This is a sub window that is used in several windows to provide assembly details for a work order or part.

Parent windows

• Production Plan Maintenance
• Work Order Maintenance

The window has 4 tab panes

• Planning Values
• Current Quantities
• Kit Issue List
• Operations List

Planning Values

Stock UoM

Standard stock unit of measure. {PTMFILE.PTMSTUM char 6}

Lead time days

Lead times in active (buy or make) days. {PTMFILE.PTMLEAD number 0dpShortnum}

Lot size

Lot size when ordered. {PTMFILE.PTMLOT number 3dp}

Single location

Stores single or preferred location. {PTMFILE.PTMSLOC char 8}

Minimum order qty

Minimum re-order quantity. {PTMFILE.PTMREQT number 3dp}

Minimum level

Minimum stock level. {PTMFILE.PTMMINS number 3dp}

Bulk issue when kitting

Bulk issue flag. {PTMFILE.PTMBULK boolean}

Re-order level

Re-Order level. {PTMFILE.PTMROLE number 3dp}

Yield % rate

Yield percent (default 100.00). If system preference MCDYIEU set Yield unit loss (default 0.00). {PTMFILE.PTMYIEL number 2dpShortnum}

Part type

Part type (A,B,M,N,O,P). {PTMFILE.PTMTYPE char 1}

View Engineering Data button

Click to directly launch Engineering Data Maintenance for the selected part.

Current Quantities

Current quantities for the assembly. For details see the Parts Current Quantity subwindow.

Kit Issue List

Assembly bill of material. If viewed on the WO maintenance window it is the kit for the Work Order that will require issue. If the order is already kitted, it will show shortages only.

Operations List

List of operations for the Assembly or Work Order. If viewed on the WO maintenance window, this is regardless of any current work completion.

TIP: If you double click on an Outwork Operation when the window is used in the context of a current work order, you will drill down to either the current Purchase Order for the operation or the PO history listing, if the item has been received.

Compiled in Program Version 6.00.  Help date last modified on 9 July 2024.

Class wpartassysub (Assembly Details) last modified 25 May 2022 FP: Process > Work Order > Select a Work Order…

The post Parts: Assembly Details                  appeared first on Caliach.

When a Non-Backflushed Work Order is created, it has its non-bulk components allocated. Just before production the kit of components must be issued. During this process the allocations are removed, stock issued and placed in kitted work-in-process. Kits can also be returned, reversing this process. This window is used for both Issues and Returns. You gain access by operating the Process — Work Orders — Issue Kit or Items to WO or Return Kit Items from WO menu functions.

You will be first asked to select a Work Order in the Select Work Order window.

Kit Issue

The system will build a list of all components needed using the Bills of Material file. No Bulk issue or non-stock parts will be included and Phantom assemblies will be exploded. The list presented will show the required quantities for the entire order quantity. If an issue has already been made, only shortages will be shown. If nothing is listed, you can continue in any event to issue Extra Items.

A quantity in the Shortage column indicates that a Shortage will be recorded. If no WO Kitting Variance is set in File — System Manager — Company Details, any discrepancy from the kitted quantity required by the Bill of Materials will be recorded as a shortage. If you set a WO Kitting Variance, and then enter a kitted quantity unequal to the BoM Required quantity but within the Variance range, you will be given the option of recording a shortage or not.

This can be useful where minor variance in kits occur. However, care should be taken, particularly when the kit is returned. The system does not save the kitted bill with the Work Order. Whenever transactions take place, the current BoM is used to determine quantities. Hence, you will find that component parts Kitted in WIP quantities are for the full BoM quantity when shortages are not recorded. When a kit return takes place the system will not take account of variances and any variance on return must be accommodated by manual stock adjustments.

You must enter the quantities kitted for each listed item into the list before confirming the issue.

Clicking on the Issue this many button will automatically set the kitted values to the quantity appropriate to the assembly quantity entered, up to the Available Quantity. Individually enter the grid cell to change an issued quantity.

Any items where the kitted quantity is less than the required quantity will be automatically recorded as Shortage items, regardless of any current stock physical quantities. You will be warned that Shortages will be created at the time of confirmation of the issue.

NOTE: You should avoid using the Issue this many quantity as a way of part-processing an order. If you intend to do this, for example making an order for 12 in 3 batches of 4, either use backflushing or create 3 WOs. The Issue this many only works with a fresh WO. After the first time you issue to a WO, any balance kit is held as shortages, and by definition shortages are needed in full, so a second kit split using Issue this many will not work.

When satisfied with the data entered on the list, click on the Process button.

TIP: You can setup the optWOKitEngChange option in Settings Maintenance. If set to 1 or 2, users will be warned = 1 or prevented = 2 from issuing component parts which have the Engineering-in-Progress set. Operates in WO kitting and backflush and PO Outwork kitting.

Parts that are flagged as Multi-location or Tracked are indicated as such in the list. You will be presented automatically with the Location/Batch assignment dialog.

If component parts have been given the Allow auto-selection of location attribute, the system will attempt to pre-select the locations. It will also abide by the Draw from several locations attribute and follow the Assembly auto-selection preferred location prefix, if any, on the Work Order assembly part record. Any auto-selections will be shown, and you must confirm them before processing can be carried out.

After confirmation, the system makes all stock adjustments and creates inventory history records and shortage records. Only one kitting process is permitted for each Work Order. The processing alters the following files:

Work Order record kit issue date is date-stamped and cost elements of all components, including Bulk Issue items, are calculated, and added to the Work Order cost fields.

Component part records are adjusted to reflect the reduction in Physical quantity and Allocated to WOs and the increase in Kitted in WIP.

Stock location records, where relevant, are adjusted or deleted if the resultant quantity is zero.

Tracking records, where relevant, are created.

Stock History records are created if System Preferences are so set.

After the issue, additional parts needed for the Work Order must be issued as shortage items, if shortages, or as extra items. This is done using the same window and menu function.

Kit Return

The Kit Return feature is provided to enable the return of items of a kit issued to a Non-Backflushed Work Order. Care must be taken with this function. In normal Operation, it’s use should be restricted to the return of all balance kit items on the Work Order. This is useful in the event of a decision to cancel a Work Order after kit issue and partial or full abandonment of assembly production. The return of ALL balance items must precede the cancellation or amendment of a Work Order. Because at each stage of processing a Work Order, the current Bill of Materials is used, a return of the kit before changing the Bill of Materials is necessary to retain data integrity. After changing the Bill of Materials, the Work Order kit can be re-issued with the new part quantities. Processing of the return is similar to the kit issue.

After selection of an issued work order, the system will build a list of all components issued using the Bills of Material file and remove any items in the shortages file that are still awaiting issue.

If you use the Full Return button to populate the list with the full kit, the work order kit will be assumed fully returned and the kitted date blanked. If after clicking on the button you change some returned quantities, any balance of the component will be assumed to have been scrapped.

If you DO NOT use the Full Return button and populate the list manually, maybe for only some of an item, the work order kit will remain kitted. The quantity returned will then be added to the order shortages.

TIP: Use this technique when you want to remove parts from one job to use them elsewhere.

TIP: To Cancel or Remake a fully kitted Work Order you can click on the Full Return button and manually zero all the returned kit quantities in the list. This will cause all the kit to be scrapped and the WO will be marked as unkitted. In this condition you can Cancel or Delete the WO or simply re-kit and re-manufacture the balance due at the time of the full return.

File Path

Process > Work Orders > Issue Kit or Items to WO…

This file path takes you to the Work Order Kit and Item Issue window.

Work Order

Work order number. {WKOFILE.WKOWONO char 6}

Assembly

Part number (parent assembly). {WKOFILE.WKOPTNO char 18}

Description

Part description. {PTMFILE.PTMDESC char 30}

UoM

Standard stock unit of measure. {PTMFILE.PTMSTUM char 6}

Link icon

Click to view any linked external files. Hold the shift key down and click to create a new file link for the record.

Select WO button

To select a specific Work Order. It opens the Select Work Order window.

Latest start

Latest kitting and start date. {WKOFILE.WKOLATE date date1980}

Planned completion

Date of planned completion. {WKOFILE.WKOCDAT date date1980}

Balance due

Balance due still for completion. {WKOFILE.WKOBAL number 3dp}

Add Extra Part button

To use a part selection dialogue to add an extra item to the component list of issued work order. Alternatively, you can drag and drop from the Parts ScratchPad or BoM Listing. (This button is not visible when processing a kit return.)

Kit Components for Issue to WO-… grid

A list of component parts to issue or return. Sorting the list will reset all editable values to the default.

BoM Ref

Component reference within structure. {BOMFILE.BOMCREF char 4}

Part number

Component part number. {BOMFILE.BOMCPNO char 18}

UoM

Standard stock unit of measure. {PTMFILE.PTMSTUM char 6}

Required

The kit quantity required for issue or available for return.

Available

The available stock. Calculated from the current part physical less any other issues. With multiple entries of the same part, this will change depending on the sort order.

NOTE: The field is provided with emphasis for un-available stock lines and double-clicking on Available cells will drill down to show the Part Process Analysis List window.

Issued

The quantity being issued or returned.

Shortage

The quantity being issued or returned.

Comment

The inventory comment that will be used when recording the part movement.

Description

Part description. {PTMFILE.PTMDESC char 30}

Clear requirements

Ticking this box will clear the requirement for the listed item.

List kit changes

With this box checked, once processed, a printable alert message will open with a detailed list of all changes that have been made when issuing the kit to the works order. This list will only appear if a change has been made.

List kit changes

With this box checked, once you have issued the kit to the works order, the Received Work Order Assemblies from Production window automatically opens with the work order data already pre-loaded.

Issue this many button

To issue the parent quantity entered of items to the extent that the available permits. (This button is not visible when processing a kit return.)

Full Return button

To return all items in full. (This button is not visible when processing a kit issue.)

Process button

To process the Issue or Return

CUSTOM CAPABILITY: There is an oCustom1 method called $WoKitIssued available in OpenVision that is run when a kit issue takes place. It has two parameters pWoRow (row variable containing WKOFILE) and pIssueQty which is the quantity entered by the user for the issue.

Compiled in Program Version 5.10. Help data last modified 28 June 2022.

Class wWoKitIssue last modified 25 May 2022.

The post Work Orders: Work Order Kit and Item Issue appeared first on Caliach.

When the product of a Non-Backflushed Work Order is completed, this window is used to record the receipt into stock of the assembly. Receiving multiple Work Orders at the same time is possible. You gain access by operating the Process — Work Orders — Receive WO Assembly menu function.

You can individually select work orders with the Select Work Order button or all kitted Work Orders using the List All Work Orders. You process one or more receipts by entering the Quantity received and scrapped and, if required, a history comment.

TIP: You can also populate the WO grid by dragging and dropping work orders from the Work Order List window. To do this click on the Select Work Order button and then select a listing rule (bottom left) and click on Show Listing.

In the File — System Manager — Company Details you may have set a WO + Receiving variance limit. In which case the permissible total quantity may be more than the Quantity Ordered.

TIP: The Work Order Receiving Variance limit can be usefully used when you build a level of scrap into the Bill of Materials. If you then get a better-than-expected yield from the production process, you can record it correctly.

Any Work Orders which have components logged as Shortages will be shown with an appropriate icon. These orders can still be received but only up to the quantity that the shortage would permit. The system only calculates this based on the immediate Bill of Materials. If the shortage originated from a Phantom assembly, you will get a message when you attempt a receipt.

The lead time since kit issue is automatically calculated from the Make calendar. Any number of sub-batch receipts can take place from a Work Order until the accumulated quantity of both received and scrapped is equal to the original order quantity. At this point the Work Order is automatically deleted from the file.

With each receipt, work history records are produced; one for each Operation on the current Process Route. If history records have already been recorded in the Process — Shopfloor — Shopfloor Data function, only the balance of missing Operation receipt history records are created. History records are never created for Operations carried out in Outwork Work Centres as these are created during the receipt from a Purchase Order.

If you record a scrap quantity, you are expected to enter a Scrap Reason code. This is not mandatory, but you will be reminded if you forget. Scrap Reason codes must be pre-defined in the System Manager: Index Codes section.

Once you have entered all the receipts in the list, you can process them by clicking on the Process Receipts button.

For Multi-location or Tracked parts that are received, the Location/Batch Assignment dialogue will be presented which must be completed before you can proceed.

WARNING: In multi-user environments you should be sure that two or more users are not receiving the same Work Orders at the same time, otherwise errors may result.

NOTE: If you record a Scrapped Quantity, a Stock History movement record will be created of type W. This is not a real movement, it is simply a record of the quantity scrapped.

TIP: You can force the automatic creation of a Non-Conformance Report (NCR) when recording a scraped quantity using the system option optNCRAutoMovements. Set this option to contain the uppercase character W.

TIP: Normally Work History Operation Comments are not recorded. However, there is an option, optWOHistOpCom, that permits the recording of comments when work operation history is recorded. When the option is set to 1, the Work Operation History Comments window is made available for each Shopfloor or Log WO Performance entry. If set to 2, it additionally opens for Receive WO and Backflush WO. With this option set to 1 or 2 you can use the option optWOHistOpComText for default comment text.

File Path

Process > Work Orders > Receive WO Assembly…

This file path takes you to the Receive Work Order Assemblies from Production window.

Select Work Order button

To select several individual work orders to list for assembly receipt. It opens the Select Work Order window.

List All Work Orders button

To list all kitted non-backflushed work orders for assembly receipt.

Work Orders Selected and Available for Receipt field

A list of work orders. Enter a received quantity in the list.

Work Order Number

Work order number. {WKOFILE.WKOWONO char 6}

Assembly Part Number

Part number (parent assembly). {WKOFILE.WKOPTNO char 18}

UoM

Standard stock unit of measure. {PTMFILE.PTMSTUM char 6}

Balance

Balance due still for completion. {WKOFILE.WKOBAL number 3dp}

Permitted

The quantity of receipt permitted after accounting for unissued shortages and outwork operations.

Received

Quantity completed. {WOHFILE.WOHQTY number 3dp}

Scrapped

Assembly scrap quantity. {WOHFILE.WOHSCRA number 3dp}

Comment

The inventory comment that will be used when recording the assembly receipt.

Due Date

Date of planned completion. {WKOFILE.WKOCDAT date date1980}

Reference

User reference for WO. {WKOFILE.WKOUSER char 15}

Ordered

Quantity ordered. {WKOFILE.WKOOQTY number 3dp}

Description

Part description. {PTMFILE.PTMDESC char 30}

When the cursor is in a list line the fields below show for that work order:

Order Comments

Comments printed on header of WO. {WKOFILE.WKOCOMM char 2000}

Order date

Ordered date. {WKOFILE.WKOODAT date date1980}

Kit issue date

Kit issued date. {WKOFILE.WKOISDT date date1980}

Assembly preferred location

Stores single or preferred location. {PTMFILE.PTMSLOC char 8}

Latest start date

Latest kitting and start date. {WKOFILE.WKOLATE date date1980}

Planned completion

Date of planned completion. {WKOFILE.WKOCDAT date date1980}

Scrap reason code

Scrap reason code (relation: IDXID = con(‘7’,WOHSCRE). {WOHFILE.WOHSCRE char 4}

Scrap reason description

Index code, scrap reason or QA test description (must have at least 1 character). {IDXFILE.IDXDESC char 255}

Show button

To show a list of available codes from which to select.

Show Eng. button

Enables you to view Engineering data for a selected part, which may contain inspection instructions. It opens the View Engineering Data window.

Show Quality

Enables you to view the Quality Assurance Test Regime for a selected part. It opens the Part Quality Assurance Regime Maintenance window.

Receive Permitted on All Listed

Click this button to populate the Received column up to the permitted quantity less any scrapped you may have entered, for all listed WOs.

Process Receipts

Having entered all receipts onto the list, use this button to process all receipts in one operation.

Compiled in Program Version 6.00. Help data last modified 28 June 2022.

Class wWoAssyRecv last modified 25 May 2022

The post Work Orders: Receive Work Order Assemblies from Production appeared first on Caliach.

Work Order history records contain fields that can hold production performance data for each Operation on the Process Route. This data must be entered after the Work Order assembly has been received into stock or Operations have been recorded in the Shopfloor Data function. This Work Order Operational Performance window provides access to all Work Order history records. You must enter a Work Order number first in the Work History WO Selection window. A list of all history records for the selected Work Order is then presented.

If the Work Order has been received in more than one batch, multiple history records will be recorded and listed.

WARNING: Care must be taken to enter the correct combined setup time. Do not enter the actual setup time twice if only one setup took place for both receipt batches.

Select a record by clicking on the list line. Enter an Employee Code, if desired, and tab to enter the actual setup and run hours for the Operation. You can use HMSP syntax here (see below). The standards current in the process route Operation hours recorded at the time of the assembly receipt are provided for comparison. A percent variance to Process Route planned is provided.

If the history record has a scrap quantity, you are expected to enter a Scrap Reason code. This is not mandatory, but you will be reminded if you forget. Scrap Reason codes must be pre-defined in the File — System Manager — Index Codes section.

Once you have completed all operations for the work order use the Save Changes button to save your entries.

You can obtain a more comprehensive analysis of costs by clicking on the Update Part Costs button. The analysis is based on the average costs for all Operation receipts and the actual parts issued to the Work Order. This analysis is based on history and does not use the same processing as other Update cost analyses that uses the Bill of Materials and Process Route values. See the Part Costs Update window for details.

WARNING: Only undertake this cost analysis once the Work Order is fully completed. Otherwise, the costs will be very misleading.

TIP: You can use the optWOHistoryEditPlan option in Settings Maintenance at any level to permit the editing of planned hours. This is useful if you have route operations that are alternates. Typically, if this were the case one operation would have valid hours (the default) and the other would have zero hours set in the route (the alternative). When you use the alternative operation, you need to zero the work history planned hours otherwise these will contribute to the cost of the WO (this is because where no actual hours are set for an operation, the planned hours are costed).

TIP: Normally Work History Operation Comments are not recorded. However, there is an option, optWOHistOpCom, that permits the recording of comments when work operation history is recorded. When the option is set to 1, the Work Operation History Comments window is made available for each Shopfloor or Log WO Performance entry. If set to 2, it additionally opens for Receive WO and Backflush WO. With this option set to 1 or 2 you can use the option optWOHistOpComText for default comment text.

File Path

Process > Shopfloor > Log WO Performance…

This file path takes you to the Log Work Order Operational Performance window

Work Order

Work order number. {WOHFILE.WOHWONO char 6}

Select Work Order

To select a specific Work Order. It opens the Work History WO Selection window.

Part Number

Part number of assembly produced. {WOHFILE.WOHPTNO char 18}

Part Description

Part description. {PTMFILE.PTMDESC char 30}

UoM

Standard stock unit of measure. {PTMFILE.PTMSTUM char 6}

Link Icon

Click to view any linked external files. Hold the shift key down and click to create an new file link for the record.

Operation List

Lists operation records for all receipts of completed assemblies under this Work Order. Click on an operation line to select and enter actual results.

Batch quantity received

Quantity completed. {WOHFILE.WOHQTY number 3dp}

Batch quantity scrapped

Assembly scrap quantity. {WOHFILE.WOHSCRA number 3dp}

Total received from WO

The total assemblies received in all receipts.

Total scrapped from WO

The total assemblies scrapped in all receipts.

Work Centre Code

Work centre unique identifier code. {WKCFILE.WKCCODE char 4}

Work Centre Description

Description of work centre. {WKCFILE.WKCDESC char 30}

Employee code

Employee code. {WOHFILE.WOHEMPL char 4}

Employee name

Employee name. {EMPFILE.EMPNAME char 50}

Scrap reason code

Scrap reason code (relation: IDXID = con(‘7’,WOHSCRE). {WOHFILE.WOHSCRE char 4}

Scrap reason

Index code, scrap reason or QA test description (must have at least 1 character). {IDXFILE.IDXDESC char 255}

Scrap reason Popup List

List of available scrap codes. Double-click to assign.

Show button

Click to show a list of available scrap reason codes.

Operation setup hours – Actual

Setup time for operation batch in hours. {WOHFILE.WOHSTIM number 2dpShortnum}

You can use HMSP syntax here.

Operation setup hours – Planned

Standard operation Setup time (hours). {WOHFILE.WOHSTST number 2dpShortnum}.

You can use HMSP syntax here.

Operation setup hours -% Variance

Any variance between the actual setup time entered and the planned time in the process route.

Operational run hours – Actual

Runtime for operation batch in hours. {WOHFILE.WOHRTIM number 4dp}

You can use HMSP syntax here.

Operational run hours – Planned

Standard operation Runtime for ordered qty. {WOHFILE.WOHSTRT number 4dp}

You can use HMSP syntax here.

Operational run hours – % Variance

Any variance between the actual run time entered and the planned time in the process route.

Operational processing costs – Actual

The calculated costs for the batch operation based on the actual results recorded above.

Operational processing costs – Planned

The calculated batch operation costs for the Process Route operation times quantity of the batch.

Operational processing costs – % Variance

Any variance between the actual and planned costs of the batch operation.

Totals for Work Order

Setup hours

The total setup hours recorded against all operation completions.

Runtime hours

The total run hours recorded against all operation completions.

Planned cost

The unit parent operation cost as calculated from the Process Route.

Actual cost

The unit parent operation cost calculated from the actual times entered.

% Variance

Any variance between the actual recorded operational cost entered and the planned operational cost of the process route.

Update Part Costs button

To provide an analysis of costs based on the actual results of this Work Order. You can update part current costs, if desirable. It opens the Part Costs Update window.

Revert button

To revert any changes to the previously saved version.

Save button

To save the changes you have made to the data file.

Entering Time Values using HMSP Syntax

The system stores and uses times in decimal hours. 1.5000 hours rather than 1hr 30min. However, you can enter time in several different ways that will automatically convert to the equivalent decimal hours when you leave the field.

Compiled in Program Version 56.00. Help data last modified 27 Jun 2022.

.Class wWohPerform last modified 25 May 2022

The post Works History: Log Work Order Operational Performance appeared first on Caliach.

Backflushed orders have no components issued on the system in advance of manufacture. Only when a batch, or sub-batch, of the completed assembly is received into stock do you account for the parts you have used in the manufacture. At the time you create a Work Order you must identify it as a Backflushed Work Order.

This function is the single function in which you record the completion of production and the consumption of component parts.

You are first required to select the Work Order you are completing. You will then be presented with this Work Order Backflushing window in which you identify the quantity completed and scrapped and the parts used in the production of that quantity.

The system assumes you are completing the Work Order with this receipt. If you are not, or if there is a quantity of assembly scrapped, you must adjust the received and scrapped quantity.

You must now construct a list of parts that have been consumed in the production of the batch of the assembly. The system can help by building a Bill of Materials list for you, which may then be modified.

Having built a list of components, you are free to change the listed part quantities in the grid lines.

NOTE: Under certain circumstances, such as fluid or metal alloy mixing operations the quantity of end product is always the sum of the component quantities. To provide for this there is an option optWOQtySumUoM which should contain the Unit of Measure text that is appropriate for the components that need to be included in the sum quantity. This enables you to include mixed units in the BoM. For example: You are mixing chemicals by weight with the end product in KGS and the ingredients in KGS with an additional component of a container with a UoM of EACH. If you set the Control String to KGS (it is case-insensitive, seeing kgs, Kgs and KGS as the same), when the list of components is built and when you adjust component quantities the Completed Quantity will be adjusted to the sum of all components which have KGS as a UoM. Remember that the string and logic is case in-sensitive so a component with a UoM of Kgs or KGs will be included in the sum, however Kgs. will not because of the extra fullstop. If you want to record a scrap quantity, make sure you enter this value before building the component list. A blank optWOQtySumUoM prevents this total processing.

If you have made any changes to the kit issue list prepared by the system, you will have the choice to Print Variance Report. If checked, a list of all changes, both reductions and additions, will be printed.

TIP: You can setup the optWOKitEngChange option in Settings Maintenance. If set to 1 or 2, users will be warned = 1 or prevented = 2 from issuing component parts which have the Engineering-in-Progress set. Operates in WO kitting and backflush and PO Outwork kitting.

Parts that are flagged as Multi-location or Tracked are indicated as such in the list. You will be presented automatically with the Location/Batch assignment dialog.

If component parts have been given the Allow auto-selection of location attribute, the system will attempt to pre-select the locations. It will also abide by the Draw from several locations attribute and follow the Assembly auto-selection preferred location prefix, if any, on the Work Order assembly part record. Any auto-selections will be shown, and you must confirm them before processing can be carried out.

When Backflushed Work Orders are processed, the kit component issues are treated in the same way as the kit of a normal Work Order and the receipt of the assembly likewise. Work Order history is also created as in a normal Work Order.

If any part has been given the Draw from several locations attribute, you will be able to split the batch you are issuing between more than one source location. To do this, double click on the part line in the lower list. If the part’s attribute has been set, you will be presented with a window in which you can enter a quantity for the new split batch.

WARNING: You must take great care with Backflushed Work Orders that your inventory controls are precise. Remember that kitting after the use of parts means that production staff must be accurate in recording what they use, especially if any of the netting options are used. Netting looks at the current physical quantities of parts and sub-assemblies, whereas the use of parts took place at an earlier time when recorded and actual physical quantities may well have been different. In addition, you must recognize that using Backflushing means that computer recorded physical quantities will not accurately reflect part quantities as there is no way that the system knows when a part is built into an assembly. There is also no allocation of components, so Projected qualities will be misleading.

NOTE: If you record a Scrapped Quantity, a Stock History movement record will be created of type W. This is not a real movement, it is simply a record of the quantity scrapped.

TIP: You can force the automatic creation of a Non-Conformance Report (NCR) when recording a scraped quantity using the system option optNCRAutoMovements. Set this option to contain the uppercase character W.

TIP: Normally Work History Operation Comments are not recorded. However, there is an option, optWOHistOpCom, that permits the recording of comments when work operation history is recorded. When the option is set to 1, the Work Operation History Comments window is made available for each Shopfloor or Log WO Performance entry. If set to 2, it additionally opens for Receive WO and Backflush WO. With this option set to 1 or 2 you can use the option optWOHistOpComText for default comment text.

File Path

Process > Work Orders > Backflush WO…

This file path takes you to the Work Order Backflush window.

Work Order

Work order number. {WKOFILE.WKOWONO char 6}

Link Icon

Click to view any linked external files. Hold the shift key down and click to create a new file link for this record.

Select WO button

To select a specific Work Order. It opens the Select Work Order window.

Latest Start

Latest kitting and start date. {WKOFILE.WKOLATE date date1980}

Planned completion

Date of planned completion. {WKOFILE.WKOCDAT date date1980}

Assembly

Part number (parent assembly). {WKOFILE.WKOPTNO char 18}

Assembly description

Part description. {PTMFILE.PTMDESC char 30}

UoM

Standard stock unit of measure. {PTMFILE.PTMSTUM char 6}

Balance due

Balance due still for completion. {WKOFILE.WKOBAL number 3dp}

Completed now

The quantity of the assembly completed and put into inventory on this backflush occasion.

In the File — System Manager — Company Details you may have set a WO + Receiving variance limit. In which case the permissible total quantity (received + scrapped) may be more than the Quantity Ordered. When you want to receive a greater quantity than ordered you should hold the SHIFT key down when leaving the quantity entry field.

TIP: The Work Order Receiving Variance limit can be usefully used when you build a level of scrap into the Bill of Materials. If you then get a better-than-expected yield from the production process, you can record it correctly.

Scrapped now

The quantity of the assembly scrapped during production on this backflush occasion.

TIP: You can set the default scraped quantity to be the yield loss with the option optWOBackYieldScrap. When this is set to 1, during the backflush of a WO the system defaults any yield loss as scrapped so that the kit quantity accommodates yield. This is NOT suitable for MRP scheduled orders because MRP will schedule the yield into the WO quantity and therefore using this option will duplicate the yield losses.

Comment

The inventory comment that will be used when recording the assembly movement.

Scrap reason code

Scrap reason code (relation: IDXID = con(‘7’,WOHSCRE). {WOHFILE.WOHSCRE char 4}

Scrap reason description

Index code, scrap reason or QA test description (must have at least 1 character). {IDXFILE.IDXDESC char 255}

Show button

To show a list of available codes from which to select.

Backflush Options field

Single-level

Will yield a single-level kit similar to a normal WO.

Multi-level with automatic netting

Will yield a multi-level kit with each sub assembly automatically netted against available inventory. Only shortages will be blown through.

This is a constructed list starting with the single-level Bill of Materials. Any sub-assembly parent parts are examined for a negative net physical. Where such a condition exists the unavailable quantity of the sub-assembly is assumed to be obtained by manufacturing that shortage quantity of the sub-assembly. This can continue right down to the lowest level. In other words, sub-assemblies are only listed to the extent that they are available in inventory.

Multi-level with selective netting

Will initially yield a single level kit. You can then blow through sub-assemblies by double-clicking on them.

This is initially the same as the single-level list. After the system has prepared the single-level list, you should identify sub-assemblies that you have manufactured along with the main Work Order assembly. If netting is appropriate, there will be a negative Net physical quantity on the list. To blow through the sub-assembly, click on the Explode Parent button. You can always arrange for an alternative mixed quantity by changing the quantity and adding the sub-assembly as an extra item (see later) after the blow-through.

Multi-level with no netting

Will yield a full to-lowest-level kit with no consideration of current physical quantities.

This is a list of all lowest-level items in the fully exploded Bill of Materials. It assumes that no intermediate sub-assembly has been drawn from inventory and that all of them have been manufactured under this Work Order.

Include Bulk Issue items

Check this option to have Bulk Issue parts included in the kit list.

This can be used on any of the list building options. If checked, the normal practice of shopfloor control of bulk issue parts is ignored, and they are included as direct issues from inventory to the Work Order.

Component Issue Grid

A list of component parts to issue or return. Sorting the list will reset all editable values to the default.

Bom Reference

Component reference within structure. {BOMFILE.BOMCREF char 4}

Part Number

Component part number. {BOMFILE.BOMCPNO char 18}

UoM

Standard stock unit of measure. {PTMFILE.PTMSTUM char 6}

Normal

The kit quantity required for issue or available for return.

Available

The available stock. Calculated from the current part physical less any other issues. With multiple entries of the same part, this will change depending on the sort order.

NOTE: The field is provided with emphasis for un-available stock lines and double-clicking on Available cells will drill down to show the Part Process Analysis List window.

Issued

The quantity being issued or returned.

Variance

Any quantity that will be posted as a shortage or remain with the supplier.

Comment

The inventory comment that will be used when recording the part movement.

Description

Part description. {PTMFILE.PTMDESC char 30}

Build List

Having set up the quantities and options, click to build the kit list below.

Explode parent button

Having built the list with the selective netting option, use this button to explode the subassembly you have selected on the list.

Add Extra Part button

To use a part selection dialogue to add an extra item to the component list of issued work order. Alternatively, you can drag and drop from the Parts ScratchPad or BoM Listing.

TIP: You can setup the optWOCanAddParent option in Settings Maintenance. When set to 1 when you wish to permit the WO assembly part itself being added as an extra part to a Backflushed WO. This provides for partial re-processing.

Process WO Receipt button

Click to process the WO receipt and simultaneous kit issue.

Compiled in Program Version 6.00. Help date last modified on 23 June 2020

Class wWoBackflush last modified 25 May 2022

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Work Order Selection

Reference Contents > Work Orders > Work Order Selection

This subwindow is used to define the range criteria for a selection of work order records.

Parent Windows

Work Order Reports Selection
Work Order Available-to-Kit Options
Link System Maintenance
Graphical Analysis Maintenance – Graphs Tab

Operation

Enter data in the data entry boxes to restrict the range of records. Records must meet all criteria entered to be selected. If the left and/or right data entry boxes are left blank for a particular criteria, records will be selected between the first and/or last otherwise qualifying record. Data entry boxes can be populated by finding a single item using Keyword Search, drag and drop from the Parts ScratchPad or by double-clicking a list item from the Keyword Result window.

Data records can be obtained using one of the following methods or a combination of them (see Tip below):

1. Enter values into the selection ranges and use the Standard Search. The context menu provides a Clear Selection function.
2. Define or use a Custom Search.
3. Create an Ad Hoc Search Calculation using the context menu function.
4. Drag-and-drop one or more lines from the Parts ScratchPad (or BoM and Where-Used Listing) onto the general window area.
5. Use the ScratchPad Transfer Selected function
6. Use the KeyWord Search Transfer Selected function

TIP: Using an Ad Hoc Search Calculation (3) overrides any Custom Search (2) and a Custom Search overrides the Standard Search (1). In any of the search cases (1, 2 or 3), ScratchPad Transfer and Drag-and-Drop or KeyWord Search Transfer (4, 5 or 6) is combinational, so that records found using any of these methods must also conform to the search criteria adopted.

NOTE: This window contains fields introduced with version 5 that enable additional search (and sometimes sort controls), such as Adhoc extra where. For more help on their use and examples see the Client-Server SQL Introduction help.

Button	Action
Custom Search	Opens the Custom Search Selection window and checks the Use custom checkbox.

See also: –

Search Options Menu Work Order Reports Selection Work Order Available-to-Kit Options Parts ScratchPad Keyword Result

Compiled in Program Version 5.10. Help data last modified 3 Jan 2015 11:27:00.00. Class wWkoSelect last modified 10 Oct 2017 11:49:00.

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Work Order Available-to-Kit Options

Reference Contents > Work Orders > Work Order Available-to-Kit Options

This option window is opened when you select the Process — Work Order — Review WOs Available-to-Kit function. You can choose an alternative selection of work orders and choose other options for the available-to-kit analysis.

Button	Action
Cancel	Aborts the process currently in session. The keyboard equivalent is the Esc key for Windows computers and Command-.(full stop or period) for the Mac.
OK	The OK button updates the data you have entered, or confirms the selection and/or processes the function you have called.

See also: –

Work Order Available-to-Kit Analysis Work Order Selection

Compiled in Program Version 5.10. Help data last modified 15 Jul 2003 18:08:00.00. Class wWoAtkOpt last modified 16 Aug 2017 03:51:31.

Reference Contents > Work Orders > Work Order Available-to-Kit Options

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New Batches Created

Reference Contents > Work Orders > New Batches Created

This window opens after processing work order receipts when assemblies are batch tracked and new batches have been created.

It lists all tracked assemblies received in this session, showing the new batch numbers assigned. Double-click to drill-down to any Non-Conformance Reports.

CUSTOM CAPABILITY: You can use a clone of the rWoBatches report class to produce labels from this window.

See also: –

Receive Work Order Assemblies from Production

Compiled in Program Version 5.10. Help data last modified 24 Apr 2012 06:51:00.00. Class wWoBatches last modified 10 Oct 2017 11:49:00.

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Work Order Kitting List

Reference Contents > Work Orders > Work Order Kitting List

This window is opened by the Process — Work Order — Review WO Kit Stock Status menu function and shows a kit list of all Bill of Material components for a Work Order assembly selected in the Select Work Order window.

Button	Action
Select Work Order	To select a specific Work Order.
Print List	To print a report of the kit listing. Right-click to change the report destination.

See also: –

Select Work Order

Compiled in Program Version 5.10. Help data last modified 8 May 2012 06:21:00.00. Class wWoKitList last modified 23 Sep 2017 10:51:14.

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Work Order List

Reference Contents > Work Orders > Work Order List

This window lists a selection of Work Orders. It opens from the Select Work Order window after choosing from the selection options dropdown list. You can use the list to print a number of documents at the same time.

Button	Action
Print Selected	After making a selection of WOs on the list, you can print them all at one time.

Printing Documents

TIP: The Bill of Material structure comment texts can be used to hold instructions for the Stockman, such as material cutting instructions, handling warnings, pre-production preparation requirements, etc..

NOTE: The Do not consolidate common BoM components on kit lists System Preferences control can be set to prevent consolidation of common components in a BoM so that BoM References and Structure comment is fully printed on the kit list.

See also: –

Select Work Order

Compiled in Program Version 5.10. Help data last modified 17 May 2012 09:45:00.00. Class wWorkOList last modified 23 Sep 2017 10:51:14.

Reference Contents > Work Orders > Work Order List

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