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Expandable Alerts users can find answers to frequently asked support questions by accessing the KnowledgeSync knowledgebase. Vineyardsoft has compiled the searchable knowledgebase from support calls.
Vineyardsoft is the developer of KnowledgeSync, the software engine behind Expandable Alerts.
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| Consultant's Corner |
by Bill Cowley |
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In this issue, I would like to share my notes from a well-attended local user group meeting covering an active group discussion on “Obsolete Parts and Where Used Analysis”.
On Wednesday, November 11, the IEUGA San Diego-Local Edition met at Quantum Design for our bi-monthly soiree. Everyone greeted as we selected lunch.
After brief introductions and announcements, we warmed up the discussion with a pre-Thanksgiving discussion of “Excess & Obsolete Holiday Leftovers.” On the white board we noted our excess issues: Turkey, stuffing, potatoes, green bean casserole, cranberry sauce, rolls, salad and pie. We listed our objectives/problems: Can’t eat it fast enough before it spoils, no room to store it, and some was just lousy to begin with. Together we generated the following solutions: Make it into lunches, stash it in the freezer, give it away as door prizes to our guests and, of course, throw away the cranberry sauce (Disclaimer: that was my suggestion because who really likes the slimy stuff?). After the warm-up our group was ready to jump into the real topic.
Chuck Boe, Teledyne API, and Greg Johnson, SKF, provided the objectives for our discussion. I have paraphrased their input: |
- How are obsolete and replacement parts easily identified (concern is spares and repairs)?
- How are new replacement part numbers conveyed to customers?
- How to deal with a replacement part number that is not backward compatible?
- When processing ECOs, a significant amount of time is spent identifying the unique BOM components that can be downgraded along with the "Parent" model number/part number. For every part number, you must drill down through all levels of the BOMs and search the "where used" …, then check stock status, open purchase orders and open sales orders. Then determine the material value for all items being scrapped and add that to the ECO.
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| Our solutions were varied and each solved a particular problem. |
| For part identification, one company creates a Spares Bill of Material for each new product. It contains the assemblies and components used for support of the product, which assures repairs are considered in “Where Used” analysis. It also provides a simple method to phase out an old replacement with a new one independent of the product in production. Other suggestions were to apply User Fields and Part Status to identify Replacement levels and timeframes. For example, note “Spares Only” in a user field or use the “Inactive” Status to mean not active in production but still used by support. |
| For replacement part numbers, someone suggested creating a Part ID for the “Model Number” for the customer catalogs. This number would never change. The customer can order the same part and the Bill of Material lists the current production assembly / component used. Another suggested using the Customer Part Number Editor to create a Model cross reference to the production assembly/component number. The Customer Part Number is the “Model Number” and is tied to the current production part. A third suggested using Configuration Control to create a new “Spares” model linked to the actual Option spares Part ID. |
| For non-backward compatible replacement parts, the discussion centered on Bill of Material effectivity and Revision control. When absolute Revision control is required, it should be an element of the Part ID. Rules must be established for Part Revision and Bill of Materials changes. Revision/ECO history can be noted with a BOM component “REV”. The reference field can be used to indicate the ECO that Started or Ended the component. |
The downgrading ECO process took interesting directions. After a dummy MRP run with exaggerated demands for production and spares/repairs, the Forecasted Usage field (in the parts master) will identify obsolete parts with no forecast. QBE for Active parts with zero forecast use will show what statuses can be changed.
It was also noted in 8.1.3 you can run the Indented Where Used report for Top Assemblies Only.
Another approach used SQL scripts to change component statuses to match the parent’s status. NOTE: Try this approach in the DEMO or TEST database. Do not run scripts on the live database without testing first. To use this approach, first select the Obsolete parts and then change all Bill of Materials component statuses to Obsolete. Repeat until the lowest level is updated. Then select Inactive parts and change all BOM components to Inactive. Repeat this until the lowest level is updated. Next select Prerelease parts and change all BOM components to Prerelease. Repeat this until the lowest level is updated. And lastly, select Active parts and change all BOM components to Active. Repeat this until the lowest level is updated. Your parts will now reflect the status based on the parent status. If a part is marked Obsolete, no assembly above will be Inactive, Prerelease or Active. |
The session then moved to Excess Inventory. Many participants used a custom report to calculate excess based on either historical usage or forecasted requirements. With future support and supply uncertain, it seemed common to use Inventory Reserves for the value of Excess & Obsolete without scrapping the material. However, it was noted that Reserves do not share the same tax advantage as scrapping the parts.
With no further questions or suggestion, the work session ended. Everyone broke into smaller discussion & networking groups. Also noted was a run on the cookies.
Many thanks to Quantum Design for hosting the event and to InnerCool for providing lunch. The group will meet again on February 13th at the Pacira Pharmaceuticals facility. |
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