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.