Conversion parts lists

Conversion parts lists / disassemble parts

This topic describes how a part can be converted or dismantled (stripped).

• Conversion parts list (as a recurring process)
• Conversion parts list (as a one-off operation)
• Dismantle parts

Conversion parts list (as a recurring process)

In the case of certain, recurring, identical customer enquiries, it can make sense to produce small series of these requested parts and to keep them in stock.
If this part is then requested by the customer, it can be taken directly from the warehouse and dispatched.
If the customer's order differs only slightly from the stock-guided part, the stock-guided part can in some cases be converted to the desired part; e.g. the motor should have a higher power.

A further, additional conversion parts list can be created for each part.

This conversion parts list first contains the finished part which is to be converted. The next item on the parts list is then the part(s) that can be optionally replaced and marked with the check mark "Conversion part". By this you get a negative quantity in the list of the parts list items (only in the list view, the quantity remains positive!), see picture:

The new part can also be added to the master bill of materials, but can also be added later in the exploded production bill of materials.
Since the new part, which has already been entered in this example, has no fixed characteristic values (it is a variant part), the order attributes control which motor is actually to be installed instead of the 1.3KW motor.

In the customer order the pump is now pulled in and stamped with the desired motor power, namely 2.7kW:

On the technical release mask, the bill of material is now selected and exploded, but now the special bill of material PU_Umbau:

In the exploded parts list the part to be removed is now marked:

After creating the parts request (Gozintograph), the dispositions can be scheduled and checked for availability.
The so-called back putaway parts are not included in the time chain, but are always scheduled for the completion date of the production order, because only then it is ensured that this part will be available again.

If the part should or can no longer be stored after dismantling because it is broken or has gone missing during dismantling, the main disposition type on the part request position must be changed to "no disposition". The costs for this part are then debited to the cost object.

During further processing of the stock parts, this return stock is posted in the material requirement forecast of the engine. In contrast to all other parts requirement items, this return stock is not posted as a requirement but as a planned receipt:

The staging list now shows the stock withdrawals and the return stock placements for the specified order:

The withdrawals and putaways can then be created from these documents via the menu.

After the putaway is created, the part request item changes from the status "Returned to Stock" to the status "Putaway", the MRP process for this part is completed and it disappears from the MRP account. As a result of the putaway, the stock of the engine has increased by the quantity put back into storage.

Conversion parts list (as a one-off operation)

In contrast to the recurring conversion of small series, it can also occur more frequently that conversions have to be carried out once. In this case it is unfavourable to create a master bill of material for each of these operations. For this reason it can be useful to create an empty bill of material "CONVERSION", which can be selected as a special bill of material as described above. After exploding this BOM, the production BOM only consists of the BOM header, which is displayed in red because no sub-items have been exploded.

The next step is now to insert the part to be converted, which should be stocked. Then the part to be dismantled and the replacement part must be added. The part to be dismantled must be marked accordingly in the parts list item. So the steps that have been taken above in the master bill of materials are done directly in the production bill of materials. In this way, the special bill of materials can be used for any parts.

After the production parts list has been completely defined as a conversion parts list, you can continue with the disposition as described above.

Dismantle parts

In addition to the conversion of parts, the complete dismantling of parts may also be relevant. In this case a part is completely stripped down with the aim of storing and reusing the dismantled parts. This function is similar to a conversion parts list where no parts are installed. The dismantling of parts should always be done from an internal order.

The user issupported by ClassiX® when creating the dismantling parts list.For this purpose, a master bill of materials and a work plan with the number "DISASSAMBLY"must be createdonly once . From the technical release window, the disassembly parts list can then be created automatically. This parts list contains the part to be dismantled, which will later be marked as stock withdrawal in the parts planning and the parts to be dismantled. Decisive for the automatic insertion of the parts to be dismantled is the master parts list of the part to be dismantled.

After the dismantling parts list has been created, the parts planning can be carried out. The parts to be dismantled are defined here as for the conversion parts list as return storage. The parts which can no longer be used can also be set to "no disposition" here.