Consolidate and Release Planned Manufacturing Orders

This document explains how you may consolidate manufacturing order proposals (MOPs) for various order categories, including Discrete orders, Process orders, and Pack orders.

On 'Manufact Order. Open' (PMS100), a 'Process code' (PCCO) is defined. The 'Process code' field value options are: '0-Discrete', '1-Standard manufacturing order (MO)', '2-End product', '3-Process order', '4-Pack order', '5-Process child order', and '6-Pack child order'. Ultimately, the MOPs can be consolidated and released in one action on 'Planned MO. Consolidate' (PMS172).

In addition to the 'Process code' field, the system checks the 'MO consolidation method' (MOCM) field on 'Item. Connect Warehouse' (MMS002/E) when packaged items (also referred to as item packs) are part of the manufacturing planning process. These are the scenarios for each selected field setting:

Outcome

The planning process allows for the generation of consolidated MOPs, also referred to as proposals or planned orders. Proposals may be consolidated based on their 'Process code' values:

A proposal also may be created manually through 'Planned MO. Open' (PMS170).

If the item being manufactured in 'Planned MO. Open' (PMS170) is a bulk item, then the 'Process code' for the MOP defaults as '3-Process order'.

Note: The 'Process code' may be updated to '0–Discrete' and therefore does not have consolidation capability.
Note: When there is a planned order for a packaged item with a 'MO consolidation method' (MOCM) of '0-Discrete,' the order is converted as a discrete order with material requirement from the packaged item product structure, but no additional packs may be added to this MO.

When there is a planned bulk order, the order is converted as a process order with material requirement from the bulk item product structure, and more output items may be added to this MO through 'Output Balancing. Open' (PMS150).

See the document Balancing Manufacturing Outputs.

On the 'Planned MO. Consolidate' (PMS172) program, there is an option to consolidate and release MOPs simultaneously.

This diagram shows the MO planning flow in relation to MOP consolidation:

Before you start

The consolidation functionality can be implemented when this prerequisite is met:

Follow these steps

  1. Start 'Planned MO. Open' (PMS170).

  2. On the B panel, select the desired rows, with the corresponding warehouse and product data, from the grid.

  3. For order consolidation activities, right-click and select Related Options > Consolidation (or CTRL+98).

  4. On the B1 panel of 'Planned MO. Consolidate' (PMS172), define these parameters for the Demand/Supply span in days to determine the selection of planned orders for consolidation:

    1. In the Starting field, specify the number of days prior to the current date to indicate the starting point of the order date range.

    2. In the Ending field, specify the number of days beyond the current date to specify the ending point of the order date range.

  5. Click Apply to retrieve the results.

  6. Specify these options in the grid:

    1. Highlight the desired rows.

    2. Update the order quantity.

    3. Right-click and select Related Options > Select/Deselect.

    4. Select Actions > Consolidate selected orders.

      Note: Two Process-type rows cannot be consolidated in into the same order.

      If there are two identical packs, the system will not consolidate them into one pack child order. Instead, there will be two separate child orders.

    5. Click Next to save your changes.

  7. If you want to reverse the consolidation of orders:

    1. Highlight the desired row(s).

    2. Right-click and select Related Options > Select/Deselect.

    3. Select Actions > Deconsolidate selected orders.

    4. Click Next to save your changes.

      The formerly consolidated orders are deleted from the Order Relationship (MWPREL) table.

  8. To release MOPs in the grid on 'Planned MO. Consolidate' (PMS172),

    1. Highlight the rows with consolidated parent MOPs.

    2. Right-click and select Related Options > Select/Deselect.

      Note: Only parent orders may be selected for release.
    3. Select Actions > Release if you want to convert the MOPs to MOs.

      Note: If there is a failure in the release of a parent order, the system prevents the release of any associated child orders.
    4. To verify the MOs that are created, go to 'Manufact Order. Open' (PMS100).

  9. If you want to consolidate and release the MOPs simultaneously on 'Planned MO. Consolidate' (PMS172):

    1. Highlight all the rows with consolidated parent MOPs in the grid.

    2. Right-click and select Related Options > Select/Deselect.

    3. If you want to convert the MOPs to MOs, select Actions > Consolidate and Release selected orders.

    4. To verify the MOs that are created, go to 'Manufact Order. Open' (PMS100).

The newly converted manufacturing orders are stored in the Order Relationship (MWPREL) table with an 'Order category' (ORCA) of '101-Manufacturing order'.

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