In the order explosion phase, Asprova generates operations from the target orders. The data in any existing operation records is left intact, with only information such as the production quantity being updated where necessary. However, if the order corresponding to the operation no longer exists or if the structure of the Integrated Master has changed, the invalidated operations will be deleted.
At the same time that the operations are generated, input instructions and output instructions are also generated. An input instruction specifies the item and its quantity to be input to the given operation and an output instruction specifies the item and its quantity to be output from that operation.
Operations, input instructions, and output instructions are basically generated according to the information in the master input instruction and the master output instruction as well as production quantities in orders.
Properties used for order explosion are "Production qty formula" and "Input qty formula" for the master input instruction and "Production qty formula" and "Output qty formula" for the master output instruction. In these four properties, the following expressions are set by default:
(Quantity of the output instruction / Yield of the master output instruction + Scrap quantity of the master output instruction) / Required quantity of master output instruction
(Production quantity * Required quantity of the master input instruction + Scrap quantity of the master input instruction) / Yield of the master input instruction
(Quantity of the input instruction * Yield of the master input instruction - Scrap quantity of the master input instruction) / Required quantity of the master input instruction
(Production quantity * Required quantity of the master output instruction - Scrap quantity of the master output instruction) * Yield of the master output instruction
If no quantity fixed level has been specified, explosion is performed from orders. In that case, above 1. and 2. will be used. If any quantity fixed level has been specified, orders may sometimes be exploded from the previous process to the next process. In that case, above 3. and 4. will be used.
By editing expressions, you can change the method of calculating quantities of operations, input instructions, and output instructions during order explosion. If the expressions are blank or incorrect, the default calculation methods as below are used ignoring the expressions.
Quantity of the input instruction = (Quantity of the operation * Required quantity of the input instruction + Scrap quantity of the input instruction) * (1 / Yield of the input instruction)
Quantity of the output instruction = (Quantity of the operation * Required quantity of the input instruction - Scrap quantity of the output instruction) * Yield of the output instruction
Usually, you specify input instructions and output instructions in the Integrated Master Editor. A basic example using the Integrated Master Editor and the order table is provided below. In the following example, there are four orders to produce two types of finished items.
|Item||Process number||Process code||Instruction type||Resource/Item||Production|
Since two processes, P12 (process number 10) and P11 (process number 20), are needed to make the product I11, order L1 will result in the generation of two operations. Each generated operation is automatically assigned a unique operation code. The operation code is made up of the order code and the process code connected with a colon (:), so in this case the two operation codes will be L1:20 and L1:10.
Now since three processes, P21 / P22 / P23, are needed to make product I21, order L3 will result in the generation of three operations. Note that since P21 is a merging process with two input items, it is represented by two input instructions in the Integrated Master Editor.
When orders L2 and L4 have been processed in the same way, we end up having a total of 10 operations generated.
At the same time that the orders are being exploded into operations, the item quantities are exploded as well. For example, since quantity of finished item needed for order L3 is 200, the output quantity of the final process L3:P21 will be 200. Output quantities for the other processes are then determined by successively multiplying the required quantities listed in the Integrated Master Editor by the output item quantity of the next process, resulting in quantities of 600 for L3:20 and 400 for L3:10.
For how to round quantities during order explosion, click here.
Orders for intermediate items
Normally, the item of an order is registered as a final item in the integrated master (in the far left column) and the master is used to explode the necessary processes as above, but it is also possible to have an order for which the item is an intermediate item.
For example, take the 3 processes below. Item A is the final item, and item A-20 is an intermediate item which is part of the process of making item A.
|Item||Process number||Process code||Instruction type||Item/resource|
|Order code||Item||Order quantity|
In the situation above, operations for these two orders would be generated like this:
|Operation code||Main output item||Production quantity|
A number of other steps are also carried out during the operation generation phase:
- Referring to master data settings, generates intermediate items if necessary. If intermediate items are auto-generated, creates master input instructions and master output instructions using the items.
- Calculates low level codes.
- Pegs instructions to purchase orders and inventory.
- Explodes and pegs orders for each low level code.
- Reflects results onto operations.
- If data is specified in the process properties field of an order record, this data is reflected onto the operation corresponding to that process in the order.
- Reestablishes links to next orders.
Auto-generation of intermediate items
As previous processing before order explosion, items, input instructions, and output instructions are auto-generated for master data for which input instructions and output instructions do not exist. Code of items to be auto-generated is determined according to the value specified for the "Auto-generated intermediate item code expression" property of the project. Input instructions and output instructions are added as having no value specified for the properties such as "Required quantity" and "Scrap quantity". In that case, values specified in the property definition will be used.
Changing process selectors and exploding orders
If you make changes to process selectors, the master data currently being referred to will change. Therefore, existing operations will be deleted during order explosion and operations will be recreated using the new master data. However, operations for which the process code is the same in the previous and new master data will not be deleted but used. Also, operations for which results data is specified will not be deleted.