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In this case, you can begin by defining your jobs with a status of Unreleased. Once you are certain that everything is ready, you can change the status of the jobs to Released and print your shop paperwork. See: Changing Discrete Job, Mass Changing Discrete Job Statuses, Discrete Shop Packet, and Discrete Job Dispatch Report.
To identify which jobs to kit, the stockroom staff can run a report for all jobs with a status of Released. See: Discrete Job Listing Report.
To identify which assemblies to build, the shop floor staff can run a report that lists assemblies with quantities in the Queue intraoperation step of the first routing operation. See: WIP Location Report.
In the first instance, stopping production on the group of jobs makes it possible for you to address the quality problem. In the second instance, stopping production allows you to evaluate how the customer's change affects material requirements and operations. You can temporarily stop production on the jobs involved by changing their statuses to On Hold. See: Changing Discrete Jobs and Mass Changing Discrete Job Statuses.
Suggestion: Jobs can be defined in sequential order using the automatic sequence generator. Sequentially ordered jobs are easier to query and mass change than non-sequential jobs.
Once the quality problem is resolved and the impact of the changes to the configure-to-order job have been determined, you can change the statuses of the jobs from On Hold to Unreleased or Released.
If all the jobs are in order, you can view job costs either on-line or using reports. See: Viewing WIP Value Summaries and Discrete Job Value Report.
Once you are satisfied that your job cost information is correct, you can close your jobs individually or as a group based on their status. See: Overview of Discrete Job Close.
Because of the production rates and lead times being used, the schedule split results in having the same assembly with two different bills on the same line at the same time. Since the first in-first out allocations are used when two schedules are released on the line at the same time, you must maintain first in-first out order when moving assemblies. Unfortunately several of the assemblies with the original bill are being may be held for repair at a Reject intraoperation step and assemblies using the new bill are beginning to pass them. This could result in the lose of physical first in-first out (FIFO) flow and improper backflushing.
To correct this problem you must separate the assemblies by changing the status of the first schedule to On Hold. This freezes the first schedule removing it from the FIFO algorithm. Later, when the rejected assemblies are ready to go, you can change the status on the first schedule to Released so that assemblies on the first schedule take precedence in the FIFO algorithm. See: Defining Repetitive Schedules Manually.
Job and Repetitive Schedule Status Changes
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