Background: WIP Movement
Use the WIP Movement (WIPM) program to enter good pieces completed, scrap parent items, and scrap components for operation sequences on a manufacturing order. See Road Map for work flow.
This topic has these subtopics:
Backflush Operation Sequences
WIP Movement tracks the progress of a manufacturing order, which is especially useful when your manufacturing process involves many operation sequences and/or occurs over a period of time. This program shows the percent complete and hours remaining for each operation sequence.
You can have each department enter the quantity they complete and record
the quantity of scrapped parents or components. If this requires more
data entry time than you want, you can enter the data at significant points
in the process. WIP Movement backflushes the standard operation sequences
prior to the one you entered. Thus, if you enter all good pieces for sequence
3, WIP Movement records all good pieces for sequences 1 and 2 for you.
If you enter data for the last operation sequence, WIP Movement backflushes
all previous sequences for you.
Note
Entry of a negative quantity only impacts the entered operation. Component
picking adjustments must be made manually (with Material Usage Maintenance
- MUA) to "un-backflush" prior operations.
Caution
If you are reporting all operation sequences, be sure to report the completion
status of an operation before the items are moved to the subsequent operation.
For example, if you have sequence 10 and 20 on a routing and sequence
10 will run for 4 hours and not be reported until the operation is complete,
if someone takes away parts to work on operation 20, they must be reported
as completed on operation 10 before they are reported at operation 20.
Failure to do this will cause operation 10 to be over reported.
Alternatively, you can select the Mfg order receipt to backflush labor? option in the System Options Maintenance (XM) program (Manufacturing Options) and have the Receiver Maintenance (IRC) program backflush all completed operation sequences for you. If you selected the Inventory interfaced to GL? option in the System Options Maintenance (XM) program (Inventory Control Options), you need to run the Manufacturing Order Receipt Register (MRJ) to update operation sequences that Receiver Maintenance backflushed.
If you click Alternate and select an alternate operation sequence, you can enter good pieces and scrapped parents or components for that sequence. However, the program does not backflush previous sequences. Likewise your entry for a standard operation sequence will not affect any alternate operation sequence.
Backflush Components by Operation Sequence
You can tie component picking to pieces completed for an operation sequence.
System Picks When You Enter a Sequence
Select the Backflush components by operation seq? option for your manufacturing branch in the System Options Maintenance (XM) program (Manufacturing Options). Create the routing for the parent item. Then, in the Bill of Material Maintenance (MPS) program, enter the operation sequence number at which you want to pick the component in the Operation Seq no field. Create a manufacturing order and do not obligate. When you enter pieces completed for a sequence, the system obligates and picks the components required.
You do not have to tie every component on a bill of material to an operation sequence if you select the Backflush comps not attached to oper? option for your manufacturing branch in the Systems Maintenance Options program (Manufacturing Options). The system backflushes components that have a blank Operation seq no field when you enter data in the WIP Movement program for the first operation sequence.
Negative Quantities
If you enter a negative quantity for Good pieces, the system does not return the components to inventory.
Select Specific Lot or Serial Controlled Components
For a controlled component, you may want to select the specific lot or serial numbers. Select the Select ctrl no for oper seq backflush? option for your manufacturing branch in the System Options Maintenance (XM) program (Manufacturing Options). The system still selects the quantity required for the pieces completed. However, you can select a different lot or different serial numbers.
Pick from Specific Warehouse/Bin Location
If you select the Use only inventory in work center loc? option for your manufacturing branch in the Systems Maintenance Options program (Manufacturing Options), the system picks components from the warehouse and bin location you specify in work center's record in the Work Center Maintenance (WCM) program. If you leave this option blank, the system backflushes components from any available location.
Costs
The data you enter affects the labor cost of an operation sequence on a manufacturing order. You can record good pieces or scrap anytime before you run the Manufacturing Order Close (MJC) program.
Alternate Operation
If you entered an alternate operation for this parent item in the Routing Maintenance (RTM) program, you can add it to the list of operation sequences. Click Alternate and select an operation. Adding an operation with this program has no affect on standard labor cost. However, actual labor costs will be based on the new routing, which will result in a variance.
Purchased Service Operation
You cannot enter a quantity complete for a purchased service operation in WIP Movement. When you receive the PO complete with the Receiver Maintenance (IRC) program, or with the Receiving and Inspection (IRI) program if inspection is required or you are using dock-to-stock receiving, the program shows that the operation sequence has been completed.
Indirect Operation
You cannot enter a quantity complete for an indirect operation in WIP Movement. An indirect operation remains .00% complete even after you receive the manufacturing order into inventory.
Scrap Parents and Components
When you scrap a parent item, WIP Movement scraps all of its components. The system does not pick replacement components for the scrapped parent. You can do that with the Material Issues and Adjustments (IMI) program, selecting the WRK option to issue the components to the manufacturing order.
When you scrap one or more components, realize that you will not have enough components to complete the build of the original quantity. You will need to use the Material Issues and Adjustments (IMI) program to issue additional components to the manufacturing order.
Backflushing
Scrap is calculated for backflushed components based on the current scrap percentage set in the Bill of Material Maintenance (MPS) program or overridden in the Manufacturing Order Maintenance (MIM) program.
Reject Components
If you selected the Material review board active? option in the System Options Maintenance (XM) program (Purchasing Options), you can reject components during the manufacturing process. Click Comp scrap, select the component, and enter the quantity in the Reject quantity field. The program prompts you to select a reason for the rejection. You can enter or have the system assign an MRB tag number.
The rejected component can subsequently be selected in the Rejected Material Disposition (MRB) program when another employee determines whether it can be stocked as is or should be scrapped.
Closing an Operation
When the remaining pieces quantity is greater than zero, you can close out the operation sequence by entering 100.00 in the % complete field.
Audit Trail
To activate an audit trail, select one of the files listed below in the Audit Trail Maintenance (XAT) program. The system records all transactions. You can then run the Audit Trails (ATR) program and select that file to print a report of these transactions.
MP9: Mfg Order Components
WIPW: Work-in-process Work File