SyteLine alternate routing and alternate BOM: a worked example
syteline alternate routing example
Also searched as
- SyteLine alternate BOM
- SyteLine alternate routing setup
- SyteLine job order which routing is used
Short answer
An alternate routing or BOM is a second valid way to make the same item, for example a different machine or a substitute component set. You maintain it as a separate version tied to the item, and the job order picks the version you specify or the default. Planning generally uses the default unless your setup directs otherwise, so verify what MRP actually assumes. Field names vary by release.
Applies to: SyteLine 9.x and CloudSuite Industrial 10.x discrete manufacturing
Set up and use an alternate
- 1Decide what differs: operations and work centers (routing), components (BOM), or both. Keep the item number the same.
- 2Create the alternate in the routing and BOM maintenance for the item with a distinct alternate identifier.
- 3Enter operations, work centers, run times and setup times that reflect the alternate process.
- 4For a BOM alternate, enter the substitute components with quantities and scrap.
- 5Cost-roll the item so you can compare standard cost of default and alternate.
- 6When creating a job order, specify the alternate you want; otherwise the default version is copied.
- 7Run MRP on a test item and check which version the planned orders reflect.
- 8Document when planners should choose the alternate (capacity overload, material shortage).
Worked example
Item PUMP-HOUSING is normally machined on a 3-axis mill (operation 10, 45 minutes run) then deburred (operation 20). When the mill is down, the shop uses a 5-axis machine at 30 minutes run with a longer setup, skipping a separate deburr. These are two routings for the same item: default and alternate.
In the alternate, work center, run time and setup differ, so labor and machine cost differ. The BOM is identical, so no BOM alternate is needed. If the alternate used a different casting supplier part, you would also create an alternate BOM.
Item: PUMP-HOUSING Default routing : OP10 MILL3AX setup 0.5h run 0.75h/ea ; OP20 DEBURR run 0.1h/ea Alternate routing: OP10 MILL5AX setup 1.0h run 0.50h/ea
How job orders and planning choose
When you create a job, you choose which routing and BOM version it copies. Once created, the job has its own copy, so later changes to the item routing do not alter it. Check the job's routing before release, especially if the alternate was chosen for a one-off reason.
Planning engines typically plan against the default version. If you want planned orders to reflect the alternate, make it the default for that period, or let the planner change the job at firming. Test with MRP so you know what your setup does rather than assuming.
Cost, capacity and governance
Alternates change cost and capacity loading. Run cost roll for both, decide how variance will be reported, and make sure the shop floor reports against the right work centers. Limit who can create alternates, since each is a controlled engineering document in regulated industries.
Retire alternates that are no longer used. Dead alternates confuse planners and clutter job creation.
Try it here, free
Component Cross Reference and Alternate Part Approval Worksheet
Track alternate and second source parts, their approval status and the saving each could bring. Editable rows, exports to Excel.
Common pitfalls
- !Assuming MRP automatically selects the cheapest or available alternate.
- !Editing the item routing and expecting open jobs to change.
- !Forgetting to cost-roll the alternate.
- !Leaving unused alternates active.
- !Creating an alternate without engineering approval in a regulated environment.
How an ERP-grounded AI assistant handles this
An assistant grounded in your SyteLine routings can list items with alternates, compare their cost and load, and show which open jobs use which version, with the query visible. For capacity overloads it can suggest which jobs could move to an alternate. The actual change is made and approved by your planners.
Frequently asked questions
What is an alternate routing in SyteLine?
A second routing version for the same item, typically a different work center or process. A job order can copy it instead of the default, which changes labor, machine time and cost.
Does MRP choose an alternate BOM automatically?
Generally planning uses the default version. Do not assume otherwise. Test your configuration, and if you need the alternate planned, switch the default or change the job when firming.
If I change the routing, do open jobs change?
No. A job holds its own copy created at job creation. Change the open jobs separately if needed.
When should I use an alternate BOM instead of a new item?
Use an alternate when the finished item is the same form, fit and function and only the components differ. If the output differs, create a new item or revision.
Related
How to Maintain the BOM and Routing in SyteLine
In SyteLine the manufacturing structure for an item is a standard (type S) job: its material lines are the BOM and its operation lines are the routing. You maintain it from the item's BOM and routing forms, set effectivity dates, then let new job orders pull a copy. Existing jobs do not update automatically, which is where most confusion comes from.
How-toHow to Run a Cost Rollup in SyteLine
Run Item Cost Rollup from Product Definition > Costing > Cost Rollup, select the site and item range, run it in Simulate mode first to review variances, then run it live to post new standard costs to Item records and the Costed Bill of Material.
How-toHow to Run MRP in SyteLine
MRP in SyteLine runs from Planning > MRP Processing as either a full Regenerative run or a Net Change run against demand from customer orders, forecasts, and safety stock; results appear as planned orders and Action Messages in the Planner Workbench.
How-toHow to Use the MRP Planner Workbench in SyteLine
After MRP or APS generates planned orders and exception messages, a planner reviews them item by item in the planner workbench, then firms, changes or releases them into job orders, purchase requisitions or transfer orders. The skill is reading the messages in the right order and releasing only what is real demand.
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Stuck on Infor SyteLine (CloudSuite Industrial)?
Talk to engineers who work inside Infor SyteLine (CloudSuite Industrial) every week, and who build private AI that answers these questions from your own ERP data.
Keep exploring
Free tools
- Component Cross Reference and Alternate Part Approval WorksheetTrack alternate and second source parts, their approval status and the saving each could bring. Editable rows, exports to Excel.
- Manufacturing Routing Sheet TemplateA routing sheet generator for operations, work centers, setup and run times, tooling and inspection points, with a worked sample you can overwrite.
- Routing Accuracy Audit TemplateA document template to audit ERP routings against the real process: sequence, work center, setup and run time, tooling and yield.
ERP fixes and how-tos
- How to Maintain the BOM and Routing in SyteLineHow to add components, operations and effectivity dates to a SyteLine bill of material and routing, and why edits do not reach jobs that already exist.
- Work order (job) item, status and routing tables in SyteLineWhere SyteLine stores work orders (jobs), routings, operations and materials: job, jobroute, jobmatl, jobtran tables, status values and sample SQL queries.
- How to Run a Cost Rollup in SyteLineRun a SyteLine standard cost rollup: use Simulate mode first, fix variance exceptions from missing routings or zero-cost items, then post new standard costs.
Runs with your ERP
- CADTALK ERP Integration with Infor SyteLine (CSI)How CADTALK turns engineering BOMs from CAD, PDM or PLM into manufacturing BOMs, items and routings in Infor SyteLine. Setup, pitfalls, alternatives, FAQ.
- Infor CPQ and Infor VISUAL (also CloudSuite Industrial): configure, price, quoteHow Infor CPQ is described as integrating with Infor VISUAL and SyteLine, how configurations drive BOMs and routings, with setup steps, pitfalls and AI ideas.
- Infor CADLink with Infor SyteLine: Items and BOMs from CADInfor CADLink lets designers create and edit SyteLine items and BOMs from inside CAD or PDM. Data flows, setup, common pitfalls, alternatives and FAQ.
Guides
- How to Set Up Routings in Infor SyteLineStep-by-step guide to setting up routings in Infor SyteLine. Define operation sequences, run times, setup times, and work center assignments for manufacturing jobs.
- SyteLine Routing Setup and Configuration Best PracticesConfigure SyteLine routings. Operation sequences, setup/run times, work center assignment, and routing optimization for production scheduling accuracy.
- AI-Powered BOM Optimization for Infor SyteLineOptimize SyteLine Bill of Materials with AI. Automated BOM validation, cost rollups, and engineering change management for Infor CloudSuite Industrial.
AI on your ERP
- AI for Engineering Change Impact on BOMs, Routings, and Open OrdersAI reads a proposed ECO against live BOM, routing, and open order data to show engineering exactly what a change touches before it gets released.
- AI on Infor SyteLine for Metal Fabricators: Quotes, Heat Lots, Routings and Job CostAI on Infor SyteLine for metal fabricators: quote and routing history, remnant and heat-lot traceability, outside processing, and job costing, kept private.