Assembled Sets Overview

• The Set header record must be coded Type AS for Assembled Set.
• The component item records may be coded any of the following Product Types:
  • PP - Purchased Products
  • WO - Work Order
  • AI - Assortment Item

Note: Component items in Assembled Sets may not be Serial or Lot controlled; there are issues recording the serial/lot numbers of components if shipped from pre-pack. Instead, define as an Inventory Model (Type MO), which always ship from components; Serial/Lot numbers will then be properly recorded for applicable components.

Use Model Maintenance (IM29/Assembled Sets folder) to identify the component products and how many are required of each component to build an Assembled Set.

In Enter Orders/Quotes (OE30), orders are entered against the Assembled Set product code. There is a double input field for the To Ship quantity whenever a Set product is entered. The "top" input field is for the quantity to be shipped from pre-pack; the field below is for the quantity to be shipped from components.

^{Example of an Assembled Set in OE30}

The B/O and To Ship boxes are automatically populated based on availability from the Set or from Components or a combination of both. Upon update of the Set detail line, the set components are automatically listed as order detail lines and if any of the shipment is being filled from components, then the To Ship quantity for the components is automatically set. If the order cannot be filled, either from pre-pack or from components, the backorder will be recorded against the Set order detail line. Note that you do not have access to the B/O and To Ship quantities for the component detail lines; they are assigned as a byproduct of whatever is entered in the To Ship boxes for the Set detail line.

An order comment line is automatically generated and printed on the picking slip directing the pickers to pick from pre-pack or components, as quantities dictate. The set components are printed on the picking slip but not on the customer invoice.

At invoicing time, the operator has an opportunity to confirm the Shipped from Pre-Pack and Shipped from Component quantities to ensure inventory will be updated properly.

Notes for Order Management:

Under Order Management, order quantities will be set as above in OE30 but the real allocation of the B/O and To Ship quantities happens when orders are allocated in OM30. The rules under Order Management are different in that you cannot easily direct the system to ship from in-stock components. First of all, components will only be considered for allocation if the Allocate from Components flag in CC00/OE Order Management/Parameters/General Folder is selected and there is insufficient quantity on Purchase Order or in Stock for the Set header.

Allocation for Assembled Sets starts with the Set header. If there is an incoming Purchase Order (or In-Transit) for the Set header, then sales orders will be allocated to On Time POs followed by In Stock and then Late POs until those quantities are exhausted and only then will OM30 try to allocate from components (even if the sales order is required before the PO receipt date). OM30 will only allocate from components if all components are available either from in Stock or from Purchase Orders. If any component cannot be allocated, the balance will be put on B/O against the Set header. Note that in this scenario, the components of the Set are not displayed in OM30.

• You cannot guarantee stock to the components of an Assembled Set.

• In CC00, if the Allocate from Components flag is not selected, then OM30 only ever allocates from the pre-pack (set header) level. If the flag is selected, then OM30 will try to allocate from pre-pack first and then components but it does not mean only ship from components.

Notes for Packing Station:

• For full details on Assembled Sets in Packing Station (PS30/Carton Detail), click here.

Stock Updates and Costing

The Selling Price is always extracted using the Set header product code but Cost is assigned and On Hand quantity is updated depending on whether the Set is shipped from pre-pack or from components. If shipped from pre-pack, sale of a Set will relieve inventory for the Set product record and Average Cost is picked up from the Set warehouse record. If shipped from components, sale of a Set will relieve inventory for the Component products and the cost assigned to the Set header order detail line will be calculated as the sum of the Average Cost of the components. The Inventory Movement record is written against the set or component product, depending on whether it was shipped from pre-pack or components.

If Sets are purchased pre-assembled, then the Set header will have an Average Cost as a by-product of the receiving process. However, if the components are received and then Sets are assembled/stocked internally, you may use Calculate Costs for Set Headers (IM62) to set the Average Cost of the Set header equal to the sum of the Average Cost of the components.

If an override cost is entered for the Set header on the order detail line, that is the cost used no matter if the order is shipped from pre-pack or from components.

Note: If a Set is transferred from one warehouse to another and it is shipped from components, then components will be received by the destination warehouse. If it is shipped from pre-pack, then quantity will be increased for the Set product at the destination warehouse.

Display Product Availability (IC45) displays inventory quantities for the Set header and also how many Sets could be made from components (display field 'Fr Comp'). IC45/Explosion folder lists the component products and their inventory quantities. If a Set header has been back ordered, you can use this folder to enter a Qty Required; the component quantities will be exploded and you can check which components need re-ordering.

Booked Units and Sales Statistics are always updated using the Set product code but are updated differently for components depending on whether the order was shipped from pre-pack or from components.

Notes:

• If a component is sold individually, booking/sales statistics are updated for the component product, as normal.

• The Sales, COS and Inventory GL control accounts are extracted using the GL Code from the Set header product record.