Disassembly Work Orders

Overview

The Disassembly Work Order is a Work Order to used disassemble an Item (aka Disassembly Item) for the purpose of receiving the Components derived (aka Derived Components) into inventory. 

Application

Often used by companies that sell used parts or use derived parts to repair items.  Disassembly Work Orders provide the ability to plan, schedule, record activity, and calculate the cost of the disassembly process.

Prerequisite
 

• System Configuration:  This record is configured by Rootstock. The indicator for “Disassembly Module Active” must be checked to use the Disassembly Work Order function.

Setup

Inventory Commodity Code for Disassembly Items
 

Navigation 

Inventory Commodity Code > Disassembly Tab

The user can optionally set the "Disassembly Indicator" as true,  indicating this item is a disassembly item, i.e., an item used to harvest Components. When this Indicator is checked, it allows the user to enter the "Disassembly Receipt Location ID" and "Disassembly Receipt Location No". When an item is disassembled, receipts of the Component Items (Derived Parts) will default to this Stock Location ID, Location Number.

Engineering Item Master – Derived Component
 

Navigation 

Engineering Item Master > Derived Components Tab  

This defines the list of Components to be derived by dismantling (disassembly) the disassembly item.

  NOTE  For the Derived Components tab to display, the "Disassembly Item" checkbox must be checked on the Engineering Item Master Options tab.

Inventory Item Master – Disassembly
 

Navigation

Inventory Item Master > Disassembly Tab

The "Disassembly Item" checkbox value defaults from the associated Engineering Item Master. The "Disassembly Receipt Loc ID " and "Disassembly Receipt Loc No" are populated from the Commodity Code. This is the location where the disassembled Items will be stored.

Processing

Step 1: Create a Disassembly Work Order Header

Navigation

Disassembly Order

Fields
 

Division:  Division the Work Order is created in.  Defaults to current user Division.

Order Number:  This is the order identifier for this Work Order. Disassembly Work Orders are manually created.  As with other manually created Work Orders, the Order Number entered here must begin with at least one alpha character.

Disassembly Item:  This is the Item Number that will be Disassembled on this Work Order.
 

  NOTE  A Disassembly Work Order can be created for an Item regardless of whether the Item's "Disassembly Item" indicator is checked or unchecked.  However, a Disassembly Work Order can not be created for Purchased Items using FIFO.

Disassembly Item Quantity:  This value represents the total quantity of the Disassembly Item that is to be disassembled on this Work Order.

Target Site:  This field indicates the Site in which this Work Order will be active. Defaulting to the Main Site, it can drive the source of the Routing and the location of consumable materials.

  NOTE  The user will not be able to change the Site if any of the components under the Consumable Components tab have been allocated or issued, or if any of the derived components under the Derived Components tab have been received.

Due Date:  The date the Work Order is due to be completed and the disassembled Components received into inventory.

Status:  The current status of this Work Order. Status values are 1 (Planned), 2 (Firmed), 4 (Released/Ready for Activity), 5 (Picklist records generated), 7 (Activity started), 8 (Complete/Fully Received) and 9 (Closed).

Project:  The Project associated with this Work Order.  When the Division is under Project Control, it can be any open Project.  If not under Project Control, it will be the Home Project. MRP will recognize this order as a supply for the stated Project only. When this Work Order is received into inventory, it will be stocked under this Project identification.

Project Charge Code:  If Project Charge Codes are active, select predefined Project Charge Code consistent with the Project defined on the given Work Order.

Post Receipt Cost Alloc. per Remaining:  This field causes Disassembly Cost Allocations done after a partial receipt to weigh the distribution percentage amongst the remaining unreceived components.

Select the Save button.

Cost Summary Tab:  Summary of all costs charged to the Order. 

Derived Components Tab:  The Derived Components are expected to be realized from the disassembly process. The initial list is populated from the Engineering Item Master > Derived Components tab.

  NOTE  To add Derived Components to this Work Order, select Add Derived Component button.

Fields
 

Derived Component:  The list of Derived Components defined on the Engineering Item Master, or previously added through this app by clicking Add Derived Component.

  NOTE  The user can add FIFO items as Derived Components.

UOM:  The Unit of Measure of the Derived Component.

Expected:  The total quantity of the Derived Component expected to be received into inventory. Calculated by multiplying the Disassembly Item Quantity times the quantity per in the Derived Component tab of the Disassembly Item.

Actual Yield:  Calculated by Rootstock using the expected and received quantities.

Received:  Quantity of the Derived Component received into inventory from this Work Order.

Cost Allocation PCT:  The percent of the Disassembly Item Cost allocated to this Derived Component. The value comes initially from the value in the Engineering Item Master Derived Component tab.

Derived Total Cost:  Total of all costs charged to the Order for this specific item.  For example, if this Derived Item holds 30% of the Disassembly Item Cost and the Disassembly Cost is $10, the Derived Total Cost will be $3.00 times the quantity received.  

Total Unit Cost: Cost of one unit.  The total Derived Item Cost divided by Received Quantity.

Location ID:  Location ID to which the Derived Component is to be received. The Inventory Location ID's belonging to the Site selected will be listed under this dropdown.

Location Number:  Location Number to which the Derived Component is to be received. 

  NOTE  If the Location Number Required Ind is true on the Site selected, the Location Number provided must be one that has been assigned to the Site selected.

Lot Number:  The lot number of the Derived Item received to inventory.

Lot Exp Date:  The Lot Expiration Date defined for this Lot of material derived from this Disassembly process. The field is editable when the Derived Component is Lot tracked. If 'Expiration Date is required' is checked on Inventory Item Master > Misc CC Override tab related to Derived Component, an Expiration Date greater than the day being processed is required when a Lot Number has been specified.

Serial Number:  The serial number of the Derived Item received to inventory, if serial controlled.
 

Consumable Components Tab:  Items consumed in the disassembly process. These are added to the Work Order and issued from inventory. They must exist on both the Engineering Item Master and Inventory Item Master Records and the Item must have an on-hand balance to issue these Components.
 

  NOTE  The Consumable Components records are auto-exploded when a Disassembly Work Order is created. These records are similar to the Work Order Components on regular Work Orders and thus the user does not have to manually add the Consumable Component records on the Disassembly Work Order.

Buttons

Add Component Button:  Select to add a Component.

Component Issue Button:  Select to issue a Component.

Generate Picklist:  Generate a Work Order Pick List of Consumable Components. After generation, the Work Order "status" will change to 5.
 

  NOTE  Navigate to Work Order Picklist to print the Picklist.
 

Regenerate Picklist:  Regenerate the Work Order Picklist. Displays after Generate Picklist button is selected.

Delete Picklist:  Delete an existing Work Order Picklist. Displays after the Generate PicklIst button is selected.

Close short the Disassembly Work Order

When the Status is '5-Pick List records generated', using the 'Close Without Completions' link from the slide-out menu (on the right side of the page), the user can close a Disassembly Work Order without issuing any Components. This changes the Disassembly Work Order Status to '9-Closed'.
 

  NOTE  The 'Close Without Completions' link is available when (1) no components have been issued and (2) Time and Quantity Booking has not been processed.

Component Item:  A Component Item to be issued to the Disassembly Work Order.

Component Qty Tab

Fields
 

Enter Qty Per:  How much of this component is required for each of the Disassembly Items being dismantled on this Work Order. When selected, the Quantity Per entry block is made available.

Qty Per:  The Quantity Per of the Component Item to be added to the Disassembly Work Order.

Enter Component Qty:  When selected, the Component Quantity for the order is entered.  This is the total quantity that will be issued of this component for this Work Order.

Order Qty:  Enter the Component Quantity of the order.  

Fixed Component Qty:  When selected, a Fixed Quantity of the Component is entered.  This quantity will be issued regardless of the number of Disassembly Items being dismantled on this Work Order.

Order Qty:  Enter the Fixed Quantity of the Component.

Inv UOM:  The Inventory Unit of Measure (UOM) of this component.

UOM Conversion Factor:  The UOM Conversion Factor to convert the BOM Quantity to the Inv Quantity. Example: If BOM UOM for component =I nch and the component is stocked in Feet, the UOM Conversion Factor would be set to .0833 (set from UOM Conversion Factor record for Eng-to-Inv for Inch-to-Feet).

Scrap Factor:  Indicates the anticipated scrap of the component. A “factor” is a multiplier and not a percentage. The value is set from the Engineering BOM Master’s MRP Override (for the given Parent/Component). Example: A 10% loss of a component should be set to .10 rather than 10.

Comments:  Enter relevant comments regarding this component’s use on the given Work Order.

  NOTE  On the Consumable Components tab, click Add Component to move to WO Components in the ADD mode.

Issue Modifiers Tab (within WO Components Section)

Fields
 

Work Center:  If a Bill of Material Override has been defined to backflush this Item, this is the Work Center of the First Operation that is backflushed.

Process:  If a Bill of Material Overrides has been defined for this Item, this is the Manufacturing Process the Backflush function will use as a trigger to issue the material.

Operation Number:  If a Bill of Material Overrides has been defined for this Item, this is the Routing Operation Number to which the Item to be issued is assigned.

Backflush Policy:  Backflush policy for this Item. It is sourced from the Inventory Item Master. Valid entries are No Backflush, First Operation; Last Operation.

Date Required:  Date the Component is to be picked and issued to the Work Order.
 

Qty Dispositions Tab (within WO Components Issue):  Tab displays the various quantities of this Component as Required, Issued, Allocated, and Remaining.

Fields
 

Qty Required:  Quantity of the Component required for this Work Order.

Qty Issued: Quantity of the Component issued to this Work Order.

Qty Allocated:  Quantity of the Component allocated to the Work Order.

Qty Remaining:   Quantity of the Component remaining to be issued to the Work Order.

Component Status: Status of this Component in this Work Order.

Issue Project Tab: 

Fields
 

Project:  The project assigned to this Work Order.

Issuing Project:  The Project from which this Item has been issued to the Project. The Issuing Project will differ from the Project when the Issuing Project is “Home” and the Project is other than home.

Unit Cost Tab 

These values are sourced based on the Division cost setting. Inventory Item Std Cost record (Standard Cost), the Inventory Item Average Cost Quantity (Average Cost without Projects Active) or Inventory by Item/Project (Average Cost with Projects Active).

Deductions Tab 

Values are updated (increased) when a Work Order Receipt is transacted, pulling costs out of Work In Process. The value of the Component's material issued to the order has been reduced from the Work Order by the Work Order Receipt transaction.

Select the Save button.

Labor Tab (Work Order):  The Routing defined for the disassembly process. If a Routing Master has been defined, the Routing Master is copied into the Work Order. 

Dimensions Tab:  Populated from existing Dimension definition. (See the help text for the Company Master for Dimensions).

Step 2: Issue Disassembly Item to the Work Order
 

Navigation

Disassembly Workbench

Fields
 

Issue Disassembly Item button.  Work Order Issue function will display.

Issue Selected Component Button
 

  NOTE  There must be adequate on-hand inventory. The Cost Summary Tab, Disassembly Item Cost will be updated when the issue transaction takes place.
 

Step 3:  Issue Consumable Components to the Disassembly Work Order 

Navigation

Disassembly Workbench / Consumable Components tab

Select the Component Issue button.

  NOTE  There must be adequate on-hand inventory to issue the Component.

Cost Summary Tab > Consumable Item Cost will be updated.

The total Cost of the Disassembly Process will be updated.
 

Step 4: Report Labor and Quantity to Disassembly Work Order

Navigation

Time and Quantity Booking

  NOTE  Cost Summary > Labor Costs will be updated.

  NOTE  Total Cost of Disassembly Process will be updated.

Step 5: Enter Actual Yield (Derived Components)  
 

Derived Component Tab - Enter the Actual Yield of each Component.
 

  NOTE  Actual Yield for the Derived Component may vary from the Expected.
 

Fields
 

Actual Yield:  Enter Quantity realized in Component UOM. This is an editable field, thus allowing the user to perform multiple receipts on a Derived Component. Once a Derived Component is partially received, based on the actual yield value, the actual yield field value can be changed to perform another receipt of the Derived Component.

  NOTE  Derived Total Cost will be updated.

  NOTE  The Cost Allocation percentages may be maintained.

Select the Calculate Derived Cost button found on the Derived Components tab.

Step 6: Receive Derived Components to Inventory

Actions: Check the select indicator on the Components to be received.

Select Receive Derived Components button
 

  NOTE  If a Derived Component is Lot or Serial Controlled, the lot and/or serial information must be entered prior to the receiving of the Derived Component. After entering this information the Accept Updated Values must be selected.

  NOTE  If the Derived Component is a FIFO item, in order to receive it the Disassembly Order should not have any Labor Costs.

The Received Quantity is updated.

  NOTE  On the Cost Summary Tab, the Total Cost of Received Derived Components is updated.

  NOTE  A reversal of a received Derived Component can be done with the Reverse Derived Component button.

  IMPORTANT  After receiving the Derived Component(s), the unit material cost for the respective item will be updated based on the received quantity and component cost. Subsequently, after reversing the received Derived Component(s), the unit material cost of the item will be restored to its original value (i.e., the value before receiving the Derived Component(s)).

  NOTE  Derived costs cannot be calculated if Derived Components are received (Calculate Derived Costs button will gray out).

  NOTE  If all Derived Components are received the Work Order the Complete Disassembly Order button will gray out and a Close Work Order button will display. If all Components are not received and the Work Order is to be completed, the Complete Disassembly Order is selected. The Work Order status will change to 8.

Step 7: Close the Disassembly Work Order 

Select the Close Work Order button.

Calculation of Cost for partially received Disassembly Work Orders

For partially received Disassembly Work Orders, the Derived Costs will be calculated in two methods based on the flag 'Post Receipt Cost Alloc. per Remaining'. The two methods are explained in the below examples:

  EXAMPLE 1:  Consider a Disassembly Work Order with the flag 'Post Receipt Cost Alloc. per Remaining' as False.

• The Disassembly Work Order has a Disassembly Item with a Quantity of 2 and a unit cost of $100.

• So, after issuing the Disassembly Item, the 'Total Cost of Disassembly Process' will be updated to $200.

• Using the Add Derived Component button, two Components are added as below:

  • First Component with Qty as 2 and 'Cost Allocation Pct' as 60%.

  • Second Component with Qty as 2 and 'Cost Allocation Pct' as 30%.

• By clicking the Calculate Derived Costs button, the total cost ($200) will be considered and the costs for the first and second Components will be calculated. Then the 'Derived Total Cost' for the first Component will be updated as $120 (60% of $200) and the second as $60 (30% of $200). The remaining unallocated cost is 10% (which is $20).

• The first Component is fully received and the second Component is partially received (partially receiving only one Component quantity). So, the Status of the Work Order will be updated as '7-Partial Receipt'.

• Now the Labor is booked for $100. The 'Labor Costs' will be updated to $100 and 'Total Cost of Disassembly Process' will be updated to $300.

• Now add the third and fourth Components with 'Cost Allocation Pct' as 6% and 4% respectively.

• By clicking the Calculate Derived Costs button, the total cost ($300) will be considered and the costs for newly added Components will be calculated. Then the 'Derived Total Cost' for the third Component will be updated as 18 (6% of $300) and for the fourth as 12 (4% of $300), leaving the costs of the first and second components as is.

• So, the total cost allocated is $210 ($120+$60+$18+$12) and the remaining $90 is unallocated.

  EXAMPLE 2:  Consider a Disassembly Work Order with the flag 'Post Receipt Cost Alloc. per Remaining' as True.

• The Disassembly Work Order has a Disassembly Item with a Quantity of 2 and a unit cost of $100.

• So, after issuing the Disassembly Item, the 'Total Cost of Disassembly Process' will be updated to $200.

• Using the Add Derived Component button, two Components are added as below:

  • The first Component with Qty as 2 and 'Cost Allocation Pct' as 60%.

  • The second Component with Qty as 2 and 'Cost Allocation Pct' as 30%.

• By clicking the Calculate Derived Costs button, the total cost ($200) will be considered and the costs for the first and second Components will be calculated. Then the 'Derived Total Cost' for the first Component will be updated as $120 (60% of $200) and the second as $60 (30% of $200). The remaining unallocated cost is 10% (which is $20).

• The first Component is fully received and the second Component is partially received (partially receiving only one Component quantity). So, the Status of the Work Order will be updated as '7-Partial Receipt'.

• Now the Labor is booked for $100. The 'Labor Costs' will be updated to $100, the 'Total Cost of Disassembly Process' will be updated to $300, and the remaining cost will be $120 (unallocated cost of 10% ($20) and 'Labor Costs' of $100).

• Now add the third and fourth Components with 'Cost Allocation Pct' as 6% and 4% respectively.

• By clicking the Calculate Derived Costs button, the costs of the first and the second Components remain as is, and now the remaining cost ($120) is considered for calculating the costs of the newly added Components as below:

  • For the third Component, the 'Cost Allocation Pct' is 6% (which is 60% of the remaining 10%). So, the 'Derived Total Cost' will be updated to $72 (60% of $120).

  • For the fourth Component, the 'Cost Allocation Pct' is 4% (which is 40% of the remaining 10%). So, the 'Derived Total Cost' will be updated to $48 (40% of $120).

• So the total cost allocated is $300 ($120+$60+$72+$48).

SEE ALSO
 

Work Order Overview
Work Order Types
Work Order Setup Requirements
Work Order Time & Quantity Booking Options
Routing Master
Routing Operations
Work Order Pick List
Work Order Statuses