How to Disassemble an Item Kit for Material Usage Within IBM Maximo

In a previous blog we talked about the benefits of Configuring Item Kits in IBM Maximo in the Item application and how to assemble a Kit in the Inventory application. Kits are a great way to cut down on time needed to pull commonly paired items by grouping them together in a single bin. Kits also cut down on the number of items that need to be issued or requested on work orders. However, what happens when you only need one of the items that is part of a kit?

Let’s consider the following scenario in which a warehouse storeroom supports Fleet maintenance.

A pickup truck comes in for emergency maintenance and only needs a top-off of oil. When the warehouse clerk checks the bin for oil, they find no quarts of oil are in stock. There are 5 quarts of oil in another bin, but they are part of a kit. The clerk has a few options:

  • Issue an oil change kit to the work order even though only the oil is needed. This would cause the cost of the work order to include all parts of the kit and result in leftover items that are now unaccounted for.
  • Pull the quart of oil out of the kit and just don’t record any actions. This would mean the next time a kit is issued it will be missing the quart of oil, causing more questions and frustration down the line.
  • The kit is disassembled and only the quart of oil is issued to the work order. This is the most effective solution and prevents future discrepancies.

How to Disassemble a Kit in Maximo Inventory:

  1. Click into the Inventory application and open the item kit that needs to be disassembled.
  2. In the More Actions, menu click the Dissemble Kit
  3. Enter the appropriate value in the Disassemble Quantity field. This will indicate how many item kits will be Disassembled. Next, click OK. how-to-disassemble-item-kits-ibm-maximo-update-material-usage-work-order-inventory
  4. Now, the Current Balance of your kit decreased while the items that make up the kit increased in balance.

By disassembling the item kit, we have not only insured that the actual cost of the work order does not exceed the necessary cost of the work performed related to inventory, and the actual inventory usage remains accurate for future purchase requests given the items used on the work performed. This not only prevents having excess inventory but also allows the item kit to remain intact when it needs to be issued for later usage.

Watch The Video Below For A Step-By-Step:

Product Launch: Automated Label Printing from NinjaFix

The A3J Label Printing report solution includes a report and an automated process to print labels as items
and materials are received. The printer used by the storeroom is defined on the storeroom record. If only
a single printer is used across all storerooms, then the automation script may be adjusted to use a system

The goal of the automation is to proactively notify warehouse personnel when an item or material is
received through a printed label report. The label report should contain information about the received
item or material with bar-coded fields to enable scanning. The labels can automatically be fixed to parts
(materials) that are received.

The report that prints at the storeroom will have all the information that the warehouse operations staff
will need to fulfill the request. It will also have bar codes for key fields that will enable mobile applications
to quickly scan and perform inventory transactions against the reservation. A3J recommends pairing this
report solution with its own suite of mobile applications called MxMobile.

This solution includes a report built and tested to work with a Zebra printer. Specifically, a Zebra 410 and
520 portable printers but should work with any label printer that supports a 4.09”x2.00” format.

The report label is built to print the following fields:

• Item number (with barcode)
• Item description
• Purchase Order number (with barcode)
• Purchase Order line number
• Bin number if received into a bin
• Quantity at receipt (custom field included in solution)
• Work Order number (with barcode)

If either item number or work order number fields are blank the label rows will be blank saving space for
additional information. To purchase click here!

Configuring Item Kits in IBM Maximo

One of our favorite features in IBM Maximo is Item Kits. Over the years A3J Group has worked with hundreds of companies across several industries but have only come across a handful using Item Kits. Item Kits are exactly what they sound like – kits of preassembled items that are often requested together from warehouses.

Let’s consider the following scenario in which a warehouse storeroom supports Fleet maintenance.

When scheduled maintenance is due on a pickup truck, the technician comes into the warehouse with a work order and a list of items they need:

  • Oil
  • Oil Filter
  • Gloves
  • Rag
  • Air Filter

A warehouse clerk visits 5 different inventory bins in different areas across the warehouse to collect the necessary items, multiple times a day. Think of the time saving significance of an item kit named ‘Pickup Truck Oil Change’. That item kit would include: the oil, oil filter, rags and gloves. Suddenly a trip with 5 stops becomes a trip with 2 stops: 1 for the ‘Kit’ of always needed items and 1 for the air filter, which may or may not be needed for an oil change. Of course the make-up of these item kits is contingent on grouping items that are usually consumed concurrently.

How to create an Item Kit in Item Master…

  • From the Item Master application click the New Item icon. Update the Item ID if needed and provide a description. Ideally, the word “Kit” should be part of the description. This indicates to users that there will be multiple items when searching.
  • From the Item tab populate all other fields that are needed like the Commodity Group and Issue Unit. Did you take notice of a checkbox for Kit? An error will be displayed if this flag is set at this stage.
  • Save the record and navigate to the Item Assembly Structure tab.
  • In the Children section click the New Row button. Next, start adding the Items that will be part of the Kit. Include all items to the item kit that seem logical. Then, be sure to update the Quantity and Remarks fields if necessary.
  • Save the record and navigate back to the Item tab.
  • Check the Kit? Make sure your checkbox is error free.
  • The final step is to update to an active status and add the Kit to a Storeroom.

If your Kit Item Master is created and added to an inventory storeroom, then it is time to assemble the item kits. Navigate to the Inventory application to begin assembling the item kits you desire.

How to Assemble a Kit in Maximo Inventory:

  1. Click into the Inventory application and open the item kit that needs to be assembled.
  2. In the More Actions, menu click the Assemble Kit option.
  3. The Possible Quantity field contains total number of item kits that can be created. This is based on the availability of items in your inventory storeroom.
  4. Enter a value in the Assemble Quantity field. This will indicate how many item kits will be assembled. Next, click OK. The number entered must be less than or equal to the Possible Quantity value.
  5. Now, the Current Balance of your kit increased while the items that make up the kit decreased in balance.

Maximo Kits allow for measurable time savings in the Asset Maintenance Lifecyle: during the stocking of a single item kit for a Job Plan, reducing the research needed when planning a CM Work Order or lowering return trips to the storeroom. The small upfront investment of time to set up an Item Kit will pay off in big ways immediately.