Work Order Pick List for Repairable Items

Abstract

This functionality introduces work order picking lists as a replacement for the requisition orders (RO) for repairable items that will be installed in an as-built structure with serial administration 0 or 2 (with inventory updates). The RO process is still available if an RO type is entered for issues in MOS120.

Background

In order to include material requirements for maintenance work orders in a supply chain, work order picking lists were introduced for regular issues. That change was also done to align the picking list process throughout M3. However, in the earlier release, there was no support for serialized items that will be installed in an as-built structure with serial administration 0 or 2 (with inventory updates). In this scenario, the serialized item must remain in stock in order to do the MOS125 installation transaction.

This development includes the following:

Supply chain orders will now include repairable items that will be installed in an as-built structure.
New order categories are created ORCA 660/670, 661/671 for material plan records, in order to differentiate them from regular issues ORCA 610/611.
Planned removal records can now be viewed in the material plan.
New settings are available to control the above-mentioned functions.

Creation of material plan transactions during order registration

During registration of a new material line in MOS101, delivery and material plan records are created with different transaction types that depend on whether the item will be issued via removal/installation transactions or via a regular picking list report. Transaction types 66/67 ORCA 661/671 are created when you use removal/installation, and a transaction type 61 ORCA 611 when you do not use removal/installation.

In addition, when a material line is added in MOS171 or a planned work order is created with existing material lines, a 670 record, a 660 record or both should be created in the material plan.

This is controlled by the Exchange field on the material line.

Alternatives

0=No
1=Yes, removal
2=Yes, removal and installation
3=Yes, installation
4=Yes, add product to work order

This field is available both on service/facility records connected to a service, on operations on work orders and on material lines. The service/facility and operation setting determines if and how the removal/installation function is automatically displayed after operation reporting.

On material lines, the field is used in combination with the dispatch policy and the remove/install setting on the work order type. The field controls whether a repairable item on a material line updates the material plan with an expected installation transaction (67) and whether a planned removal transaction is also created (66). The default value is 2 if the remove/install setting on the work order type is enabled. If the operation is for an installation only, this field can be set to 3 so that no planned removal transaction is created. If it is set to 0, a normal issue will be done and the material plan transaction will be a 61 as for normal spare parts.

Alternative 4 is only available on the service/facility record and is used to automatically create a material line for the maintenance object when the product itself is rebuilt, so that actual cost can be updated correctly. This should only be used in combination with actual costed items and with Update material plan set to 1 (manufacturing/rebuild) on the work order type.

This means that the exchange setting can be used on a material line to define whether this specific material is for a planned removal and/or installation. This can be used to define that we are only expecting an installation for this specific service/WO, which means that we will consume a serialized item since nothing will be removed or returned. This can also be used when a removal (Exchange=1, -1 EA) will be performed early during a maintenance visit and the installation (Exchange=3) will be done later in a separate operation.

Process flow and material transactions

This process flow is to the same as a normal flow until the user selects "Confirm issue" in MWS420/422. When this is done, a move to dock transaction to "To be installed" location is performed instead of a normal issue. The valid location comes from the material line on the work order, which in turn comes from the "To location" field on the work center for the operation that the material line is connected to. After you confirm the issue, the material line status remains at 80, and the delivery and allocation remains until a MOS125 installation is performed.

When removal/installation is done, MOS125 should issue the serialized item from stock with a TTYP67, close the delivery and remove the allocation. If a 661 planned return was created at material line creation (Exchange=2), this will be removed at this step. When this record was created there was no material line created on the work order, so the material sequence number is the same as the planned installation record (670/671). If only one repairable item is issued against the referenced work order operation in MOS125, the transaction will be created automatically. However, if a message is displayed a new field is displayed in MOS125. Action is only required if the user sees the message "Material plan record for planned removal must be selected". In this case, the user must browse and select the material plan record that should be removed by this removal transaction.

Return/removal of a core item

If the issued serialized item is classified as a core item in MMS001, the MOS125 process is slightly different. In this scenario ATS101 will appear after MOS125 in order to update the attributes/condition of the removed item. The removed item will not end up in the warehouse until the OIS390 core return process is performed.

Return of unused repairable

If the issued repairable is not being used and the MOS125 transaction is not done, the repairable must be returned to stock. In this new scenario, the delivery for the issue is still open in status 80 and can be reversed by using "Return to standard location." This should be done instead of copying the material line to a negative line, which was the case using the RO flow and is still the process for issued spare parts.

Follow These Steps

Create a material line for a planned removal and or installation.
Process the delivery/picking list when the work order is created.
Install the serialized item in an as-built structure.

Outcome

A repairable/serialized item is issued to a work order and installed in an as-built structure. During the process the material requirements can be viewed in the material plan and, if they are connected to a supply chain, can also be viewed when you monitor the supply chain in MWS150.

Configuration

Define MOS120 setting 210 Dispatch policy.
Define MOS120 setting 215 Use Remove/Install of repairable items.
Define the setting Exchange on material lines in ECS312, PDS002, MOS171, and MOS101.