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Assembled Sets
Packing Station is able to accommodate Sales Orders containing Assembled Sets. When processing Sales Orders with 'AS' as the product type, a modified set of rules apply during Packing Entry (PS30).
Here are 3 examples illustrating how Assembled Sets (Prepack and Component) are entered in PS30:
- Assembled Sets - Prepack only on the Sales Order (P:5 C:0):
- The Packer scans or enters the Set Header record into the Item Entry field on the Carton Details folder.
- When the Quantity Entry Method is Prompt, both the Pack Qty and the Pack Qty Components fields open up. Enter a pack quantity of 5 in the Pack Qty field.
- In this example, entering a quantity in the Pack Qty Components field results in the following message: "The Sales Order xx, Line xx contains a product which is a set where the quantity to ship from Open Stock is 0. Over packing this product at the component level is not permitted."
- When the Quantity Entry Method is Auto, the list box automatically updates with a quantity of one and the cursor returns to the Item Entry field. Following the example, the Packer scans or enters the Set Header record 5 times. Each scan/entry automatically updates the line in the list box until the Pack Qty equals 5.
- The Review folder displays the Set Header record with a Pack Qty of 5 (when the 'Issues Only' checkbox is not selected). The component items are not listed on the Review folder. This is correct and the Pack can be closed.
- The Packer scans or enters the Set Header record into the Item Entry field on the Carton Details folder.
- Assembled Sets - both Prepack and Components on the Sales Order (P:4 C:2):
a) Packing the Set Header record only:
- The Packer scans or enters the Set Header record into the Item Entry field on the Carton Details folder.
- When the Quantity Entry Method is Prompt, both the Pack Qty and the Pack Qty Components fields open up. The Packer has two options:
- Following the example, we have 4 Assembled Sets from Prepack and 2 Assembled Sets from Components. Enter a pack quantity of 4 into the Pack Qty field and a component quantity of 2 in the Pack Qty Components field.
When the 'Issues Only' checkbox is not selected, the Review folder displays the Set Header record with a Pack Qty of 6, and the component items are listed with a Pack Qty of 0. This is correct and there are no Issues associated with the packing of the Assembled Sets on the Review folder. The Pack can be closed.
- Enter a pack quantity of 6 into the Pack Qty field.
The Review folder displays the Set Header record with a Pack Qty of 6 (when the 'Issues Only' checkbox is not selected), and the component items are listed with a Pack Qty of 0 AND an Issue "Short Ship. Not Packed". Because the Set Header record contains the correct Pack Qty, the Pack can be closed regardless of the Issues.
- Following the example, we have 4 Assembled Sets from Prepack and 2 Assembled Sets from Components. Enter a pack quantity of 4 into the Pack Qty field and a component quantity of 2 in the Pack Qty Components field.
- When the Quantity Entry Method is Auto, the list box automatically updates with a quantity of one and the cursor returns to the Item Entry field. Following the example, the Packer scans or enters the Set Header record 6 times. Each scan/entry automatically updates the line in the list box until the Pack Qty equals 4 and the Pack Qty Components
equals 2.
When the 'Issues Only' checkbox is not selected, the Review folder displays the the Set Header record with a Pack Qty of 6, and the component items are listed with a Pack Qty of 0. This is correct and there are no Issues associated with the packing of the Assembled Sets on the Review folder. The Pack can be closed.
b) Packing both the Set Header record and the Component Items:
- The Packer scans or enters the Set Header record into the Item Entry field on the Carton Details folder.
- When the Quantity Entry Method is Prompt, enter a Quantity of 4 in the Pack Qty field.
- When the Quantity Entry Method is Auto, the list box automatically updates with a quantity of one and the cursor returns to the Item Entry field. Following the example, the Packer scans/enters the Set Header record 4 times. Each scan/entry automatically updates the line in the list box until the Pack Qty equals 4.
- When the Quantity Entry Method is Prompt, enter a Quantity of 4 in the Pack Qty field.
- The Packer scans or enters the first Component item.
- When the Quantity Entry Method is Prompt, in the Pack Qty field enter the packed quantity (this should be the same as the Ship quantity from the Sales Order).
- When the Quantity Entry Method is Auto, the list box automatically updates with a quantity of one and the cursor returns to the Item Entry field. Following the example, the Packer scans/enters the Component item until the list box displays a Pack Qty equal to the Ship quantity on the Sales Order.
- Repeat this step (either method) until all of the Components are packed.
- When the Quantity Entry Method is Prompt, in the Pack Qty field enter the packed quantity (this should be the same as the Ship quantity from the Sales Order).
- When the 'Issues Only' checkbox is not selected, the Review folder displays the the Set Header record with a Pack Qty of 4, and the component items are listed with a Pack Qty equal to the Ship quantity on the Sales Order. This is correct and there are no Issues associated with the packing of the Assembled Sets on the Review folder. The Pack can be closed.
Note: The detail list box displays Component items with a '*' in the C (Component) field on the Carton Details folder and the Review folder.
- The Packer scans or enters the Set Header record into the Item Entry field on the Carton Details folder.
- Assembled Sets - Components only on the Sales Order (P:0 C:5):
- The Packer scans or enters the Assembled Set Component items into the Item Entry field on the Carton Details folder.
- Entering the Set Header record results in the following message: "Product XXX does not exist on the Sales Order with a shippable quantity or is fully packed. Do you wish to add it?". If the Packer adds the Set Header, it will be added as an 'A' (Additional) line.
- When the Quantity Entry Method is Prompt, only the Pack Qty field opens up. Enter a pack quantity of 5 in the Pack Qty field.
- When the Quantity Entry Method is Auto, the list box automatically updates with a quantity of one and the cursor returns to the Item Entry field. Following the example, the Packer scans or enters each of the Component items the required number of times.
- The Review folder displays the Set Header record with a Pack Qty of 0, and the Component items are listed with the appropriate Pack Qty. This is correct and there are no Issues associated with the packing of the Assembled Sets on the Review folder. The Pack can be closed.
- The Packer scans or enters the Assembled Set Component items into the Item Entry field on the Carton Details folder.
Rules that Apply when Packing Assembled Sets:
- You can over ship the Set Header record up to the Order Quantity on the Sales Order. For example, if the Ship Quantity on the Sales Order indicates 4 Assembled Sets from Prepack (P:4), and the Order Quantity is 6, you can over pack up to the Order Quantity of 6 on the same line. Any additional Set Header records packed will be added as 'A' (Additional) lines.
- Over shipping is not permitted on Components of Assembled Sets. The quantity packed cannot be greater than the Ship Qty from the Sales Order for the Set Header or the Component items. Entries greater than the Ship Qty will be rejected.
- Additional Assembled Sets can be added to the Packing Session as 'A' Lines, but only for the Set Header record.
- When entering the Set Header and Components as a single line in the Pack Qty and Pack Qty Components fields, the individual component items cannot be entered in PS30 as part of the Assembled Set.
- When a Sales Order contains Assembled Sets from Prepack only (P:4 C:0):
- Entering component lines for the Assembled Set results in the following message: "Product XXX does not exist on the Sales Order with a shippable quantity or is fully packed. Do you wish to add it?". If the component line is added, it is added as an 'A' line and not a Component item.
- Entering information in the Pack Qty Component field is not allowed. An FYI message advises that over packing the product at the component level is not permitted.
- The Review folder displays the Set Header record information only. The component items are not listed on the Review folder.
- Entering component lines for the Assembled Set results in the following message: "Product XXX does not exist on the Sales Order with a shippable quantity or is fully packed. Do you wish to add it?". If the component line is added, it is added as an 'A' line and not a Component item.
- When a Sales Order contains Assembled Sets from Components only (P:0 C:2):
- Entering Assembled Sets from Prepack results in the following message: "Product XXX does not exist on the Sales Order with a shippable quantity or is fully packed. Do you wish to add it?". If the Set Header is added, it appears as an 'A' (Additional) line.
- You can pack Back Orders for Assembled Sets from Prepack only. When packing a Back Order from a Sales Order with Assembled Sets from Components only, you can ship from the Prepack but a message displays warning you that you may be over packing if you continue.
- If a product is on a Sales Order several times, both as a Component of an Assembled Set and as an individual product, PS30 packs from the first time the product is found up to the Shippable Quantity; once the Shippable Quantities are packed, Back Orders are filled. If the product is scanned/entered once both the Shippable and Back Order quantities are filled, a new line is added (A line).
