Build Assembly (Physical) - Stock Control

This option builds the assembly for stock – in the process the stock file is updated to show the reduction in the physical stock level of the component items used when building the assembly. As such this option would not normally be used if the Bill of Materials has been purchased.

The primary differences between this option and Bill of Materials are firstly its immediacy, where components are issued and the assembled item built in one process with no allowance for the time taken to build the assembly. Secondly, Bill of Materials offers greater reporting capabilities over the Stock Assembly build process.

The Build Assembly option allows that, for example, when we make five PC’s for stock, the individual components of monitors, keyboards, etc., are reduced by the component quantity multiplied by the number of PC’s being built. The physical quantity of the assembled item – the PC System – is increased by the number made. This whole process may be used in a negative way where there is a need to disassemble or ‘de-kit’ a finished product and put the components back into stock.

Build an Assembly

When you first select to Build an Assembly you are asked to verify the transaction date – the system date is displayed and can be accepted by pressing <Enter> or overtyped with another date as required. This date is validated according to the period rules outlined in the Stock Transactions processes above.

Assembly Number?

Assembled Stock Code?

Next you select the assembly to be built – at this point you can either select the assembly reference or, by pressing <Enter> on a blank Assembly Number, the stock code being built. <F4-Select> is available on both inputs as required, note that if select the Stock Code then it is possible that more than one assembly could be configured to build that item – if so a pick list will list the assembly definitions available for selection.

Assembled Quantity

This is the quantity of the assembly you wish to build. This quantity is normally a multiple of the build quantity – where the build quantity is ‘1’ then any whole number is accepted, where the build quantity is another quantity (remember economies of scale may require this) then the quantity you are building should be a multiple of this. If the quantity isn’t a multiple you are warned accordingly and asked to re-key the quantity. If the quantity entered is that required then the <F7-Option> key is available to override this warning.

De-Kit to Level

When building assemblies if a component is a sub-assembly then that assembly could either be built or issued from stock (dependent on configuration and quantities). Therefore when breaking down, or de-kiting, an assembly the system has no way of knowing whether the sub-assembly was originally issued from stock or built. This option, available only when entering a negative qty, asks for the assembly level number to break down the assembly to. The Stock System Profiles allow you to configure a default level to de-kit to.

Use Which Stock Level

When issuing component stock the quantity issued is validated against the physical quantity and if greater than this the appropriate warnings are given. If validate against ‘Physical’ this assumes that the component is not a saleable item in it’s own right and that the entire physical quantity is available for use in the assembly build. Where components are saleable items you may want to amend this option so that the component issue quantity is validated against either available stock – physical less reserved – or free stock – physical less reserved plus on-order. The Stock System Profiles allow you to configure the level to use by default. NB: This prompt is not applicable when using negative quantities to de-kit/breakdown an assembly into its component parts.

After confirming the build details you are asked if you wish to change any of the component details for this build – any changes made here are not saved back to the assembly definition.

The system then pre-processes the components – checking quantities are available, prompting for batch/serial details and building sub-assembly components were required.

Insufficient Stock?

If there is insufficient stock available for a component then the item is displayed on screen and you are asked how you wish to proceed.

Several options are available, some of which may not be appropriate for the item you are building:

Abandon the Assembly to re-try at a later point when more stock is available.

Replace the component with an alternate similar item

Proceed without Component where the out of stock item can be added manually later

Specify Reduced Quantity where the balance can be added manually later

Let Quantity go Negative where components are ordered on demand.

Building Sub-Assemblies

Where a component is a sub-assembly then various other actions are possible depending on settings.Where not set to auto-expand sub-assemblies ‘at all’ then an option is added to the above list to build the assembly in a ‘nested’ process. Alternatively, if auto-expand options are defined then the system will automatically build the assembly either for the shortfall or for the full quantity required.

Where a sub-assembly is automatically built the build is processed automatically except where there is any insufficient stock of its components and no default method of handling this shortfall is set. Up to ten levels of assembly can be processed in this manner.

Batch / Serial Tracked Stock Items

Where the assembled item or one of its components is a batch/serial tracked item then the system will pause to ask for the batches to be built and/or issued.

When issuing components the system offers the batches as per standard stock transactions – either selecting the batch details on a FIFO/sorted bases for confirmation or allowing you to key, scan or select via <F4-Select> the batch code to be issued.

When assembled stock items (or sub-assembly stock items) are batch tracked then the system prompts for the batches being built. This could be an auto-generated batch number prompted for confirmation or you can key or scan in the batch number being built.

After completing the assembly stock checks and confirmations you are asked if it is ‘OK to Build Assembly’. If you respond ‘Yes’ then the system updates the assembly build and then asks you to print the assembly details.If you respond ‘No’ then remember any sub-assemblies required would still have been built and the system, and if any where built the system asks you to print the build details for these items.

Stock File Updating

When the stock files are updating the following actions occur for each item on the assembly:

For Assembly Builds the physical stock level is increased by the quantity built

For Component Issues the physical stock level is reduced by the quantity issued

FIFO details are updated for the Assembly Builds

Cost Price, if set, is updated for the Assembly Build items

The period and year-to-date demand figures for the component stock items are increased by the quantity issued.

The period and year-to-date sales values for the component stock items are increased by the sales value of the issue (sales value equal to cost)

The period and year-to-date cost values for the component stock items are increased by the cost value of the issue

The last transaction date is updated for both assembly and component stock items

An assembly (type 9) transaction with a positive quantity is written for the assembly build items

An assembly transaction with a negative quantity is written for the component stock items.

When batch/serial stock items are built/issued the following actions occur for each item on the assembly:

The physical stock of the assembly serial/batch is increased by the quantity built

The physical stock of the component serial/batch is reduced by the quantity issued

An assembly (type 9) transaction with a positive quantity is written for the assembly items built

An assembly transaction with a negative quantity is written for batches issued