Scenario


We often get requests on how to set up a disassembly job to break down a purchased item kit into multiple items.  These output items can also potentially be purchased individually.


Challenge


The BOM screen requires that you define a primary output for production.   In this case there are only secondary output items involved, and each of the component parts can also be purchased individually.  


Work Around


Create a special disassembly template BOM to be used to create a manual Job for disassembly of a purchased kitset into multiple individual Items outputs.  You will create a place holder parent Item ID, that will be receipted at zero cost and then you will inventory adjust the quantity to zero after you finish the Job.   The parent Item ID is a dummy placeholder for the manual process of disassembly.   


Create a Template Item and BOM for Manual Disassembly Jobs

  1. Create an M Item
  2. Create the M item header record with a standard BOM type
    1. No need to add any components or outputs to this placeholder BOM.  The details will be added to the manually created Job.



Create a Manual Job for your Disassembly Job

  1. Use your special disassembly BOM template to create a manual Job
  2. Optionally add a routing to capture labor if it is significant to the process.
    1. Use a Standard hour type with a time per completion (do not attempt to track actual hours)
  3. Add your kitset item as the Input for the Job.  This is the kitset you will be disassembling into your various output items.
  4. Add Outputs for all of your Items that you will be disassembling from your kitset.   It is ok for these items to be purchased individually as well.
    1. Add Cost Ratio percentages to all of your outputs.
    2. Note:  Since your will not be receiving an output for your place holder disassembly M item, you will not be able to enter a cost ratio of zero against the parent item.   TIP:  the total of all of the outputs must be 100%.  To trick the system enter a cost ratio of your final output that brings the total close to zero for the parent.  In the screenshot example, instead of 25%, and entry for 24.999999% was entered.   This will effectively set the cost ratio against the parent place holder item XXX-DIS to zero.



Optional Standard Hours Type Routing for the Disassembly



Manually add an input for your Kitset Item that you will be disassembling

  • This is an item that you should have already purchased.



Add Outputs for all of the Items that you will be disassembling from the Kitset

  • These items must already exist in the system most likely as P items.  In this example, for the final output cost ratio, we enter decimal places to effectively take the parent (XXX-DIS) cost ratio down to zero.





Process Job as normal

  1. Job Issue the Kitset Item to your Job
  2. If you have a standard routing defined, report your completion in Job Labor
  3. Perform Job receipts for all of the secondary items
    1. Receipt a Qty against each output and the system will suggest a unit cost based on the Cost Ratio and the total Job Est Cost.



Receive a Qty for each and every Secondary Output you pull from your kit item



The upper panel will look like this after you save all of your receipts.



Perform the Final Receipt of the Parent Item Placeholder at Zero Cost

  • Receipt your placeholder item at zero cost
  • This will Finish the Job
  • Immediately afterward, you will inventory adjust this place holder Item ID quantity to zero



Go to Inventory > Stock Adjustments and Reduce the Place Holder ID Quantity to zero

  • The placeholder Item ID should have a quantity on hand at zero value
  • Since the placeholder Item is not to be used, you need to adjust the inventory quantity out of the system.




Close the Job

  • Close the Job to complete the process