| Production order splits - overviewWith the split-off functionality you can split a production
order. By splitting an in-process production order you divided it into multiple
production orders. You can select the split-off quantity that goes to the new
child order, or split off rejected items. A split can be required in situations such as the following: - The total order quantity cannot be completed in time due to
capacity issues.
- Insufficient material is available to complete the total order
quantity in time.
- A part of the total order quantity is nonconforming, expedited,
or delayed.
Note After a child order is created, it is independent of the
parent order, and its inherited characteristics can be manually adjusted. A
child and parent order will always reference each other. A parent order can
reference several children, whereas a child order references only the
parent. To automatically split off the rejected quantity of a
production order, you must select the Split Order when Reporting Rejected Quantity check box in the Production Order Parameters (tisfc0100s000) session.
Caution! Splitting production orders may affect efficiency variances
in several ways including: - A production order accounts for a certain fixed amount of scrap during production. If the order is split into two
separate production orders, the scrap quantity can increase because the new
order will generate additional scrap upon completion.
- Setup times are doubled when an order is split: active
operations also have a queue time. For example, if the original order has a
setup time of one hour, after the split, both the parent and child order have
this setup time, which increases the total setup time by one hour. This means
capacity needed after the split is increased as well.
If Production Order Reference on Subassemblies check box
in the Production Order Parameters (tisfc0100s000) is selected, the order split process is
affected, see example. Master data Before you can split production orders, you must select the Allow Production Order Splits check box in the Production Order Parameters (tisfc0100s000) session. With the production order split functionality activated,
these settings become available in the Production Order Parameters (tisfc0100s000) session: Splitting production orders You can split production orders in the Split Production Order (tisfc0208m000) session, which can be started from the Production Orders (tisfc0501m000) session or, if the split off concerns rejected items,
from the Report Operations Completed (tisfc0130m000) and Report Orders Completed (tisfc0520m000) sessions. In turn, a child order can be split. Therefore, a production
order can be both a parent and a child order at the same time. You can start
the Order Split Tree View (tisfc0708m000) session to view all levels of a split
in a graphical browser framework. Production orders with a serialized or unit effective end
item can be split by serial number or effectivity unit. When you click Select behind the Split Quantity in the Split Production Order (tisfc0208m000) session, one of these sessions is started in
which you can select the serial number or effectivity unit that must be split
off to a child order: These conditions must be met to split an
order: - A production order can be split only when the production
order has the Released or Active status
- A split is possible only when a greater or equal to the routing quantity (unit) remains with the parent order.
- When an order is split, a new production order or child
order is created with the order quantity equal to the (user-defined) split-off
quantity from the original production order. The child order inherits order
characteristics, such as delivery date, production planning, operation steps,
and material requirements, from the parent production order.
- The total order quantity on the production order from which
the order split was initiated, is decreased based on the order split
quantity.
- The bill of material (BOM) or routing is checked to determine the estimated materials
or the JSC production planning. The data is copied from the parent
order.
- If the parent order contains a project cost distribution,
the child obtains the distribution lines which have the latest requirement
dates.
- Along with the order characteristics, the child order
inherits the order status and the operation status from the parent order.
- There are no restrictions on the number of splits that can
be applied to a single production order as long as the order fulfils the split
conditions.
- Order quantities already completed and delivered to a
warehouse cannot be split off. Completed quantities on order level or operation
level always stay with the parent order at split.
Splitting off rejected items When reporting operations or orders are completed, they may
contain rejected items. Instead of reporting these items as rejected in the Report Operations Completed (tisfc0130m000) or Report Orders Completed (tisfc0520m000) sessions, you can split off the rejected parts
of the order. When the rejected items are split off, they can be reworked as a
separate order. If you start the Split Production Order (tisfc0208m000) session from the Report Operations Completed (tisfc0130m000) or Report Orders Completed (tisfc0520m000) sessions, the Split Quantity is already defaulted from the Rejected field. The advantage of splitting off the rejected items is, that
no quantity rejected will be reported on the original production order at
closing. Splitting production orders with a project peg
distribution If a production order contains a project peg distribution,
this must be taken into account on order split. The split-off quantity is
derived from the distribution lines selected by these criteria: - The distribution lines with the latest need dates are split
off first.
- If all need dates on the distribution lines are equal,
anonymous demand is split off first. Distribution lines for project cost-pegged
demand are split off if no anonymous demand is on hand.
- If only project cost pegged demand distribution lines exist
and the need dates are equal, the lines are moved based on the last
distribution line sequence.
In contrast with a production order that does not contain a
project-pegged distribution, the planned delivery date is based on the earliest
need date of the linked project pegs. Note: - After a quantity is split off from a production order with
a project-pegged distribution, LN updates the order pegging for both parent and child
to acquire updated need dates.
- The project pegs that are copied to the child order are
generated by LN. You
cannot manually adjust them.
Recalculation of estimated materials at order
split An order split requires an update of the estimated materials
on the parent order, even if the estimated materials lines are already
frozen. Based on the initial production order materials of the
manufactured item and order quantity that remain on the parent order after the
split, operation input quantities are recalculated and estimated quantities are updated for each required material.
This update is done against initial valuation price, as estimated costs only change based on
the adjustment of the estimated quantity. If a project-pegged production order contains project cost
pegged materials, the estimated materials line and the estimated material
distribution are updated. For a newly created child order, the estimated material
lines are created based on the estimated materials of the parent production
order, the production order quantity, and the calculated input quantity of the
operation. Material issues and (production) warehouse
orders At order split, all material lines on the parent order are
updated. If required, this update, in turn, triggers an update of the related
production warehouse orders for materials with the type Issue,
based on these rules: Parent Order All materials issued on a production warehouse order are
registered as the actual quantity shipped to the parent production
order. - If an order is split, but the full quantity of a required
material was already shipped, you must manually redistribute the materials
between the parent and child order by returning the excess from the parent, and
then issuing it to the child order.
- After the split, the total actual quantity issued to the
operations is checked. If the actual quantity issued to an operation is less
than the updated material quantity required by the operation, the warehouse
issue orders are updated to reflect the quantity of the material still to be
issued to the operation on the parent order.
- If the total actual quantity of a material issued to an
operation is greater than the updated quantity that is required by the
operation, any outstanding material requests for this material must be manually
removed.
Child Order If, at the time of split, the full quantity of required
materials has already been shipped to the operation on the parent order and no
more unfilled warehouse orders exist, no child order level warehouse orders to
issue materials need to be created for the same operation. A portion of the
actual material costs (based on the order split quantity proration) will be
acquired from the parent order. - If only a portion of the required materials had been
shipped to an operation at order split, warehouse orders are created for the
quantity of materials to be issued to the operation on the child order
level.
Note: If, on operation level, the quantity of the manufactured
item is completely delivered, LN creates a warehouse order for material if both these
conditions are met: - At the time of splitting, the actual quantity of material
issued against the parent order is lower than the quantity required
- Outstanding warehouse orders to issue the remaining
quantity are present
- If both conditions are met, on the child order level a
warehouse order is created that contains a quantity to be issued which equals
the outstanding quantity that was supposed to be issued on the parent order
level.
When the operation status becomes Completed, a portion of the actual material costs is
obtained from the parent order. The exact portion of the material costs to be
transferred is determined based on the value of the Actual Material Costs breakdown for Transfer Postings field in the Production Order Parameters (tisfc0100s000) session, which is applied to completed
operations. Issued materials can be returned only from the production
order that holds the actual warehouse issue for the material. Even if materials
were issued to the parent production order, and at order split actual material
costs were transferred to a child production order, the return can only be
executed from the parent production order, as the warehouse order lines were
linked to the parent. Splitting production orders with multiple subcontracted
subassemblies Production orders with subcontracted operations can be split
only if the subcontracted operation is not yet active, or the operation
necessary for production have been completed. If subcontracting with material
flow is used, the returned subassemblies must be processed and completed as
well. If he Production Order Reference on Subassemblies check box
in the Production Order Parameters (tisfc0100s000) session is selected, al subassemblies
must be issued before the order can be split as the subassemblies can only be
issued to the order they are linked to.
Example In the following situation, errors will occur: - A production order has two subsequent operations that are
subcontracted to different subcontractors. The first operation was completed
and the subassembly received.
- If the Production Order Reference on Subassemblies check box
is selected, the received subassembly has a production order
reference.
- You decide to split off the remainder of the production order,
including the second subcontracted operation.
A subassembly returning from the subcontractor can only be
issued to an operation on the same production order as it was shipped from. If
the production order was split, the returning subassembly cannot be issued to
the child production order as the child order has a different production order
number than is referenced on the returning subassembly. Material supply lines can only be handled and the subassembly
transferred and issued to the shopfloor warehouse linked to the receiving
operation, if a subcontracting purchase order with the status Active. Note: A production order with a subcontracting purchase order
with the status Active cannot be split. | |