The Smart Materials Site module stores reserved or issued material quantities for reservation jobs or issue reports against the BOM directly on the BOM tables. The basic philosophy behind this processing is that once the site workflow is reached, the design phase definitively has ended, and BOM modifications will most likely not occur any longer. However, the exceptional cases in which major design changes must be reflected in the BOM data occur (although reservations and issues have already been done against affected BOMs) and must be taken into account by OMI.
The actual business case for this scenario is one of the following events, if a reservation or issue has been made against BOM data in the highest issue status at a specific BOM node:
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Deletion of the BOM positions (either explicitly or by deletion of the complete BOM structure) is attempted.
If either reserved or issued quantity is stored on a BOM position, Smart Materials does not allow deletion any longer. Instead, the error message "MAR-20234: Position #1 at node #2 has reserved/issued qty on site, cannot delete" is raised.
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Import of a replacement position data set via OMI for this issue status is attempted.
This case is equivalent to the previous one. OMI rejects any position data for the same issue status if any existing position in that issue status has either a reserved or issued quantity.
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Import of position data with a higher issue status than the present highest one for the affected BOM node is attempted, where any position in the present highest issue status has either a reserved or issue quantity.
The position data set in the present highest IFC issue status keeps the site quantities. Forecasting/reservation and issuing is normally done using the Smart Materials Best Quantity algorithm, which only takes into account the highest IFC issue status (this issue status has Site Quantities) at a node. If a higher issue status is loaded, the next forecast/reservation/issue still uses the IFC issue status, as only the IFC status is visible in the Site module. However, engineering can work with the new highest engineering issue status in the meantime; the site quantities remain in the IFC status until the BOM check TSQ is used.
This last case is the one where OMI applies its Transfer Site Quantity logic, if the Transfer Site Qty check box has been checked. Otherwise, OMI simply imports this new highest issue status.
The TSQ logic is a 'Best Match' algorithm: for each affected position in the old highest issue status, OMI attempts to find a matching position in the new highest issue status. If one is found, the reserved and the issued quantities are moved to this position, and are set to zero on the old one. If no matching position can be found, an equivalent position with quantity 0 is created in the new highest issue status and site quantities are transferred in the same way.
The search for a matching position itself is performed in one of two possible ways:
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The first possibility only uses ident, unit, and parent position reference (that is, using the internal foreign key column parent_lp_id). It is in effect when no values have been defined for the ZX_BOM_UK1...ZX_BOM_UK4 parameters. If this check finds more than one matching position, it takes the one where the difference between the new position quantity and the old position issued quantity is smallest.
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The second possibility is in effect when at least one of up to four possible BOM position attributes have been defined as a logical BOM unique key using the ZX_BOM_UK1...ZX_BOM_UK4 parameters. This possibility basically performs the same comparison logic as the first possibility; however, this additionally makes sure to select a position where attribute values for specified attributes also match.
When exactly one match is found, the transfer logic described above is applied. All other cases cause a warning with type SITE_QTY to be logged by OMI. These warnings can be viewed in the second window (Import protocol) of the B.40.01 screen, or by printing the B.40.R.01 Import Protocol report.
Additionally, OMI checks whether importing a new highest issue status for a BOM node affects any unposted Material Issue Report or any open Reservation Run Result. If so, this situation is also logged with the relevant information about the MIR header and/or the Reservation job header.
If the Design Change Control option (ZI_OMI_DCC) is enabled, the following logic also takes place:
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OMI calculates the outstanding quantity for a BOM position. This quantity is just the difference between the new position quantity and the issued quantity, or 0 if the issued quantity is greater than the new position quantity.
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OMI logs reservation shortages to the C.50.01 BOM Design Change Log screen. A reservation shortage is found if the reserved quantity is smaller than the outstanding quantity.
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OMI logs over-reserved quantities to the C.50.01 BOM Design Change Log screen and cancels over-reserved quantities automatically. An over-reservation is found if the reserved quantity is greater than the outstanding quantity.
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OMI logs design change issue quantities to the C.50.01 BOM Design Change Log screen and reissues these quantities to the appropriate design change warehouse automatically. A design change issue quantity is just the difference between the new position quantity and the issued quantity if the issued quantity is greater than the new position quantity. The design change issue warehouse to which the DCI quantity is issued is the warehouse that is assigned to the original MIR subcontractor and has the Design Change Issue indicator checked on the C.10.02 Warehouses screen.
After the OMI job has finished, all such log entries are available for review on the C.50.01 BOM Design Change Log screen. Additionally, the C.50.R.01 report can be run to print the log information.
All design change log entries need to be acknowledged by the user. For each acknowledgment, a new Material and Design Maintenance Control number (MDM number) is generated by the software, and log entries are stored in context of that MDM number for later review.
The project default parameter ZI_OMI_DCA is provided to specify how OMI should handle old unacknowledged design change control log entries that it may eventually encounter during load of a new highest issue status position data set into a BOM node. This situation can happen if several OMI import jobs that import into the same BOM structure that has site quantities are being run one after another without reviewing and acknowledging C.50.01 data. Possible values for this parameter are:
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ERR: Raises an error and rejects the complete BOM node OMI input data if there are any unacknowledged log entries in C.50.01 for that node. This error implies that a new data set with a new highest issue status can only be loaded if all previous design change log entries have explicitly been acknowledged by the user on the C.50.01 screen.
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ACK: Have OMI automatically acknowledge the design change for the old highest issue status and keep the log entry.
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DEL: Have OMI ignore the unacknowledged design change for the old highest issue status, delete the log entry, and, eventually, create new log entries if appropriate for new imported quantities.