The “disassembly” process is the opposite of “assembly.” This requires a reverse bill of material. A conventional BOM’s components are “inputs” that are consumed during the course of the job. With a disassembly BOM the components are “outputs” that are received to stock during the course of the job.
Bill of Manufacturing
A disassembly BOM, like any BOM, requires a parent item, which is considered the “primary” output. All other outputs are considered “secondary” outputs.
The most significant output should be the BOM parent
The output item you consider to be the most significant should be designated as the primary output and is used as the BOM parent item. Therefore, the primary output item must be set up as an M item.
The routing is confined to disassembly labor
The routing should be confined to the steps that are involved in the disassembly process.
The used core version is the primary component
The primary BOM component in a disassembly BOM is the used core version of the item. Make sure that the used core version has a different item ID than the standard version of the item. Typically, a suffix is appended to the standard item ID, such as an ‘X’ or ‘-X’, etc. to distinguish the used version from the standard version. You may wish to give the used version its own Item Category for separate tracking on reports.
Disassembled parts are outputs
The used parts that are disassembled from the core component are set up on the Outputs tab. Each output is given a percentage of the total job cost in the Cost Ratio field. The total job cost is a combination of the disassembly labor involved as well as the cost of the core component.
Use caution when defining standard items as outputs
You can add standard purchased items and manufactured items as secondary outputs. These are items that you can also purchase directly or manufacture. You can assign an appropriate Cost Ratio for each respective output. This may take some experimentation to get an estimated cost that approximates the Item Est Cost. Be aware that MRP will not generate Jobs for secondary output demand. MRP will only create Jobs based on demand for the primary output item.
Disassembly jobs are created manually
Unlike standard manufacturing jobs, which are generated by MRP in response to actual demand, disassembly jobs are created manually in the Jobs screen as needed.
Disassembly jobs are less standardized
Technically, a disassembly job is the same as a standard manufacturing job in the sense that you will apply labor to the job and you will issue the used core component to the job from stock.
The job itself tends to be less standardized. You can start out the job with a set of pre-determined outputs and a routing, but during the course of the job you may find that some of the outputs are unusable, or unexpected outputs are discovered, or unanticipated labor processes are required. You can freely modify job details as needed during the course of the job.
Job processing steps are the same
The actual job processing steps – creating the job, modifying job details, issuing the core component from stock, reporting labor – is the same with disassembly jobs as it is with regular manufacturing jobs.
Job receipts involve multiple outputs
A key difference between a disassembly job and a standard manufacturing job is that the disassembly job involves multiple outputs instead of a single output. When you process job receipts in the Job Receipts screen, you are presented with numerous output lines. As you process each line, its cost is determined by its Cost Ratio, which is its percentage share of the overall job cost.
