This chapter contains these topics:
Section 19.4, "Completing Partial Quantities on a Work Order"
Section 19.5, "Processing Work Orders through Super Backflush"
Section 19.6, "Processing a Work Order Using Quantity at Operation"
Section 19.7, "Completing a Work Order with Serialized Components"
When you finish production of a process on the shop floor, you need to record the completions to inventory in the system. The completion transactions that you enter in the Shop Floor Control system update the quantity records in the Inventory Management system.
You use the Super Backflush or Completion programs to record completions. Use these programs to perform one of two functions:
Report all co-products and by-products as complete after the entire work order is complete
Report partial completions as they occur throughout the production process
When you choose to report completions depends on the process, the co-products and by-products it produces, and your cycle time. Depending on the nature of the manufactured item, you can report partial completions or report total completions in one transaction. Reporting partial completions also can indicate the stage or progress that is being made on an order in production, and identify any delays in the production process.
When you use the Completions program to complete more than the quantity ordered, the system highlights the Completed Quantity field and warns you that completing the quantity you designated will generate an over completion.
You can set a tolerance level for over completions in processing options.
If a previous completion exists for a work order, the system displays information in the lot, grade or potency, and status fields. Also, if you enter a quantity, the system adds inventory to the lot at the grade or potency and the current status.
Topic | Description |
---|---|
Lot processing | If lot processing is used, the system assigns the lot number according to the rules set up for lot control. However, you can override this value on the Lot Date Override screen.
See Chapter 9, "Understand Lot Processing". If grade and potency is used, this data item displays and the standard from the Item Branch table. The standard can be overridden. |
Blending, filling, and packaging | When you complete a work order to a blending, holding, or storage tank, the system checks the tank capacity and displays an error if the completion would exceed the tank's capacity.
When you complete a work order with co-/by-products with lube oil blending, the system verifies the blending tank contains the correct product group. The system uses the completion location from the Work Center Master file (F30006). The system also displays the bulk information format specified in the ECS (Energy Chemical Systems) constants. When you complete inventory the system allows you to access the Dip Volume Calculator/Meter Readings program to enter readings. Work order completions allow you to enter ambient quantities and current temperature and/or density information. The system calculates and stores the standard quantity and weight accordingly. |
Warehouse Management system interface | If you process transactions for a branch/plant that uses warehouse control, the Location Detail window appears when you enter backflush transactions and a second location detail information record is created. In this case, you select Location Detail Information records for processing. To ensure that the quantities in the Location Detail Information table (F4602) are consistent, you should make a selection from the window.
The original quantity being processed through this transaction program, using the Location Detail window, displays in the top of the Super Backflush window. If the item being processed has a unit of measure structure or storage containers, the system enters them in the detail area of the Location Detail window. Although you can override these values, the system performs the following edits:
The system always displays this window when adding inventory to the branch/plant, except in the following case:
|
Quality Management test results | As you enter work order completions, including quantity completed and quantity scrapped, you can:
As you backflush labor and ingredients for a work order, you can:
See Working with Test Results in the JD Edwards World Quality Management Guide for more information. |
From Shop Floor Control (G31), choose Process Daily Order Reporting
From Daily Order Reporting - Process (G3114), choose Partial Completion
You can use the Completion program to record completed quantities for a work order, without backflushing the ingredients, in one of two ways:
Full completion allows you to complete all quantities for all products on a work order.
Partial completion allows you to complete parts of the quantity ordered for a work order.
The screen displays completed and scrapped quantities and percent complete information for a work order.
To complete work orders without backflushing
Complete the following fields:
Order Number
Quantity Complete
Quantity Scrapped
Date Complete
Status
Lot Status
Complete the following fields if you are completing to a location other than the primary location:
Location
Lot
The Co-/By-Products Completions screen appears.
Figure 19-2 Co/By-Product Completion screen
On Co/By Product Completions, complete the following fields:
Completed Quantity
Scrapped Quantity
Field | Explanation |
---|---|
Unit of Measure | A user defined code (system 00/type UM) that identifies the unit of measurement for an amount or quantity. For example, it can represent a barrel, box, cubic yard, gallon, an hour, and so on.
Form-specific information If you leave this field blank, the system uses the unit of measure from the Work Order Header table and updates the quantities in the Item Location table in primary units of measure. If this value is not the primary unit of measure, the system converts it to the primary unit of measure. |
Use the Completion with Backflush program to record full or partial completions while backflushing the ingredients. Running this program completes the quantity to stock.
You use backflushing to report the issue transactions for ingredients you use in a process after the co-products and by-products of the process are produced. Therefore, backflush issue transactions occur when you report partial or full completions of co-products and by-products on a work order.
You must identify the percentage of the ingredients that the system issues to a specific co-/by-product. If there are co-/by-products at the final operation, their resource percent must equal 100 for the system to issue all ingredients.
In the following example:
Cumulative cost = cost this operation + cost of previous operation - cost of the co-/by-product produced in the previous operation.
The total of all percentages at an operation cannot exceed 100%.
The total of all percentages at the last operation must equal 100%.
Operation | Co-/By- Product | % |
Cost This Operation | Cumulative Cost | Co-/By- Product Cost |
---|---|---|---|---|---|
10 | By 1 | 10 | 100.00 | 100.00 | 10.00 |
20 | Co 1 | 30 | 100.00 | 100.00 + (100.00 - 10.00) = 190 | 57.00 |
Co 2 | 20 | 38.00 | |||
30 | 100.00 | 100.00 + (190.00 - 95.00) = 195.00 | |||
40 | Co 1 | 60 | 100.00 | 100.00 + 195.00 = 295.00 | 177.00 |
Co 2 | 30 | 88.50 | |||
Co 3 | 10 | 29.50 |
Completing a work order through backflush consists of:
Setting the resource percent for the co- and by-products
Completing a work order
Releasing sales backorders during completions (optional)
Managing completions using receipts routing (optional)
Set the appropriate processing options to access the Inventory Issues program and to identify the version to use
Before you release backorders during completion, set processing options to enable the backordered sales orders to appear and to identify the version of the Backorder Release program to use
Before you can manage completions using Receipts Routing, set a processing option to initiate the receipt routing process
Set the appropriate processing options to issue ingredients for each co-product and by-product separately, and allow completion of unplanned co-products and by-products
To set the resource percent for the co- and by-products
From Product Data Management (G30), choose Daily PDM Process
From Daily PDM Process (G3012), choose Enter/Change Process
Choose Co/By-Product Revisions.
Figure 19-3 Process Resource Revisions screen
On Process Resource Revisions, access the detail area.
Figure 19-4 Process Resource Revisions screen
Complete the following optional field:
Resource Percent
Field | Explanation |
---|---|
Co/By-Product/Intermediate | Distinguishes standard components or ingredients from co-products, by-products and intermediates. Valid values are:
C – Co-products are (concurrent) end items as the result of a process. B – By-products are items that can be produced at any step of a process, but were not planned for. I – Intermediate products are items that are defined as a result of a step but are automatically consumed in the following step. Generally, intermediates are non-stock items and are only defined steps with a pay-point for reporting purposes. Blank Standard components (Discrete Manufacturing) or ingredients (Process) consumed during the production process. |
Output Qty | The quantity of finished units that you expect this bill of material or routing to produce. This field allows you to specify varying quantities of components based on the amount of finished goods produced. For example, 1 ounce of solvent is required per unit up to 100 units of finished product. However, if 200 units of finished product are produced, 2 ounces of solvent are required per finished unit. In this example, you would set up batch quantities for 100 and 200 units of finished product specifying the proper amount of solvent per unit.
Form-specific information This value specifies the quantity of each co-/by-product that the process produces. If you use batch bills, this is the quantity that the batch produces. |
Feat Cost % | A percentage used by the Simulate Cost Rollup program to calculate the cost of a feature or option item as a percentage of the total cost of the parent.
Enter the percentage as a whole number: 5% as 5.0 Form-specific information This value is used in Cost Rollup to calculate what percent of the cost, up to and including the operation, that the co-/by-product comes out of, is apportioned to the co-/by-products at that step. The total of all percentages at an operation cannot exceed 100%. The total of all percentages at the last operation must equal 100%. |
Resource % | If this option is chosen, this value indicates what percent of the ingredients should be issued separately to co-products and by-products.
Form-specific information This is used to issue ingredients separately to co-/by-products at work order completion, rather than a total issue for each ingredient. For co-/by-products at the final operation, their resource percent must equal 100 to issue all ingredients. |
From Shop Floor Management (G31), choose Daily Order Reporting under Process
From Daily Order Reporting - Process (G3114), choose Completion with Backflush
Figure 19-5 Completion with Backflush screen
Complete the following fields:
Order Number
Quantity Complete
Quantity Scrapped
Date Complete
Status
Lot Status
Complete the following fields if you are completing to a location other than the primary location:
Location
Lot
Press Enter.
The Co-/By-Products Completions screen appears.
Figure 19-6 Co/By-Product Completion screen
Caution:
The system displays a warning message when if you try to exit the program prior to completing all the steps required for full BackflushOn Co/By-Product Completions, make any necessary changes in the following fields:
Completed Quantity
Scrapped Quantity
Figure 19-7 Co/By-Product Completion screen, Detail area
Review and make changes to the following field, as needed:
Resource Percent
Note:
The resource percent is the percentage of the ingredients to be issued to the co-/by-product you identified on the Process Resource Revisions screen.If you are using lot processing, the system assigns the lot number according to the rules set up for lot control. If you are using grade or potency, the system displays the data item using the standard from the branch/plant. However, you can override this value on the Lot Date Override screen (F15). After you enter the appropriate changes, the system re-displays them for you.
Press Enter. The Work Order Inventory Issues screen appears.
Note:
After you accept the record, the system updates the on-hand inventory for the co-/byproducts. The Inventory Issues screen appears, for each co-/by-product, to issue the ingredients separately to each co-/by-product, if you set the processing option on the Completions program.Figure 19-8 Work Order Inventory Issues screen
Field | Explanation |
---|---|
Unit of Measure | A user defined code (system 00/type UM) that identifies the unit of measurement for an amount or quantity. For example, it can represent a barrel, box, cubic yard, gallon, an hour, and so on.
Form-specific information If you leave this field blank, the system uses the unit of measure from the Work Order Header table and updates the quantities in the Item Location table in primary units of measure. If this value is not the primary unit of measure, the system converts it to the primary unit of measure. |
Resource Percent | If this option is chosen, this value indicates what percent of the ingredients should be issued separately to co-products and by-products.
Form-specific information The system displays the value from the Process Resource Revisions window (P3002P). If there are co-/by-products at the final operation, their resource percent must equal 100 to issue all ingredients. |
To release sales backorders during completions
From Shop Floor Management (G31), choose Daily Order Reporting under Process
From Daily Order Reporting - Process (G3114), choose Completion with Backflush
The JD Edwards World Sales Order Management system identifies items that are being manufactured as backordered items. When you complete the items in the Shop Floor Control system using the Completions program, you can release the sales order backorders.
On Completion with Backflush
Complete the work order by accepting the records displayed.
The Release Backorders - Online screen appears.
Figure 19-9 Release Backorders - Online screen
On Release Backorders - Online, review the following default information:
Order Number
Order Type
Item Number
Quantity Backordered
Quantity To Ship
If the available quantity plus the amount being received is enough to fill any or all of the backorders, the system enters the amount for that order in the Quantity to Ship field on the Release Backorders - Online screen.
Field | Explanation |
---|---|
Units - Qty Backordered/Held | The number of units backordered in Sales Order Management or in Work Order Processing, using either the entered or the primary unit of measure defined for this item. |
To manage completions using receipts routing
From Procurement (G43), choose Stock Based
From Stock Based Procurement (G43A), choose Receipt Routing
From Receipt Routing (G43A14), choose Routing/Analysis Revisions
You set up a receipt route in the Procurement system by specifying a unique receipts routing code name in the user defined code table 43/RC and an operation name in table 43/OC. You enter a Y in any of the update fields on the Receipt Routing Definition screen to have the system update the appropriate field in the Item Location table when an item arrives at the operation.
The system considers items on-hand and eligible for payment only at the end of a receipt route. You must enter a Y (Yes) in the On-Hand column for the system to assign the last operation to a route. The system assigns a Y in the Pay field on the operation to which a Y is assigned in the On-Hand column.
You enter disposition information for a route in the Procurement system when you use the Disposition Setup program. This information includes whether items dispositioned out of a receipt route are eligible for payment. If you classify a category as eligible for payment, the system creates journal entries when it dispositions items in the category. The code in the General Ledger Category field determines which account the system debits. The system credits the Received Not Vouchered account.
For the system to direct items through a receipt route, you must assign a route to each item. You assign receipt routes to items based on item/supplier relationships, using the Supplier/Item Information program.
Note:
For manufactured items, the supplier must be *WO.On Routing/Analysis Revisions
Figure 19-10 Routing/Analysis Revisions screen
Complete the following fields:
Normal Route
Effective From
Effective Through
Topic | Description |
---|---|
Completing unplanned co-products and by-products | An unplanned completion can be necessary due to a condition that caused the process to produce another item when it normally would not, for example, temperature or humidity. Set the appropriate processing option in the Completion program to allow the system to complete these co-products and by-products.
To enter an unplanned completion, enter the part number, branch, and sequence number on the Co-/By-Product Completions window. |
Issuing ingredients from locations not listed on the ingredients list | After you complete the work order by accepting the records shown on Completion with Backflush, do the following:
For co-products and by-products, you can change a location by using a selection option to access Multiple Locations from Co-/By-Products Completions. |
Locating the status of the receipts routing | Use the Status Inquiry screen to locate the status of the receipts routing. You can access the Operation Movement Detail screen to view the details of a step. You can set a processing option in the Completions program to initiate receipts routing. |
See Also:
Reviewing Manufacturing AAI's (P40950) in the JD Edwards World Product Costing and Manufacturing Accounting Guide
Assigning Receipt Routs to Items in the JD Edwards World Procurement Guide
From Shop Floor Control (G31), choose Process Daily Order Reporting
From Daily Order Reporting - Process (G3114), choose Partial Completion
You can use the Partial Completion program to record complete parts of the quantity ordered for a work order. The screen displays completed and scrapped quantities and percent complete information for a work order.
Complete the following tasks:
Complete partial quantities on a work order
Complete a work order for multiple locations (optional)
To complete partial quantities on a work order
Complete the following fields:
Order Number
Completed Quantities
Scrapped Quantities
Complete the following optional field:
Date Complete
Complete the following field if you did not set it in the processing options:
Status
Complete the following fields if you are not completing to the primary location:
Location
Lot
Lot Status
To complete a work order for multiple locations
On Partial Completion
Complete the following fields:
Order Number
Completed Quantities
Scrapped Quantities
Complete the following optional field:
Date Complete
If you did not set the status in the processing options, complete the following field:
Status
Press Enter.
The system displays Co/By-Product Completions.
Figure 19-13 Co/By-Product Completion screen
Complete the following field:
Quantity
Choose Select Multiple Locations.
Figure 19-14 Select Multiple Locations screen
On Select Multiple Locations, complete the following fields:
Quantity Completed
Location
Lot
Review the following default information:
Branch/Plant
Press Enter to accept the data and close Select Multiple Locations.
Press Enter to accept the data and close Co/By-Product Completions.
From Shop Floor Control (G31), choose Process Daily Order Reporting
From Daily Order Reporting - Process (G3114), choose Super Backflush
Super Backflush is a DREAM Writer batch program that creates backflush transactions against a work order or rate schedule at pay points defined in the routing. Super backflushing allows you to relieve inventory at strategic points throughout the manufacturing process.
You can enter completed and scrapped quantities by operation and employee. The system completes the work order or rate schedule, or you can review and revise the transactions. The super backflush procedure can perform the following transactions by operation:
Issue ingredients to the work order or rate schedule
Record hours and quantities against the work order or rate schedule at standard values
Record inventory completions
The system records the transactions from the pay point you indicate in the routing back to the first operation or the previous pay point, if one has been defined.
You can set the processing options for the Super Backflush program to:
Indicate the versions of associated programs to access
Select document types to be used when creating transactions
Select update status codes for operations and the work order or rate header
Indicate a status code beyond which entries to work orders or rates cannot be made
Store hours and quantities in related tables for review.
Update hours and quantities for later processing by manufacturing accounting.
Either access a specified version of the following programs or automatically execute the process without the screen displaying:
Hours and Quantities
Material Issues
Work Order Completions
To process work orders through super backflush
Complete the following fields:
Order Number
Shift
Transaction Date
Employee
Quantity Complete
Status
Press Enter.
The Work Order Inventory Issues screen appears.
Figure 19-16 Work Order Inventory Issues screen
Caution:
The system displays a warning message when if you try to exit the program prior to completing all the steps required for Super Backflush.On Work Order Inventory Issues, the system automatically provides values in the following fields:
Status
Issues
Unit of Measure
Branch/Plant
Location
Press Enter.
The Hours & Quantities Entry screen appears.
Figure 19-17 Hours & Quantities Entry screen
Note:
Process all transaction screens and the system processes the information according to the issue type code and pay point type assigned to each operation.If an operation is defined as a pay point, and the pay point is set up to issue material and report labor, when the operation is recorded as complete, the system issues the ingredients and backflushes labor from the last defined pay point up to the previous pay point.
On Hours & Quantities Entry, review the following fields:
Employee Number
Operation Sequence Number
Type of Hours
Beginning Hours
Ending Hours
Hours
Quantity
Unit of Measure
Status
Employee Name
Press Enter.
The Super Backflush detail area screen appears.
Figure 19-18 Super Backflush screen, Detail area
Complete the following optional field:
Pay Point Status
The Co/By-Product Completions window appears.
Figure 19-19 Co/By-Product Completions window
Press Enter to accept the data and close Co/By-Product Completions.
Field | Explanation |
---|---|
Pay Point Status | A code that indicates whether the operation should be taken to complete or partially complete status. Valid codes are:
Blank – Not reported P – Partially complete C – Completed |
Unit of Measure | A user defined code (system 00/type UM) that identifies the unit of measurement for an amount or quantity. For example, it can represent a barrel, box, cubic yard, gallon, an hour, and so on.
Form-specific information If you leave this field blank, the system uses the Work Order Header table to update the quantities in the Item Location table in the primary unit of measure. |
Units - Quantity at Operation | The quantity that is physically at the step at the work center at that time.
Form-specific information The quantity at operation is displayed in the intermediate unit of measure, if one exists for the operation. In addition, if an operation has an intermediate, the quantity can be entered at any valid unit of measure for the intermediate item. When the quantity is completed, it is deducted from the operation and added to the next operation. |
Topic | Description |
---|---|
Resources | The information in the detail area of the screen is from the Shop Floor Control Routing Instructions table (F3112). The information in the screen header is from the Work Order Master table (F4801). |
Operation numbers | Operation numbers defined as pay points appear in reverse image on the screen. |
Using quantity at operation for intermediates | If there is an intermediate for the operation, all screen quantities are displayed in the unit of measure defined for the intermediate. When the system completes the quantity, it is deducted from the operation and added to the next operation. |
Blending, filling, and packaging | When you use the Super Backflush program with bulk products the system:
|
Import/Export for Work Order Time Entry (P311221) | You can use the Import/Export functionality in this program. See Overview to Import/Export in the JD Edwards World Technical Tools Guide for information about importing data into the system. for more information. |
From Shop Floor Control (G31), choose Process Daily Order Reporting
From Daily Order Reporting - Process (G3114), choose Super Backflush
You report quantities against work order operations using either Hours and Quantities or Super Backflush. These programs differ in the following ways:
Hours and Quantities allows entry of different types of hours worked, in addition to quantities.
Super Backflush allows entry of quantities only.
Hours and Quantities runs in batch mode. After you enter hours and quantities, you can review and revise these hours and quantities until you update the work order routing.
You update Super Backflush quantities online.
You can enter completed and scrapped quantities by operation and employee. The system completes the work order if the last operation is defined as a pay point, or you can review and revise the transactions. However, quantities completed at a given operation cannot exceed the quantity completed at the preceding operation. For example, Super Backflush totals the entries for quantity completed and scrapped for the operation and compares that to the quantity at operation. If the total exceeds the quantity at operation, the system highlights the fields and displays an error message.
When you use Hours and Quantities entry, before the update process, the system verifies the quantity at operation as though the transactions were updated in the Work Order Routing table. The system uses the previously entered data to verify the quantity at operation. This only occurs for data entered on the current day or previous to the current day.
You can set a processing option for the Super Backflush program to indicate whether the system verifies, for a given operation, that the total quantity completed plus scrapped does not exceed the quantity at operation.
To process a work order using quantity at operation
Complete the following fields:
Order Number
Transaction Date
Shift
Employee
Quantity Complete
Status
Access the detail area.
Pay Point Status
The Hours & Quantities Entry screen appears.
Figure 19-22 Hours & Quantitied Entry screen
Review the following fields:
Employee Number
Operation Sequence Number
Type of Hours
Beginning Hours
Ending Hours
Hours
Quantity
Unit of Measure
Status
Employee Name
From Shop Floor Control (G31), choose Process Daily Order Reporting
From Daily Order Reporting - Process (G3114), choose Partial Completion
When you record a completion for serialized components, the system accesses the Associate Issued Item LSN's program. The associations screen is only accessible if you are associating serial number controlled components to serial number assemblies. The system displays the pre-assigned serial numbers and any memo lot information.
You can use one of two display modes of the Associate Issued Item LSN's program:
Associate components with a single assembly
Display all components and associates to multiple LSNs
After you generate serial numbers for your work order, you associate your serialized components to a serialized assembly. To associate a serialized component to a serialized assembly, enter the associating quantity.
In addition, the Completion program allows you to enter a memo lot number that is used when both lot and serial numbers are required for tracking assemblies. The system verifies the memo lot number and serial number if you set the Serial Number Required field on the Item Branch/Plant Information screen appropriately.
Caution:
If you set the appropriate processing options in the Completion program, the system allows you to complete multiple items using the same serial number.Topic | Description |
---|---|
Completing non-serialized components | If you complete work orders with non-serialized components you cannot assign serial numbers to the assemblies at completion. |
To complete a work order with serialized components
On Partial Completion
Complete the following fields to locate your order:
Order Number
Branch/Plant
Complete the following field to record a completed quantity:
Completed Quantity
The system displays the Serial Number Associations screen.
Figure 19-24 Serial Number Associations screen
Press F17 to select a Parent Lot/SN:
Figure 19-25 Assign Serial Numbers screen
After a selection has been made the program returns to the Serial Number Associations window, populating the Assembly Information Lot/SN:
Press F15 to select from Serialized Items Issued:
Figure 19-26 Serialized Items Issued screen
Press enter after making a selection and you will be returned to the Serial Number Associations window.
Figure 19-27 Serial Number Associations screen
Now that both Parent and Component Lot/SN Associations have been made, complete the following fields:
Enter A in the Action Code
Optionally enter Memo Lot 1 and Memo Lot 2
After pressing Enter the system will default in the next available sequence number and clear the screen. Press F3 to exit to the Partial Completions screen.
Field | Explanation |
---|---|
Lot/SN | A number that identifies a lot or a serial number. A lot is a group of items with similar characteristics. |
Memo Lot 1 | A higher classification or grouping of serial number or lot processed items, maintained within the lot master (F4108). |
Memo Lot 2 | A higher classification or grouping of memo lot 1 maintained within the lot master (F4108). |