the planned
committed costs and planned committed hours of the individual requisitions
are combined to show the planned committed values attributed to the new
shop order. If the requisitions are merged to an existing shop order, the
planned committed values are added to the existing planned committed values
of the shop order.
- If the part is serial tracked and has either Structure Effectivity
or
Routing Effectivity set to Serial then the structure alternate and routing
alternate coinciding with the serial(s) registered in the shop order requisition
will be used to generate the materials and operations in the shop order.
- Serial and/or lot/batch numbers reserved to the shop order
requisition(s) are transferred to the shop order(s).
- If alternate components have been used in the material requirements planning netting
process, the Alternate Component Used field in the Shop Orders
page will
be indicated. This indicates that the planner should replace one or more
components to alternate components before
releasing the shop order to avoid shortage problems.