DOP Header and DOP Order

DOP Header

The DOP header contains the following information:

Creating a DOP header is the first step towards creating a DOP structure. An inventory part with DOP as the default supply type can be set up in three different ways in order to configure how a customer order line should behave during release. These are Manual DOP, Automatic DOP, and Release DOP. This setting will be the default for the DOP connection when a DOP supplied customer order line is created, but can be changed on the customer order line prior to release. The above setting in the customer order line will be overridden to Release DOP if a capability check has been performed for a customer order line prior to release.

Status

Status Description
Created A DOP header has been created but does not yet have a DOP structure.
Unreleased The DOP structure has been created for the DOP header.
Netted The netting process has been performed on all or some DOP orders in the structure.
Released Supply orders have been generated for all or some DOP orders in the structure.
Cancelled The DOP header has been canceled. There are no netted parts and no quantity to be delivered.
Closed The DOP header has been closed. All parts have been delivered to the pegged customer orders and all underlying DOP orders are closed.

Settings

When creating a DOP structure, the following settings are available for each DOP header:

Allow Changes to DOP Structure

The Allow changes to created DOP structure setting is used to specify whether it should be possible to manually add and remove components (both configurable and not configurable) and operations within the DOP structure. If the top level part is a standard part, the default setting is enabled and for configurable parts it is disabled.

When configurable parts are added, a default configuration is created based on the configuration defined in the DOP header. The configuration is set to the Parked status and must be manually edited and set to the Completed status. Right-click, point to Change DOP Structure and click Add Branch to create the configured DOP branch. When editing a configuration and a branch has already been created, the branch will be updated directly when saved. There are no configuration alarms on individual DOP orders.

Note that if the configuration from the customer order demand or top level DOP header is modified and the resulting configuration alarm is resolved, the existing structure will be replaced with this configuration. Any manually added components or configuration changes on components will be removed and replaced by the configuration logic.

DOP Order

DOP orders are the basic elements of the DOP structure. Each DOP ID may have a different product structure. A DOP order is a structure element equivalent to each part in the bill of material (BOM). A DOP order holds the data required to manage the acquisition of the part in question. The DOP order contains ordering information. This is information about how DOP deals with the requirements of each component part. When netting is not carried out, DOP orders correspond to actual shop/purchase orders, though not necessarily with a one-to-one match. For example, if additional shop/purchase orders are created as a result of increased demand quantity after release, more than one order will be pegged to this DOP order. In addition, when pegging is performed, the information on the pegging is also managed here. Project specific DOP orders will be tagged with the project ID and activity sequence to which they are connected.

The DOP header's settings are used as the default for netting parameters for the lower DOP order when you create a DOP structure using a standard BOM. In addition, a parameter corresponding to each existing DOP order is applied without any change when you create a DOP structure by copying another existing DOP structure. These parameter settings enable you to support a wide range of production types all from Engineer to order to Make to stock.

DOP Order Status

Status Description
Created The DOP order has been added manually. The status will be changed to Unreleased once the order is planned.
Unreleased The DOP structure has been generated, but no shop order or purchase requisition has been created to supply it why you can easily change the date and quantities.
Netted The netting process has been performed for the DOP order.
Released Pegged supply order(s) has been created for the demand quantity of the DOP order.
Started Work has started on at least one of the pegged supply orders.
Cancelled The DOP order will not be used further, and all quantities will be set to zero (0).
Closed All supply orders have completed the quantity pegged to the DOP order, and all parts have been delivered to the parent DOP order/customer order/to stock, or unreserved from temp inventory.

Plan DOP Orders

DOP orders within a DOP structure can be planned either backwards or forwards. Backwards planning is the most common approach, but forwards planning may also be used. See sections Backwards Planning and Forwards Planning for more information.

Backwards Planning

Backwards planning of DOP orders in a structure is done in various scenarios, such as when a DOP structure is created or during upstream date propagation from a parent DOP order to child levels. The topmost DOP order is planned by aligning its due date with the due date of the DOP header, while a component DOP order is planned by aligning its due date with the date when it is required by the parent DOP order.

The specific timing of when a component DOP order is required, and therefore how a component DOP order is planned, varies:

When the due date of a DOP order has been set, the start date is determined by backwards planning the DOP order, as described in the section Set DOP Order Start Date by Backwards Planning.

Forwards Planning

Forwards planning of DOP orders in a structure is done when performing downstream date propagation from a component DOP order to parent levels. The due date of the component DOP order determines the planning of its parent DOP order. If that parent DOP order is a component of another DOP order, its new due date determines the planning of its parent DOP order, and so on upwards until reaching the topmost DOP order. The DOP header is planned by aligning its due date with the due date of the topmost DOP order.

Exactly how a parent DOP order is planned varies:

Set DOP Order Start Date by Backwards Planning

When the due date of a DOP order has been set, the start date of that DOP order is automatically updated by planning the DOP order backwards from the due date. The due date of a DOP order is set, for example, when the DOP order is created, when performing upstream date propagation from a parent DOP order to child levels, and when manually editing the Due Date field of the DOP order.

For a DOP order with a manufactured part, how the start date is set depends on several factors:

For a DOP order with a purchased part, if the part has Plan Manufacturing Supply on Due Date disabled, the start date is set by subtracting the purchasing lead time from the due date, using the site manufacturing calendar. If Plan Manufacturing Supply on Due Date is enabled, the start date is set by subtracting one day less than the purchasing lead time from the due date, using the site manufacturing calendar.

Set DOP Order Due Date by Forwards Planning

When the start date of a DOP order has been set, the due date of that DOP order is automatically updated by planning the DOP order forwards from the start date. The start date of a DOP order is set, for example, when performing downstream date propagation from a component DOP to parent levels without a lead time offset between the component and the parent, and when manually editing the Start Date field of the DOP order.

For a DOP order with a manufactured part, how the due date is set depends on several factors:

For a DOP order with a purchased part, if the part has Plan Manufacturing Supply on Due Date disabled, the due date is set by adding the purchasing lead time to the start date using the site manufacturing calendar. If Plan Manufacturing Supply on Due Date is enabled, the due date is set by adding one day less than the purchasing lead time to the start date, using the site manufacturing calendar.

Release DOP Order

For the release process for DOP, you can specify the scope as follows:

The release can be done step by step from a lower level DOP order. This can minimize the impact of changes that are made after the release; changes made before the release can easily be handled.

A pegged purchase requisition or pegged shop order is created when a DOP order is released for the quantity remaining to supply after netting. These pegged purchase requisition lines/purchase orders/shop orders are called pegged orders or supply orders. When a pegged order is released, reservations from the lower components that are completed owned by the corresponding DOP order will also be transferred to the pegged order. Therefore, there is no need to reserve again for the pegged order.

Supply orders generated for parts with a scrap factor will be created with a quantity higher than the DOP order quantity to cover the planned scrap.

Once the DOP order is released, you must be careful when it comes to changing the DOP structure. A DOP order can be changed until it is set to the Closed status. If the pegged order and the DOP order do not match concerning time or quantity, the user will receive an alarm. When the DOP order has a shortage, you can create a new pegged order manually from the DOP order as an additional supply.

Settings

The DOP orders created in the DOP structure will inherit its setting from the DOP header setting as default, but it can be manually changed if required. The DOP order specific Create Pegged setting indicates whether pegged orders will be created for the specific DOP order or not, possible values are Pegged Order or No Pegged Order. The default value is Pegged Order.

Update Flags

There are two lists that indicate up to which status shop orders or purchase orders pegged to the DOP order are allowed to be updated. The defined value determines the highest status for the DOP pegged shop order or purchase order when quantity and date changes are allowed.

DOP Pegged SO Update - This value is inherited from the manufactured part settings on the Manufacturing tab on the Inventory Part page.

DOP Pegged PO Update - This value is inherited from the purchased part setting on the General tab on the Purchase Part page.

Both these values can be manually changed during the process.

Replication to Supply Orders

Changes made to a DOP order with pegged supply orders can be replicated under the following conditions:

Project Connection

If the DOP header is connected to a project activity, the DOP orders in the structure will be tagged with the project ID and activity sequence. However, not all these DOP orders will necessarily be supplied from inventory and supplies connected to the same project. This is decided based on the Create Pegged and Std Planned Item settings for each DOP order:

When DOP orders with Create Pegged set to Pegged Orders are released, the system generates project connected shop orders or purchase requisitions/orders dependent on the part type. These orders will be received in the project inventory.