| # Assembly Line Material Supply Different supply methods are available for the supply of shop floor warehouse which are related to one or multiple line stations on the assembly line. The internal and/or external supply methods are as follows: Supplier Internal warehouse Production The material supply methods are as follows: Push The shop floor warehouse is supplied based on planning information. Pull The shop floor warehouse is supplied based on a supply trigger. KANBAN The supply is based on a manual trigger, such as the scan of a barcode. This method is mostly used for floor stock items for which no registration at shop floor warehouse is required. TPOP The supply is triggered by a SIC run for the shop floor warehouse concerned. Order Controlled / Batch (OCB) The supply is completed anonymously for multiple assembly orders together, based on triggers in the assembly process. Order Controlled / SILS (Supply In Line Sequence) The supply is completed for every assembly order separately, based on triggers in the assembly process. The parts are delivered Just-in-time in the sequence that products are passing along the assembly line. Linking generic items to assembly lines Start Manufacturing > Assembly Planning > Generic Item - Assembly Line (tiapl2500m000). Use this session to define which generic item can be produced on which assembly lines. LN requires this information to determine the master company of the generic item. Several processes can run only in the master company. For example, if you enter a sales order, LN creates a product variant in the master company. In the Generic Item - Assembly Line (tiapl2100s000) details session, you can specify a basic sales price and cost price. Assembled items through warehousing after roll-off from main line Store finished generic items - setup This topic describes how to set up the items to be able to store the finished end product of an assembly order in inventory. To store a finished generic item in inventory, you must define two items: a generic item and a standard item. Both items represent the same physical item. In Assembly Control, you use the generic item. In Sales Control and Warehousing, you use the associated standard item. To specify which standard item is associated with the generic item, use the Generic Item - Assembly Line (tiapl2500m000) session. Item settings For the generic item and the standard item, use the following item settings:
Session | Field | Generic item | Standard item
--- | --- | --- | ---
Items - General (tcibd0501m000) | Item Type | Generic | Manufactured
Items - General (tcibd0501m000) | Serialized | Yes | Yes
Items - General (tcibd0501m000) | Revision Controlled | (Not used) | No
Items - Ordering (tcibd2500m000) | Order System | FAS | FAS
Items - Warehousing (whwmd4500m000) | Serials in Inventory | (Not applicable) | Yes
Items - Warehousing (whwmd4500m000) | Lot in Inventory | (Not applicable) | (See below)
The Serials in Inventory check box must be selected because Warehousing would otherwise not be able to distinguish between product variants. Additional instructions The generic item and the standard item must have the same inventory unit. If you use unit effectivity, you must define both items as unit effective items in the Items - General (tcibd0501m000) session. If the standard item is lot controlled, you must use the lot-in-inventory type of lot control. To make an item lot controlled, select the Lot Controlled check box in the Items - General (tcibd0501m000) session. To use the lot-in-inventory type of lot control, select the Lot in Inventory check box in the Items - Warehousing (whwmd4500m000) session. Cost price calculation of the standard item The standard item must have an effective cost component structure. The standard inventory valuation functionality for items in inventory requires such a cost component structure. To specify the inventory valuation method, in the Warehouse - Item (whwmd2510m000) session, select a value in the Inventory Valuation Method field. To obtain the most accurate inventory valuation, select an inventory valuation method based on actual costing. The recommended inventory valuation method is Serial Price (Serial). If the inventory valuation method is Fixed Transfer Price (FTP), which is not an actual costing method, you must calculate a cost price in the Cost Price Calculation module. In this case, LN valuates the item against the calculated fixed transfer price (FTP) of the standard item and ignores differences between the product variants. Storing finished generic items Introduction In LN, an item of type generic cannot be stored in inventory. To store a finished generic item in inventory, you must associate the generic item with a standard item. The item type of the standard item is Manufactured. Both items represent the same physical item. In Assembly Control, you use the generic item. In Sales Control and Warehousing, you use the associated standard item. You can use this setup to carry out post-assembly operations in regular work centers after an item leaves the assembly line. Note If you send the item to the customer immediately upon completion of the assembly order, you only need the generic item. Setup The items must have the following properties: The order system of the generic item and the standard item must be FAS. Both items must be serialized items. If you use unit effectivity, both items must be unit effective items. To specify which standard item is associated with the generic item, use the Generic Item - Assembly Line (tiapl2500m000) session. Restrictions If a manufactured item is associated with a generic item, you cannot do the following with that item: Use the item in Purchase Control Create a bill of material (BOM) for the item, or use the item as a component in another BOM Create a production order for the item, other than a rework order Plan the item in Enterprise Planning, because the item's order system is FAS You cannot return an FAS item to the assembly line for rework. Note You can create routings for post-assembly operations of the standard manufactured FAS item. Procedure Sales order entry To define a sales order line for a generic item that must be stored in inventory after completion, enter the associated standard item on the sales order line. Based on the standard item that you entered, LN retrieves the generic item that is linked to this standard item in the Generic Item - Assembly Line (tiapl2500m000) session. LN sets the Delivery Type field on the sales order line to Warehouse. You must define the generic item 's product variant in one of the following ways: Configure the generic item in Product Configuration or in Assembly Planning, as determined in the Configurator check box in the Assembly Planning Parameters (tiapl0500m000) session. Select a previously configured product variant. Use an external tool/system to deliver the configured product variant to LN. Note If a generic item has an associated standard item, you can still enter the generic item on a sales order line. If you enter the generic item on a sales order line, LN sets the Delivery Type field on the sales order line to Work Center and you cannot store the finished item in inventory. Assembly order handling If a sales order line has an item with the order system FAS, LN creates an assembly order in the Assembly Control module by running the Generate Assembly Orders (tiapl3201m000) session. The item on the assembly order is the generic item. When the assembly order is sequenced, LN generates the end item's serial number. When the assembly order's final operation is completed, LN completes the following actions: LN generates a warehousing order to receive the finished item in inventory. The item on the warehousing order is the standard item. The assembly order status becomes To be Completed. LN sets the Ownership field on the inbound-order line to Company Owned. After the item is received in inventory, and any required inbound inspection has been performed, the assembly order gets the status Completed. If the item is rejected or destroyed after inspection, the relevant product variant obtains the status Canceled. If a product variant obtained the status Canceled, to continue processing the assembly order, manually cancel the sales order and create a sales order by using another product variant. The product variant is Canceled only when the following conditions are met: The Sell Multiples of Same Configuration check box is selected. A manufactured FAS item is listed on the sales order line. LN links the as-built structure to the standard item instead of to the generic item. Note Before you can release the sales order line to Warehousing, a sales order line for a standard FAS item must have a serial number. Post-assembly operations To perform additional operations on an item after the item comes off the assembly line, create a rework order. Delivering to customers directly from the assembly line Delivering to customers directly from the assembly line process is based on generic assembly items. For sales order processing, the Delivery Type field on the sales order is Work Center. A warehouse order is created and will be delivered from the work center to the customer. For more information, refer to Product variants in Warehousing |