Kit Assembly Order

Kit Assembly Order (KAO) is an IFS Cloud page where it should be created manually or automatically depending on the scenario and this is the object used to modify existing Kit parts as well as to create new Kit parts. This is a new entity that is persistently stored in the database. This object should have a primary key which is a number from the Oracle Sequence, along with the Part Number of the Kit Part, the Site, Serial Number of the Kit and Lot/Batch number.

To start with the Kit Assembly Order, the following prerequisites need to be met,

Kit Part should exist as an Inventory Part.
Kit Definition should exist for the Kit Part.
If using the existing company, then it needs to be updated from the STD company template to work with newly introduced posting types M311 and M312.

Kit Assembly Order can be created from Inventory Parts In Stock page via the ‘Modify with Kit Assembly Order’ command to modify an existing Kit Serial. During the command execution following parameters will be passed to create Kit Assembly Order header: Part number, Serial number, Lot/Batch number, Site, Location No Order number is an Oracle sequence and will be saved as the Order number for the Kit Assembly Order.

Conditions to check when creating Kit Assembly Order from a stock record (from Inventory Parts In Stock):

Stock record should be for a Kit Part (Kit Part toggle = True)
Available qty should >0
Ownership should be Company Owned
Since the Kit Part is issued from the stock when creating Kit Assembly Order header, any existing validation for Issuing out Inventory part (e.g. Part Availability Control) should fire when saving the Kit Assembly Order header.

Once the Issuing out of the Kit Part serial is successful, Kit Assembly Order header will be saved. This will automatically populate the Kit Components based on the Kit Definition, in the Required Content tab of the Kit Assembly Order.

During the assembly process;

Cost of the Kit Part will be transferred to the WIP account (Posting Type M311) by creating the Transaction KAOKSISS (Issue of a Kit Serial from stock for content modification through a KAO)
Component Issue and reversal transactions will be created depending on issuing and un-issuing components to the Kit Assembly Order, which will update the WIP.
When receiving the Kit Assembly Order, KAOKSREC transaction will be created (Receiving back to inventory of a Kit Serial that was previously issued from Inventory for a modification of its content) transferring the WIP amount back to M1. There could be instances where the inventory part unit cost of a kit component part changes between the point of assembly and disassembly, creating a unit cost difference. This would in return create a situation where the unit cost of the kit part is smaller than zero. Therefore, such remaining balances on kit part unit costs will be cleared out using a KAODIFF+ transaction.

Tabs in Kit Assembly Order

Following Tabs are available in the Kit Assembly Order:

Required Content, Content Details, Inventory Transactions

Required Content Tab

Components listed in Kit Definition along with quantities required. For fresh Kits, this tab should populate the Kit Definition at the start, with Qty Connected = 0 for all components. This will also display the sum of the quantity assembled so far per component line. This sum will include the alternates as well, providing the user with a progress summary of the assembly process.

To connect components, the user should select a component line and then click on the 'Add Component Quantity' command to open up an assistant (Add Component Quantity for Kit Assembly Order) which will show the available Parts in stock. This assistant will have to display the available stock records of the standard component part and the stock records of all the available alternates for that part. Once the user enters values in Qty to Connect field and confirms, the Qty Connected values in the Required Content tab get updated.

Content Details Tab

This Tab will show all the details of the kit components connected so far, along with serial numbers and lot batch numbers on separate lines. If the Component connected is an Alternate Part, the Standard Part Column will show the Standard Part number corresponds to that component part.

Inventory Transactions tab

This will show all the inventory transactions involved with the Kit Assembly Order number.

Commands on the Kit Assembly Order

Add Component Quantity: Both standard component parts and Alternate component parts will be shown in a one List. Ok button - After entering Qty to connect will save and close Cancel button - Will close the Assistant without saving
Remove Component Quantity: Component parts can be un-issued from the Kit Assembly Order by using the ‘Remove Component Quantity’ Command. This Command will open Remove Component Quantity from Kit Assembly Order assistant which allows to enter qty to disconnect and Location.
Receive Kit to Inventory: Receive Kit To Inventory assistant will contain Site and Location details (including Warehouse / Bay / Row / Tier / Bin. Also the Expiration Date can be entered when receiving the Kit Serial.
Cancel Order: Cancelling Kit Assembly Order can be done when the Kit Assembly Order is in In Progress status and all component issue transactions and parent kit part issue transaction should be reversed during cancelling Kit Assembly Order.
Delete:It is possible to Delete the Kit Assembly Order header when it is in Planned status. (i.e. No transactions created).

Kit Assembly Order Status

Kit Assembly Order will be in Planned status as soon as a Kit Assembly Order header is created for a new Kit Part (i.e. not for an existing Kit Serial).

When Kit Assembly Order is created for an existing Kit Serial (e.g. from Inventory Parts In Stock) the status should be In Progress. As soon as an issue transaction is created (either for the parent Kit part or for a component part), it will be a trigger for In Progress state.

It is possible to Delete the Kit Assembly Order header when it is in Planned status. (i.e. No transactions created)

There will not be any Close Command. Receiving the Kit Assembly Order will move it to Closed state.

Status will be changed to Canceled after executing the Cancel command.

Planning Kits in IFS Cloud

Kit parts, like standard inventory parts, can be planned for demand using the Material Requirements Planning (MRP) solution. When shortages occur, MRP can generate purchase requisitions as supply orders to cover demand from work orders or material requisitions. However, Kit Assembly Orders—used to assemble kits on site—are not integrated as supply orders in MRP and are also not recognized as demand orders in MRP or other planning tools. As a result, MRP cannot create Kit Assembly Orders for shortages, nor can it plan component parts for existing Kit Assembly Orders. This means planning for Kits is limited to the parent Kit parts through Purchasing, and assembly-related planning must be managed outside standard MRP processes.

Although Kit Assembly Orders are not integrated into MRP as supply or demand orders, their statuses can still be leveraged to support planning and order handling. For any kit requirement, the planning team—or the personnel responsible for demand and supply management at the site—can create Kit Assembly Orders for new Kit Serials in a Planned state. These planned orders can then be processed by warehouse staff, helping streamline the Kit assembly process and improve coordination between planning and execution.