Completing Operations and Recording Scrap

This chapter provides an overview of the online completions process and discusses how to:

• Record completed operations and scrap for in-house production IDs.

• Move completed end items and assign serial and lot numbers.

• Record completions and scrap for production IDs with multiple outputs.

• Record completed and scrapped end items for production schedules.

• Edit component lists.

• Run the Completions Update COBOL/SQR process (SFPDCDRV).

• Create reversing entries to correct data entry errors.

• Complete production.

• Move excess inventory back to a stores location.

• View and report material shortages.

• View scrap and earned conversion cost information.

• Record and view actual machine and labor hours.

Understanding Recording Completions and Scrap

Within a manufacturing enterprise, you need to track end items as they make their way through the production area. With PeopleSoft Manufacturing, you can manage production by orders, repetitive schedules, backflushing, or creating a schedule to record completions and scrap after you have completed production. Subcontracted operations are fully supported. You can assign serial and lot numbers to completed end items and complete end items to containers while moving them to inventory or to another production area. While recording completed operations, the system accumulates manufacturing costs and variances. You can also record actual machine and labor hours for each production order or production schedule.

PeopleSoft Manufacturing tracks the serial genealogy of production. This enables you to trace the movement of a specific serialized assembly and its components throughout the manufacturing process.

Note. During completions, you can choose from serial IDs previously associated with a production ID, or you can enter a new serial ID for which the system automatically creates the serial association. Additionally, lot auto numbering only applies to configured orders.

PeopleSoft Manufacturing tracks the costs of material, labor, outside processing, and machines used to manufacture a product and manages the transactions necessary to report and track the status of a particular order or schedule by day and shift. The system supports these order types:

• Production IDs for regular, rework, or teardown production.

• Production schedules for tracking regular production by day and shift.

If you're recording completions and scrap for a production ID with subcontracted operations, you record the operation completions for the subcontracted operations slightly differently than for in-house production.

You can also record completions and scrap using electronic data collection.

See Recording Completions and Scrap Using Electronic Data Collection.

Recording Completions with Multiple Outputs

You can also record completions and scrap for production IDs and production schedules that have multiple outputs. Multiple outputs consist of:

Expected Output When Using Yield by Operation

The system recalculates the expected output quantities when over-completions or over-scrap are performed. Over-scrap is when the scrap quantity exceeds the expected scrap, based on the operation yield. For example, the system recalculates a new output quantity if the actual scrap quantity exceeds the expected scrap quantity at an operation.

Transferring Completions Data to PeopleSoft Quality

If your installation includes PeopleSoft Quality, and you have defined quality configuration information and quality plans in PeopleSoft Quality for a manufactured item and its process, then the Quality link is active on the Record Completions/Scrap page. You click this link to transfer to PeopleSoft Quality to initiate a data entry session to record quality control information for the manufacturing process.

Completions Actions and Effects to Quantities on Hand

This table lists the results of completions actions:

See Also

Collecting Quality Data

Subcontracting

Maintaining Bills of Material

Manage Production Using Discrete Orders

You can manage discrete orders for regular, rework, or teardown production by creating production IDs for each production quantity that you want to track. Once you've created the production ID, you release production, and then either generate pick lists to issue material to production or maintain a maximum quantity on hand for components in a WIP location.

Once production begins on the shop floor, perform the following steps. These steps assume that all operations are performed in-house and none of the operations are subcontracted.

To record completions and scrap for in-house production IDs:

1. Indicate whether the business unit will record completions and scrap production IDs using the online or deferred method by selecting the PID Completion option on the MFG BU Prdn Options page. Select one of these:

   1. Online: The background process calculates the associated production costs (such as earned labor and machine hours) and overhead conversion costs and consumes material utilizing the issue or replenishment issue methods.

   2. Deferred: This option indicates that you're running the completions process at a later time.

      All associated production costs are calculated when the completions update background process is run. You must run the Prdn Compl/Scrap process (production completions and scrap process) if you select this option.

2. Record completions and scrap quantities for in-house production using the Record Completions/Scrap page.

   Record completions by operation, by count point, or for the entire production quantity, or perform a partial backflush of completed end items.

3. (Optional) If you're completing a production ID with multiple outputs, the Outputs Detail area appears.

   You can complete planned or unplanned by-products at any operation. Scrapped end items are recorded at the batch level, but not for each output. You must record completions and scrap for primary items and co-products at the last operation.

4. (Optional) Change component information using the Edit/Issue Components page.

5. (Optional) Transfer completions data to PeopleSoft Quality by clicking the Quality link.

6. (Optional) If you're using serial in production or serial- or lot-controlled items, and the components are issued to production using the Replenish or Issue method, select the serialized components or lots from which to consume the components.

   1. Automatically generate serial numbers by using the Rapid Serial Numbers page.

   2. Access the Edit/Issue Express page, or click the button next to the serial- or lot-controlled component on the Edit/Issue Components Summary page. For lot-controlled components you can use the backflush lot selection rule to automatically select lot IDs during backflush. For more information on the backflush lot selection rule, see the "Automatically Consuming Lot-Controlled Stock During a Backflush" section of this chapter.

   3. Use the Route-To PID/Stor Locations (route to production ID and storage locations) scroll area on the Record Completions/Scrap page to assign a lot if the completed end item is lot-controlled.

      Note. You can move end items to an existing lot or create a new lot.

7. Move completed end items out of production.

   You may route them to a production ID, to another production area for further processing, or to a stores inventory location. You cannot route waste by-products.

   1. (Optional) Click the Apply Defaults link to route the end items to a default putaway location.

      Note. The completions process puts away items in their standard units of measure (UOM).

   2. (Optional) Select an alternate putaway location.

      Note. If you're routing the end item to another production ID, the putaway process is not required.

   3. If you are using serial genealogy, you must perform completions at the last operation.

      In addition, select the serial number for the appropriate assembly.

8. (Optional) Run the Completions Update process.

   You run this process to update completions transactions that are staged by other processes, such as Edit Components updates, production completions, or subcontracted completions recorded through electronic data collection.

9. (Optional) Make reversing entries to correct data entry errors.

   You can return components to their original storage location or to an alternate location. If you're returning lot- or serial-controlled components, you must select the serial IDs or lot IDs from which the components were originally consumed.

10. (Optional) Move excess components out of WIP locations using the Maintain Inventory navigation.

    You can move these components to another production area or back to a stores inventory location. You can also move excess components from the production ID using the Kit issues transactions. Kit issue transactions are used for components whose issue method is Kit.

11. Record actual labor and machine hours.

12. Indicate that production is complete by using the Complete Production page.

Manage Production by Day and Shift (Production Schedules)

PeopleSoft Manufacturing generates a schedule for processing by day and shift for regular production by:

• Creating a production schedule as part of the supply planning process.

• Creating a production schedule at the end of a production run.

  Note. Production schedules support in-house production only. If you have subcontracted operations on a routing, you must use a production ID to track production.

  Once you've created the production schedule, you release production, and then either generate pick lists to issue material to production or maintain a maximum quantity on hand for components in a WIP location.

  If a production schedule has not been created, you can still record completions. At that time, the system prompts you to automatically add the production quantity to the schedule.

  To record completions and scrap for production schedules:

1. Record completions and scrap quantities for production schedules using the Record Completions/Scrap page.

   Record completions and scrap for the entire production quantity, or perform a partial backflush of completed end items. You can record completions for production schedules with multiple outputs. However, all multiple outputs and scrap must be completed at the last operation.

   Note. If a schedule for the production date and shift has not been created when recording end item completions and scrap, the system creates a production schedule and releases production.

2. (Optional) If you're completing a production schedule with multiple outputs, the Outputs Detail area appears.

   You can add unplanned by-products. Scrapped end items are recorded at the batch level, but not for each output.

3. (Optional) Change component information using the Edit/Issue Components page.

4. (Optional) Transfer completions data to PeopleSoft Quality by clicking the Quality link.

5. (Optional) If you're using serial- or lot-controlled items, and the components are issued to production using the Replenish or Issue method, you must select the serialized components or lots from which to consume the components.

   1. Automatically generate serial numbers by using the Rapid Serial Numbers page.

   2. Access the Edit/Issue Express page, or click the button next to the serial- or lot-controlled component on the Edit/Issue Components Summary page. For lot-controlled components you can use the backflush lot selection rule to automatically select lot IDs during backflush. For more information on the backflush lot selection rule, see the "Automatically Consuming Lot-Controlled Stock During a Backflush" section of this chapter.

   3. Use the Route-To PID/Stor Locations scroll area on the Record Completions/Scrap page to assign a lot if the completed end item is lot-controlled.

      Note. You can move end items to an existing lot or create a new lot.

6. Move completed end items out of production.

   You may route them to a production ID, to another production area for further processing, or to a stores inventory location. You cannot route waste by-products.

   1. (Optional) Click the Apply Defaults link to route the end items to a default putaway location.

      Note. The completions process puts away items in their standard UOMs.

   2. (Optional) Select an alternate putaway location.

      Note. If you're routing the end item to another production ID, the putaway process is not required.

7. (Optional) Run the Completions Update process.

   You run this process to update completions transactions that are staged by other processes, such as Edit Components updates, production completions, or subcontracted completions recorded through electronic data collection.

8. (Optional) Make reversing entries to correct data entry errors.

   You can return components to their original storage location or to an alternate location. If you're returning lot- or serial-controlled components, you must select the serial IDs or lot IDs from which the components were originally consumed.

9. (Optional) Move excess components out of WIP locations using the Maintain Inventory navigation.

   You can move these components to another production area or back to a stores inventory location.

10. Record actual labor and machine hours.

11. Run the Close Production SQR process to indicate that the production schedules are complete.

Automatically Consuming Lot-Controlled Stock During a Backflush

Backflush is a method of consuming components for a production ID or production schedule. The system backflushes components with an issue method of Issue or Replenish. Typically, backflushing occurs when completion or scrap quantity is entered for an assembly. Backflushing consumes material from the WIP locations.

When consuming lot-controlled components, the backflushing process must decide which lot IDs to choose within the WIP location. The backflush lot selection rule enables you to determine which lot IDs are automatically selected for consumption when a backflush is performed. The backflush lot selection rule can be defined at:

• The business unit-level using the MFG BU Prnd Options page. The options for the backflush lot selection rule are located in the Backflush Lot Option group box and include:

  • Manual:(default) Select this option to require the user to enter the specific lot IDs consumed during backflushing. The system does not automatically select any lot IDs.

  • Earliest Expiration Date: Select this option to have the system select the lot IDs for consumption based on the lot expiration date. The system first selects the lots with the earliest expiration dates.

  • Earliest Available Date: Select this option to have the system select the lot IDs for consumption based on the available date. The system first selects the lots with the earliest available dates.

• The business unit and item-level using the Define Business Unit Item - Manufacturing: General page. The options for the backflush lot selection rule are located in the Backflush Lot Option group box and include:

  • Default from BU: (default) Select to use the backflush lot selection rule defined at the manufacturing business unit level on the MFG BU Prnd Options page.

  • Manual

  • Earliest Expiration Date

  • Earliest Available Date

The backflush lot selection rule defined at the business unit and item combination (the Define Business Unit Item - Manufacturing: General page) overrides the option selected at the business unit level (the MFG BU Prnd Options page).

See Defining Manufacturing Information for an Item.

See Setting Up Manufacturing Business Unit Production Options.

How the Backflush Process Uses the Backflush Lot Selection Rule

The backflush lot selection rule is used during the backflush process to determine the lots to consume from each WIP location for lot-controlled components. The Record Completions and Scrap-Edit/Issue Express page is one location where you can see some of the impacted fields:

If the backflush lot selection rule is Manual, then the backflush process does not default lot IDs. You must manually enter the specific lot IDs and the quantity from each lot for consumed lot-controlled components.

If the backflush lot selection rule is Earliest Expiration Date or Earliest Available Date, then the backflush process consumes lot-controlled components by choosing the lot IDs and quantities from each lot ID within the WIP locations. The following rules are applied:

• The backflush process does not override an existing lot entry but populates any blank fields or default-value fields.

• The process can select one or more lots. For example, if 15 units are needed, the first 8 units are selected from lot L200, when this lot is exhausted then the last 7 units are selected from lot L500.

• The process consumes lot-controlled stock until the consumed component is satisfied or the existing stock in the WIP location is exhausted. If there is not enough lot quantity in the WIP location, then the process leaves the remaining quantity in the pending issue quantity and pending loss quantity, as appropriate.

• If the rule finds multiple lots in the WIP location that could be used, then the first tiebreaker is the opposite date (that is, the Earliest Expiration Date rule uses the earliest available date and the Earliest Available Date rule uses the earliest expiration date). If there still are multiple lots, then the next tiebreaker is the ascending lot ID value.

• For consigned items, the process uses the stock in the owned WIP location. If more quantity is needed, then the non-owned WIP location is used.

The backflush lot selection rule cannot be applied to:

• Items that are both lot-controlled and serial-controlled.

• Items using serial genealogy.

• Items that has the component issue method of Kit.

For these items, the backflush lot selection rule is set to the value of Manual.

Components Impacted by the Backflush Lot Selection Rule

The backflush lot selection rule is applied during backflush and impacts the following components:

• Record Completions and Scrap (Production Control, Process Production, Complete Production, Record Completions and Scrap).

• Edit/Issues Components (Production Control, Process Production, Issue Materials, Edit/Issue Components).

• Receive Subcontract Assembly (Production Control, Process Production, Subcontract Production, Receive Subcontract Assembly).

The above components can be used in online or deferred mode. If you are using the online mode (PID Completion Option on the MFG BU Prdn Options page), the online pages display the results of the backflush lot selection rule; that is, the lot ID and quantity to be consumed from the WIP location. You can view and override the selected lot IDs and quantities. If you are using the deferred mode (PID Completion Option on the MFG BU Prdn Options page), the system does not consume the components until later; however, you can use the online pages to enter override lot IDs and quantities.

Using the online mode, if the backflush process has completed and then a field is changed that causes the pending quantities field to be recalculated, this causes a recalculation of backflush lot selection rule. Fields that trigger the recalculation of the pending quantities include:

• Completion Quantity

• Scrap Quantity

• Completion Op Sequence

• Back thru Op Sequence

• Component ID

• Component's Op Sequence

• Component's Qty Code

• Component's Qty Per

• Picking a substitute item

In addition, entering a pending issue quantity or a pending yield loss quantity when there is no completion or scrap quantity triggers the calculation of the backflush lot selection rule. If the lot consumption fields have already been populated and then you manually change the pending issue quantity or a pending yield loss quantity, the system displays the following message:

Message Text: Recalculate the Lot IDs to consume (Y/N)?

Explanation: You have modified the pending issue or pending loss quantity for a component that contains values in its lot scroll. Select Yes to clear the lot scroll and repopulate based on the entered quantity - all other occurrences of this component on the component list which share the same WIP location will also have their Lot IDs recalculated. Select No to keep the pending quantity entered without changing the lot scroll - you will then need to modify the lot scroll so that its quantities correspond with the pending quantity entered. Select Cancel to cancel the action - the original pending quantity will be restored and the lot scroll will not be modified.

Using the Production Completions and Scrap Process with the Backflush Lot Selection Rule

Prdn Compl/Scrap (SFPDCDRV) process (Production Completions and Scrap process) can perform a backflush and looks to the backflush lot selection rule to determine the method for the lot consumption from the WIP locations. This Prdn Compl/Scrap process is located in both the SCM Integrations menu (SCM Integrations, Process Transactions, Manufacturing, Production Completions/Scrap) and the Production Control menu (Production Control, Process Production, Complete Production, Process Completions and Scrap). The Production Completions and Scrap process uses data stored in the BCT tables to update the production tables and can record completions and scrap for:

• Electronic data collection files and other EIP messages. The data transactions are stored in the BCT tables.

• Online components using the deferred mode (PID Completion Option on the MFG BU Prdn Options page). The online data entry is stored in the BCT tables.

If you have selected the backflush lot selection rule of Earliest Expiration Date or Earliest Available Date, then the incoming files are not required to have a lot ID for consumed components. The lot ID is assigned during the Production Completions and Scrap process; therefore, the incoming files are not put in the error status for correction in the Transaction Maintenance component (SCM Integrations, Transaction Error Handling, Maintain Transactions, Transaction Maintenance). If the incoming file does contain some lot IDs for consumed components, then the Prdn Compl/Scrap process uses those entries rather than the backflush lot selection rule. In addition, the incoming files must contain the lot IDs for consumed components if you have selected the backflush lot selection rule of Manual.

See Running the Completions Update COBOL/SQR Process (SFPDCDRV).

Setting Up the Backflush Lot Selection Rule

Before changing the backflush lot selection rule in your PeopleSoft system, you should examine the physical movement in your WIP locations to:

• Verify the physical usage of the lot components in the WIP locations match the chosen backflush lot selection rule. For example, if stock with the earlier expiration date is selected first from the WIP location during production, then you should select the Earliest Expiration Date option for the backflush lot selection rule.

• Ensure your data movement transactions to and from the WIP locations are accurate and promptly recorded. If you are using data collection systems for material movement or completions and edit component transactions, the batch jobs that process these transactions must be processed in a timely manner.

• Confirm that you have one primary method for entering completion transactions. If you vary the method used to record completions, (for example; sometimes using data collection completions and sometimes using on-line pages), then the backflush lot selection rule may cause inaccurate results due to timing issues.

Before changing the backflush lot selection rule, it is recommended that you process all pending transactions in the staging tables (BCT tables) that impact production completion. If pending transactions are in the BCT tables, use caution when changing the backflush lot selection rule on the MFG BU Prnd Options page or the Define Business Unit Item - Manufacturing: General page. Changing the rule can impact how the pending transactions are processed.

Integrating PeopleSoft Manufacturing with a Third-Party System

You can integrate PeopleSoft Manufacturing with an electronic data collection system or a Manufacturing Execution System (MES), or both.

Electronic Data Collection

You can use electronic data collection to collect completions and scrap transactions, then import them to PeopleSoft Manufacturing. You can also collect and import actual hours transactions using electronic data collection.

For actual hours, the data collection method employs the same breakout of hour types as the online method such as setup, run, fixed run, and post-production. Electronic data collection allows for individual or crew reporting as well as single or multiple machine reporting.

Use the Actual Hours EIP to import actual hours information from a third-party system.

See Recording Completions and Scrap Using Electronic Data Collection.

Manufacturing Execution System (MES)

If you're integrating PeopleSoft Manufacturing to an MES, you can record operations completed, quantity completed, and scrap quantity in the MES. You can then import completion transactions to enable the optimization of production activities from production order launch to completion of finished goods. All production IDs, production schedules, and operations must be recognized in the PeopleSoft system; otherwise the system marks the transactions as errors in transaction maintenance. You then need to make corrections so that the transaction can be processed.

For multiple output transactions, you can record actual outputs in the MES, including completed quantities for co-products and by-products. You must send the completed output quantity if the batch quantity complete is not reported. You can report only unplanned by-products, not unplanned co-products.

You can also report the serial, lot, or container numbers for items produced or consumed in production. If the produced item requires lot, serial, or container details in the PeopleSoft system, the system marks transactions sent without this information as an error in transaction maintenance. For serial-controlled components or components that are both lot and serial-controlled, the serial numbers and lot IDs must be provided to the system or the transaction is marked in error to be corrected in transaction maintenance. For lot-controlled components, the incoming data must contain the lot IDs for consumed components if you have selected the backflush lot selection rule of Manual. If you have selected the backflush lot selection rule of Earliest Expiration Date or Earliest Available Date, then the incoming files are not required to have a lot ID for consumed components.

You can also report component consumption and communicate it to PeopleSoft Manufacturing using the Production Order Issue EIP. This EIP is a batch subscribe (inbound), asynchronous message.

When you pass component usage from the MES, all component consumption for a production order is sent, regardless of whether the quantity consumed was the default quantity. If components consumed are under serial or lot control, the lot or serial numbers are passed from the MES to update PeopleSoft Inventory. For lot-controlled components, the lot IDs can be automatically added by the Prdn Compl/Scrap (SFPDCDRV) process if you have selected the backflush lot selection rule of Earliest Expiration Date or Earliest Available Date.

The system validates component consumption transactions coming into the PeopleSoft system to ensure that the production IDs and items are valid in the business unit. The items must be valid for the BOM or as substitutes. If the consumption transaction would drive inventory negative in a business unit where negative inventory is not permitted, the system doesn't process the transaction.

See Also

Understanding SCM Integration

Recording Actual Machine and Labor Hours

Getting Started with PeopleSoft Manufacturing

Prerequisites

Before you begin production:

1. Review the production documents, if available, to determine if any of the items are serial- or lot-controlled, or if there are any subcontracted operations.

2. Verify that all items that you'll be manufacturing have been assigned to a production area.

   • If the production item will have multiple outputs, you must define the outputs by using the BOM Maintenance - Outputs page before generating the production ID or production schedule.

   • If you're tracking an item within a production area with production IDs, first generate the production ID for the item that you want to produce.

   • If you're using production schedules, you can predefine the production quantity to be produced for a shift, or you can enter the quantity produced when recording end item completions.

3. Verify that material has been issued directly to the production ID or that the production WIP locations have been stocked with adequate inventory.

   Use the Shortage report to identify any potential component shortages before beginning production.

Common Elements Used in This Chapter

Recording Completed Operations and Scrap for In-House Production IDs

At some point during the in-house production process, you must record completed operations and scrap. Using the Record Completions and Scrap component, you can:

• Record completed operations for all or part of the production quantity.

• Record completions and scrap for the production run with multiple outputs.

• Scrap end items at an operation.

• Backflush the entire production run or order.

• Report completed setup or post production work independent of recording the completion of any end items.

• Automatically consume components based on the quantity completed.

• Automatically complete end items based on the batch completed quantity.

• Manually substitute components where there is a shortage of an item or an item is out of stock.

• Transfer completions data to PeopleSoft Quality, if your installation includes PeopleSoft Quality and you have defined quality configuration information and quality plans in PeopleSoft Quality for the manufactured item and its process.

  You record quality control information for the manufacturing process for the end item and then access the Record Completions/Scrap page.

• Assign serial numbers and lot numbers to completed end items before moving them out of the production area.

• Route completed end items to another production ID or WIP location to be used on subsequent end item production.

• Route completed end items (including primary items, co-products, and recycle by-products) to another production ID or WIP location to be used on subsequent end item production.

• Indicate that production has been completed for the production ID.

Note. Primary items and co-products can be completed only at the last operation. By-products, such as recycle or waste, can be completed at any operation.

If you have enabled PeopleSoft Workflow, when you record end item scrap, the system sends notification to selected roles defined by you by using the Assembly PID Scrap Notification workflow. These roles might include a quality manager or a production control manager.

Understanding the Process of Recording Completions and Scrap for In-House Production IDs

With production IDs, you can:

• Record completions and scrap by operation.

• Record completions and scrap by count points.

• Record partial production completions.

• Complete an entire production ID.

• Move the completed end items to stock, WIP location, or another production ID.

Note. There is no difference between the method that you use to record completed and scrapped end items for regular production and the method that you use for rework production. When recording completions for teardown orders, you report the number of end items torn down. The system calculates the quantity of the teardown end items based on the quantity of the end items being torn down. As is the case with all production types, you can override the teardown quantity for each end item.

Using the Record Completions and Scrap component, you can record in-house operation or end item completions and scrap for production IDs with a status of:

• Entered or Firmed: The system automatically releases the production ID and the status changes to In Process.

  The ability to release a production ID with a status of Entered or Firmed is dependent on the Manufacturing business unit production options for the autorelease of production IDs. When setting up the business unit, you can select Prompt for Auto Release, Auto Release, or No Auto Release.

• Released: The system changes the status to In Process.

• In Process.

Important! If you're using the production issue or production kit material issue method for regular production, you must still issue material to the WIP locations using the Pick Plan and Material Release components. If you're using the production replenishment method, ensure that sufficient inventory exists in the WIP location.

Pages Used to Record Completions and Scrap for In-House Production IDs

Recording Completed Operations and Scrapped End Items for Production IDs

Access the Production Selection page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Production Selection).

Defining Completions and Scrap Information for Production IDs

Access the Record Completions/Scrap page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completions/Scrap).

Previous Completions Information

Recording Operation Completions

Viewing Operations Data

The Operations Data scroll area displays production details based on operation sequence. You can view operation-related information such as assembly starts quantity, scrap quantities, expected completed quantity, and operation yield.

Click the Work Center link to view work center-related information.

Example: Recording Completions

Production start quantity: 10

Quantity completed: 10

Completing at operation sequence: 30

In this example, you want to complete a quantity of 10 at operation sequence 30. You selected the Update Prior Operations check box on the Record Completions/Scrap page, and indicated that you wanted to update previous operations back to operation sequence 20. The system calculates any production and scrap completed at operation sequences 20 and 30:

Once you've completed 10 at operation 30 and updated back through 20, the operations appear as follows:

Warning! You cannot update prior subcontracted operations using this option. If there is a prior subcontracted operation and the Update Prior Operations check box is selected, the system ignores the subcontracted operation when recording the prior operations as completed. Use the Subcontract Receipt component to record completed operations and scrap for the subcontracted operation.

Yield by Operation Example: Completing Less Production End Quantity than Expected

When using yield by operation, the beginning production quantities at subsequent operations are affected when either good or scrap production quantities are greater than expected. This example illustrates the effect of yield by operation when you scrap more end items than you originally expected.

Operation sequence: 30

Operation start quantity: 80

Operation yield: 98 percent

Scrapped quantity: 5

In this example, a quantity of 80 was issued and completed through operation 10. Because there is a 100 percent operation yield, a quantity of 80 is expected at the end of this operation. The original quantity complete at operation 50 was 70.

However, at operation 30, there is a 98 percent operation yield, and overscrapping of a quantity of 5 also occurs. This means that out of the operation start quantity of 80, only 75 are expected to be completed. As these 75 flow through operations 40 and 50, further loss is expected at operation 50, and the expected completion quantity for the order is now 67.

Yield by Operation Example: Completing More End Items than Expected

This example illustrates the effect of yield by operation on subsequent operations when you scrap fewer end items than you originally anticipated.

Operation sequence: 30

Operation start quantity: 69

Operation yield: 98 percent

Scrapped quantity: 0

In this example, a quantity of 69 was issued and completed through operation 10. Because there is a 100 percent yield, a quantity of 69 is expected at the end of this operation. The original quantity expected complete at operation 50 was 60.

However, at operation 30, there is a 98 percent operation yield and underscrapping occurred (scrapped less than expected). Out of the operation start quantity of 69, all were completed and continue to flow through production. As these 69 flow through operations 40 and 50, further loss is expected at operation 50, and the expected completion quantity for the order is now increased to 62.

See Also

Subcontracting

Recording Scrapped End Items

Access the Production Scrap Details page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completions/Scrap. Click the Enter Scrap Data link).

Note. If you're scrapping production that has an operation yield less than 100 percent, the scrap cost calculation is not performed.

The difference in expected and actual scrap is recorded as operation yield variance.

With production IDs, you have the option of scrapping end items at any operation or at the end of production when you can complete end items to stock or another production area. If you're recording scrap at an intermediate operation on a multiple output production ID, you're recording the scrap quantity for the batch and not the individual output items.

When recording scrap at an intermediate operation, the scrap quantity is associated only to the operation where the scrap was recorded. However, if you have selected to complete back through prior operations, the scrapped quantity will be presumed to have been completed at those prior operations.

Example: Scrapping at Operation 30 and Completing Back Through Operation 10

With no prior completed quantity, if you scrap 10 units at operation 30, the operation list would look as follows:

Note. You cannot record scrap at the output level. Scrapped end items for production with multiple outputs are recorded at the batch (BOM) level.

Recording Scrap When Using Count Points

When using count points, scrap can be recorded at any operation, regardless of the count point designation. The system updates the scrap quantity for the operation where the scrap occurred. In addition, the system assumes the scrapped quantity was completed at all previous operations up to the previous count point.

Count point operations: 30, 60

Production start quantity: 15

Step 1

Production start quantity previously completed or issued: 10

Step 2

Scrap quantity: 5

Scrapping at operation sequence: 30

Example 2

Production start quantity previously completed and issued: 10

Scrap quantity: 5

Scrapping at operation sequence: 50

In this example, you have recorded scrap at a noncount point operation. In this case, the system records completions for any previous operations back to the operation after the previous count point (operation 40):

Once an end item is scrapped, the scrap end item value is calculated and expensed. Item costs for expensed and floor stock items are not included in the end item scrap cost. The end item, including the components used to that point, and the labor, machine, and overhead costs earned to that point are no longer accounted for in WIP inventory.

Note. If you record scrap for an operation that precedes a subcontracted operation, and the purchase order has already been generated for the production quantity, the system sends a purchase order change request to PeopleSoft Purchasing, indicating a change in production quantity. This change must be processed before the end items are sent to the subcontractor.

See Also

Subcontracting

Generating Serial Numbers

Access the Rapid Serial Numbers page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completions/Scrap. Click the Generate Serial IDs link).

Recording End Item Completions Using Count Points

You can use count points to record end item completions.

To record completions and scrap for production IDs using count points:

1. Access the Record Completions/Scrap page.

2. Enter the Completed Quantity for the operation sequence.

   If you enter the completed quantity first, only the count point operation steps are available.

3. Select the Op Seq (operation sequence) that is a count point.

   If you click the operation sequence look up without entering a completed quantity, all operation sequences appear.

   Note. When you record completions at the last operation (which must be a count point), the system assumes that you have or will complete at all prior count points. Therefore, the completed quantity is updated only back to the prior count point.

   Because the system automatically completes back to the operation after the previous count point, the Update Prior Operations and the Back Thru Operation fields are unavailable and the operation after the prior count point (operation sequence) appears by default. This indicates that the quantity completed will also be recorded for operations up to, but not including, the prior count point. If you're recording completions at the first count point, the system automatically completes back through and including the first operation.

4. All other processes, such as entering scrap data and routing completed end items, remain the same as those used with completing production IDs at intermediate operations.

Example: Recording Completions Using Count Points

Count point operations: 30, 50

Production start quantity: 10

Step 1

Quantity completed: 10

Count point at operation sequence: 30

In this example, you want to complete a quantity of 10 at operation sequence 30, which is a count point. The system calculates any production and scrap completed at operation sequences 10, 20, and 30:

Step 2

Quantity completed: 5

Count point at operation sequence: 50

In this example, you want to complete production for a quantity of 5 at operation sequence 50, which is a production ID count point. The system doesn't include operation sequence 30 because it is the prior count point:

Recording End Item Completions at the Last Operation

To record completions at the last operation:

1. Access the Record Completions/Scrap page.

2. Enter the last operation on the operation list in the Op Seq (operation sequence) field if you want to complete all operations for the production ID and all of the operations are performed in-house.

3. Select Update Prior Operations, then select the first operation from the Back Thru Operation options.

4. Enter the number of completed end items in the Completed Qty (completed quantity) field.

   You can record completions for the entire production quantity for the production ID or any portion of the quantity.

5. All other processes, such as entering scrap data and routing completed end items, remain the same as those used with completing production IDs at intermediate operations.

   Note. Co-products can only be completed at the last operation.

See Also

Moving Completed End Items and Assigning Serial and Lot Numbers

Moving Completed End items for Production IDs with a Single Output

Access the Record Completions/Scrap page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completions/Scrap).

When completing end items at the last operation, the Route-To PID/Stor Locations scroll area on the Record Completions/Scrap page becomes available. You can route the completed end items to a storage area, another production ID, or to a WIP location. Additionally, if the end item is lot- or serial-controlled, or if you're utilizing containers, you can assign serial numbers, lot IDs, or container IDs to the completed end items.

If a default putaway location is defined for the end item, you can route the completed end items to that location using the routing portion of the page.

Click Apply Defaults to indicate that you want to put away the end items to the default putaway location.

Note. The completions process puts away items in their standard UOMs.

Moving Completed End Items and Assigning Serial and Lot Numbers

To define default putaway locations, use the Default Putaway Locations (DEFAULT_LOCATION) component. Use the DEFAULT_LOCATION_CI to load data into the tables for this component.

Once you have recorded completions for the last operation sequence on the operation list, you can move the completed end items:

• To predefined stores locations within PeopleSoft Inventory.

  Use this method when you want to put away completed end items to default stores locations defined in PeopleSoft Inventory. After completing the last operation, use the Completions/Scrap Update process. There is no need to use the Route-To PID/Stor Locations scroll area unless you need to identify serial numbers, lots, or containers.

• To other production areas to fulfill component requirements and relieve shortages out on the shop floor.

  Use the Route-To PID/Stor Locations scroll area to move the completed end items.

• To a specific location where you want to stock the completed end item.

  Use the Route-To PID/Stor Locations scroll area to specify the location.

• To a production ID, if the end item is a component on a higher-level end item using the Kit issue method.

  This bypasses the putaway process into inventory. You can use the Route-To PID/Stor Locations scroll area to specify the production ID.

In addition, select the serial number for the appropriate assembly that is being completed and moved.

For serial genealogy production, you must enter the specific serial ID that is being completed. If the serial ID has not previously been associated, you are given the option to create the association.

If you're assigning a lot or serial number for teardown outputs that were based on an original production ID's components, the system compares the new lot or serial number to the original component serial or lot numbers and issues a warning if they are different.

Note. If the assembly is serial in production and you are tearing out a serial ID that has not been issued to this assembly, you receive this message: "Tearing out more than has been issued to the original assembly serial. Okay to continue?" Double-check the quantity and serial ID. Click OK to continue or cancel to change information. The edit check is only looking one level deep, not through all the nested subassemblies.

Route-To PID/Stor Locations

When you route to a production ID, the system checks that:

1. The item being completed is a component of the production ID parent item.

2. The issue method is Kit.

3. The production ID status is Released or In Process.

4. The shortage quantity is greater than zero.

When routing an end item to another production ID from a production ID, you needn't run any putaway processes. The system automatically updates the issue quantity for the component on the target production ID as well as the quantity completed for the source production ID.

However, if you're routing the end item to a production ID from a production schedule, you still need to run the Completions Update process to update the production information for the production schedule, either at save time or as a deferred process.

Note. You cannot route waste by-products. They are expensed in the same manner as scrapped end items.

Capacity Checking

You activate weight and volume capacity checking on the PeopleSoft Inventory Options page. You can define the capacity for each storage location on the Volume/Weight Capacity page, which you can access from the Material Storage Locations page.

If the item is designated as an isolate item on the Inventory-Shipping/Handling page in the Define Business Unit Item component, the item can only be put away or transferred to empty storage locations or to locations containing stock with the same item ID. The system prevents you from putting away an isolate item to a location with other items.

If you designate a storage location as storing only one item on the Volume/Weight Capacity page, the system only puts away material with that item ID in the location. If you do not specify an item ID for a single-item storage location, the first putaway transaction to the empty storage location defines the only item ID that the location can contain until the item quantity has been fully depleted.

Prerequisites

Before you move the items to another WIP location, production ID, or inventory stores location:

• Assign serial and lot numbers to the completed end items if the completed end items are serial- or lot-controlled.

• (Optional) Identify a container to which you want to move the completed end items.

• Select the production ID to which the completed end items will be moved.

Pages Used to Move Completed End Items and Assign Serial and Lot Numbers

Moving End Items for Completed Production

Access the Route-To PID/Stor Locations scroll area on the Record Completions/Scrap page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completions/Scrap).

You can move the completed end items to a storage area, another production ID, or a WIP location. In addition, if the end item is lot- or serial-controlled or if you're using containers, you can assign serial numbers, a lot ID, or a container ID to the completed end items using this portion of the page.

Note. If you're completing operations at an operation sequence where a by-product is generated, the Route-to PID/Stor Locations scroll area appears. However, the operation sequence for all end items, except by-products, is unavailable.

Viewing Production Shortages

Access the Shortages page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completion/Scrap. Click the Shortages button in the Route to PID/Storage Locations scroll area).

A component is considered short if the pending consumed quantity or the pending yield loss quantity is greater than zero. The production ID is In Process or Pending Complete if the issue quantity is less than the current scheduled quantity.

Route-To Production ID

Selecting Default Putaway Storage Locations

Access the Apply Defaults page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completions/Scrap. Click the Apply Defaults link).

Assigning Containers

Access the Record Completions/Scrap page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completion/Scrap).

Selecting a Lot ID

If an end item is lot-controlled, select the lot ID to which you're assigning the completed end items. The system assigns the specified lot ID to all the end items indicated as completed on the Record Completions/Scrap page. You can select from existing lots, or you can create a new lot ID.

Staging End Items for Putaway

To move completed end items to a stores or other inventory location, complete these tasks using PeopleSoft Inventory:

1. Run the Load Staged Items process.

   The system suggests the location where the end item should be put away. If you have entered a location on the Route-To PID/Stor Locations scroll area, the system stocks the completed end items in the specified location. If you select Flag Items for Autoputaway, you can bypass the Stockroom Feedback process and run the Putaway page. To streamline the process, you can run the multistep process using PeopleSoft Inventory Auto Putaway.

2. Run the Stockroom Feedback process.

   This page enables you to change the location suggested by the load staged items process.

   • If you're satisfied with the putaway location suggested by the system, you must first select the putaway check box, if it is not selected.

     Then click Putaway to initiate the putaway process.

   • If necessary, change the location, and then click Putaway to initiate the putaway process.

   • If you selected Flag Items for Autoputaway on the Load Staged Items page, you do not need to run the Stockroom Feedback process.

3. Run the Putaway page.

   This processing page updates the stock location with the quantity received from the WIP location.

Putaway at Receipt Save Time

Use this option to initiate the putaway process after you have recorded completions and saved the page. This method creates a schedule process that automatically initiates the putaway process.

Recording Completions and Scrap for Production IDs with Multiple Outputs

You use the Record Completions/Scrap component to record completions and scrap for production that generated multiple outputs: primary items, co-products, and recycle and waste by-products.

See Also

Receiving and Putting Away Stock

Pages Used to Record Completions and Scrap for Production IDs with Multiple Outputs

Entering Completions Quantities for Production IDs with Multiple Outputs

Access the Output Details scroll area on the Record Completions/Scrap page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completion/Scrap).

To enter batch completions quantities (for production IDs with multiple outputs):

1. Access the Record Completions/Scrap page.

2. Enter a completed quantity and select an operation sequence.

   The Output Details scroll area becomes available.

   Note. If you're recording completions at an intermediate operation, the system displays all by-products. If you're completing operations at the last operation, the system displays all outputs: primary, co-products, and by-products.

3. (Optional) ClickView All to display all end items being completed.

4. Enter the completed quantity for each output.

   The completed quantity for each end item is calculated based on the batch (BOM) quantity. You can, however, override the output quantity for each end item.

5. (Optional) Click Add to add by-products.

   1. Select the output type; you can only add Recycle or Waste by-products.

   2. Select the output item.

   3. Select the operation sequence where the by-product is being generated.

      The default operation sequence is zero, and if you do not change the default, the system treats it as the last operation.

   4. Enter the output quantity based on per end item or per order.

6. Click Save to process the multiple output completion.

Output Details

Example: Batch Calculation

If you entered a completed quantity of 5 on the Record Completions/Scrap page, the system calculated each output quantity based on this quantity of 5. However, you can change the completed quantity for any of the outputs in the Output Detail scroll area. Overriding the completed quantity at the output level for primary and co-products recalculates the batch completed quantity using the resource percentages defined on the BOM.

Over-Completing Production IDs

There may be situations when you need to over-complete expected production ID quantities. For example, perhaps the oranges that you used to make orange juice were a bit juicier than normal, and instead of producing 75 gallons of orange juice, you actually produced 80. If this is the case, you would enter 80 in the Completed Qty (completed quantity) field on the Record Completions/Scrap page. When you tab out of the field, you receive a message indicating that the output item's completed quantity is greater than the production quantity.

When you click OK, the system recalculates the completed quantity for all output items based on this new quantity.

Note. If you want to change the production quantities for the batch, which changes the primary and co-product quantities, change the production start quantity or production end quantity for the production ID on the Production ID Maintenance page.

Moving Completed End Items for Production IDs with Multiple Outputs

After recording completions for production IDs with multiple outputs, you can route each completed output to a storage area, another production ID, or a WIP location.

See Moving End Items for Completed Production.

Editing or Issuing Components During the Completions Process

Use the Edit/Issue Components pages if you want to modify or view the components that will be consumed based on the quantity completed or scrapped, or if you need to select the serial or lot numbers for those components that were consumed when you recorded the completion.

See Editing Component Lists.

Recording Completed and Scrapped End Items for Production Schedules

For production schedules, you can record partial production completions, or you can complete the entire schedule.

Use the Record Completions/Scrap component to:

• Record completed operations for all or part of the production quantity.

• Record completions and scrap for production schedules with multiple outputs.

• Scrap end items.

• Completely backflush the entire production run or order.

• Automatically consume components based on the quantity completed.

• Automatically complete end items based on the batch completed quantity.

• Manually substitute components where there is a shortage of an item or an item is out of stock.

• Assign serial numbers and lot numbers to completed end items before moving them out of the production area.

• Route completed end items, including primary items, co-products, and recycle by-products, to another production ID or WIP location to be used on subsequent end item production.

• Indicate that production has been completed for the production schedule.

If you have enabled PeopleSoft Workflow, when you record end item scrap, the system sends a notification by using the Assembly Prdn Schedule Scrap Notification workflow to selected roles defined by you. These roles could include a quality manager or a production control manager.

Using this component, you can record in-house operation or end item completions and scrap for production schedules with a status of:

• Entered or Firmed: The system automatically releases the production schedule, and creates the component list and operation list (if a routing exists).

  The status is automatically changed to In Process.

• Released: The system changes the status to In Process.

• In Process.

If you're using production issue or production kit method for regular production, you still must issue material to the WIP locations using the Pick Plan and Material Release components. If you're using the production replenishment method, ensure that sufficient inventory exists in the WIP location.

Note. Quantities of an item that are stored in a nettable, available WIP location and reserved for production use are not available for other purposes.

You can record in-house operation or end item completions and scrap for production quantities that haven't been previously entered as scheduled quantities.

In this case, the system prompts you for the schedule quantity and the production schedule is automatically created with a status of In Process. You can then backflush a partial quantity or the entire production quantity and record any scrap.

• If you're using the production issue method, you still must issue material to the WIP locations to ensure that there is sufficient quantity on hand to satisfy the production schedule quantities.

• If you're using the production replenishment method, make sure that sufficient inventory exists in the WIP location.

This section lists common elements and discusses how to:

• Record completed and scrapped end items for production schedules.

• Peg to a specific production schedule.

• Add a new production schedule during completions.

• Define completions and scrap information for production schedules.

• Record completions and scrap for production schedules with multiple outputs.

• Move end items for production schedules.

Common Elements Used in This Section

Pages Used to Record Completions and Scrap for Production Schedules

Recording Completed and Scrapped End Items for Production Schedules

Access the Production Selection page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Production Selection).

Pegging to a Specific Production Schedule

Access the Schedule Selection page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Production Selection. Enter the production area and item, and then click the Complete to a Specific Schedule link).

You may want to complete for a specific production schedule because a substitution was made or a data entry error needs to be corrected. In addition, by pegging to a production schedule, you update the specific production schedule when you run the Completions Update process.

Adding a New Production Schedule During Completions

If the system indicates that no current outstanding production schedule quantities exist for this production area/item combination as of the BOM/routing effective date or effective date, you receive a warning message indicating that no outstanding production quantities exist for an area or item.

If you click Yes, the system creates a new production schedule. The system checks for any outstanding production schedules by comparing any unprocessed BCTP detailed transaction logs (BCT_DTLs) (Completed + Scrapped ) quantities and netting them against those matching open production schedules (production end quantity > completed + scrapped quantity) in the system.

The default rate quantity per shift from the production area or item definition appears as Production Rate Quantity. Click OK to accept this quantity or change the quantity to the quantity that you're currently producing.

Recording Completions and Scrap for Production Schedules That Haven't Been Released

You can also record completions and scrap for production schedules that have not been released.

To release Entered production schedules, use the Prod Schedule Status Change page or the Production Status Change process (SFPARELS). This process looks for production schedules that match the date, shift, BOM code, routing code, and primary end item of the selection criteria. The system releases all the production schedules with a status of Entered that match the selection criteria. You can then record completions and scrap for the production schedules.

Firmed production schedules are automatically released during the completions process.

Defining Completions and Scrap Information for Production Schedules

Access the Record Completions/Scrap page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completions/Scrap).

The process for recording completions and scrap for production schedules is similar to the process used for production IDs. However, there are a few differences:

• Completions and scrap are recorded at the last operation sequence only.

• You select one of these completions actions:

  Completions/Putaway on Save	Use this option to initiate the Completions Update process for the selected production schedule upon saving the page. The production end quantity completed and scrapped information is updated as well as the storage area quantity on hand. All completions processing is performed, including component updates.
  Stage Compltns/Putaway on Save	Use this option to run the Completions Update process at a later time.

Recording Completions and Scrap for Production Schedules with Multiple Outputs

Access the Record Completions/Scrap page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completions/Scrap).

To record completions and scrap for production schedules with multiple outputs:

1. Enter the completed quantity that represents the batch (BOM) production end quantity.

   This quantity doesn't represent completed quantities for each output in the Output Details area. You can enter a quantity here or optionally enter the quantity of each output. If you enter specific output completions, the system determines the quantity of the batch completed.

2. The Op Seq field is unavailable and the last operation step appears.

   Note. Because you're completing a production schedule, the Update Prior Operations check box is unavailable, and the first operation step appears by default in the Back Thru Operation field. These fields are display-only and cannot be changed.

3. Click the Enter Scrap Data link to make corrections to the scrapped component quantities.

4. Access the Output Details scroll area on the Record Completions/Scrap page.

5. Enter the completed quantity for each output.

   The system calculates the multiple output quantities based on the batch completed quantity from the Record Completions/Scrap page. For example, if you entered a completed quantity of 5 on the Record Completions/Scrap page, the system would calculate each output quantity based on this quantity of 5. However, you can change the completed quantity for any of the outputs on the Output Details scroll area.

   Note. If you want to change the production quantities for the batch, which changes the primary and co-product quantities, change the production end quantity for the production schedule on the Production by Area Summary or Production by Area Details pages.

6. (Optional) Click Add to add recycle or waste by-products.

   1. Select the output type and output item.

   2. Select the operation sequence where the additional by-product is being generated.

   3. Enter the completed quantity, which is the output quantity that you're currently completing.

   4. Enter the output quantity.

      This quantity represents the output production end quantity based on per end item or per order.

7. Click Save to record the completions and scrap.

Moving End Items for Production Schedules

With production schedules, you can only complete end items at the last operation. When you enter the completed quantity on the Record Completions/Scrap page, the Route-To PID/Stor Locations scroll area becomes available. You use the Route-To-PID/Stor Locations scroll area to route completed end items for production schedules with a single output or multiple outputs.

Editing Component Lists

At some point while recording operation completions and scrap, you may need to view or modify the component list or select the lot and or serial numbers for the consumed components. Using the Edit/Issue Components pages, you can:

• Add components to or delete components from the component list.

• Add substitute components to or delete substitute components from the component list.

• Change the scheduled quantity, quantity per order or per assembly, operation sequence, or component yield percentage.

• Change the pending issue or pending yield loss quantity.

• View or edit components even if you haven't reported any end item completions or scrap.

• Consume components that couldn't be consumed previously due to shortages in the WIP location.

• Select the serial numbers or lot numbers of the components to be consumed. For lot-controlled components that are not serial-controlled, you can view or change the lot numbers assigned during backflush, if you have selected the backflush lot selection rule of Earliest Expiration Date or Earliest Available Date.

  See Automatically Consuming Lot-Controlled Stock During a Backflush.

In addition to using this page to record the consumption of components in the process of recording completions or scrap, you can also use this page to:

• Record miscellaneous consumption of components, independent of backflushing.

• Consume pending component quantities that were created when you backflushed and a shortage existed in the WIP location.

  If a shortage existed and you already recorded completions, you must first issue material to the WIP location and then use the Edit/Issue Components pages to consume those quantities.

Keep these in mind when editing component lists:

• For regular production, the system displays the components in effect for the end item at the due date for production or for the item revision, if one is specified.

  If a component for the item is designated as a phantom on the production BOM, the phantom item's components—not the phantom item—is listed here. The operation sequence for the phantom is used for the phantom components.

• For production IDs using serial genealogy, and component's trace usage = serial or lot, the issue qty field is display-only.

  Use the Component Association or the Maintain Serial Genealogy commands to associate and consume these components. To consume trace usage components that are not associated with a serial assembly enter quantity in the pending yield loss qty field.

• For rework production, the end item is the only component listed unless you're using a rework BOM or have previously maintained the component list and added those components necessary to rework the end item.

• For teardown production, the end item to be torn down is the only component listed, unless you have previously added additional components to the component list.

• You can change any component to a different item ID, or you can add a new component or substitute.

  You cannot change the component ID or operation sequence it is associated with once the component has been issued. In addition, for rework production, you cannot change the end item that is being reworked and for teardown production, you cannot change the end item to be torn down.

• For all production types, when you add new components with an item status of Discontinue, you receive a warning message.

  For regular production, you receive a warning message when you add a component with an item status of Hold. In both cases, receiving the warning message doesn't prevent you from performing the action. For rework and teardown, components with an item status of Hold are issued.

• When using the online mode of this component (PID Completion Option on the MFG BU Prdn Options page), if the backflush process has completed and then a field is changed that causes the pending quantities field to be recalculated, this causes a recalculation of backflush lot selection rule. Fields that trigger the recalculation of the pending quantities include:

  • Completion Quantity

  • Scrap Quantity

  • Completion Op Sequence

  • Back thru Op Sequence

  • Component ID

  • Component's Op Sequence

  • Component's Qty Code

  • Component's Qty Per

  • Picking a substitute item

• For regular production, you cannot add the end item as a component.

  On the other hand, for rework production, you cannot delete the reworked end item from its component list. Duplicate components can exist as long as the operation sequence is unique. You cannot add a configured item as a component unless the end item is a configured item.

• When deleting components, the system checks to see if:

  • The issue quantity for the component is greater than zero.

    In this case, you cannot delete the component. To delete the component, reverse the backflush, unconsume the component, or use the Kit Issue/Return page to return the component, and then delete it.

  • The component's issue method is Kit,and a pick plan has been generated for this component.

Note. If you need to add a phantom component to the component list, you must enter all of the items that make up the phantom component. A substitute component cannot be a phantom or a component of a phantom. Where substitutes exist for a component, the component cannot be changed to a phantom.

Editing or Issuing Components for Production Schedules

You can also use the Edit/Issue process to consume existing pending quantities for a production schedule. After selecting the area or item and dates of the production schedule and clicking the Search button, a message appears if there are any existing pending quantities for production schedules that match the selection criteria. If Yes, then the components with existing pending quantities appear.

Workflow Notification

If you have enabled PeopleSoft Workflow, you can use the Replenishment Notification workflow to notify the stockroom when the quantity on hand for components with a component issue method of Production Replenishment falls below its minimum stocking quantity in that location. This notification indicates that the location must be replenished.

Note. When you're editing or issuing components, the system doesn't allow you to modify component information for components whose issue method is Kit. Use the Kit Issue/Return Component to edit or issue these components. Additionally, you can view but cannot modify components whose source code is Floor Stock.

Issuing Components and Effects on Quantities

Capacity Checking

You activate weight and volume capacity checking on the PeopleSoft Inventory Options page, and define the capacity for each storage location on the Volume/Weight Capacity page accessible from the Material Storage Locations page.

If the item is designated as an isolate item on the Inventory-Shipping/Handling page in the Define Business Unit Item component, it can only be put away or transferred to empty storage locations or to locations containing stock with the same item ID. The system prevents you from moving an isolate item to a WIP location with other items.

If you designate a WIP location as storing only one item on the Volume/Weight Capacity page that is accessible from the Material Storage Locations page, the system only issues material with that item ID to that location. If you do not specify an item ID for a single-item WIP location, the first issue transaction to the empty WIP location defines the only item ID that the location can contain until the item quantity has been fully depleted.

Pages Used to Edit or Issue Components

Selecting Production for Editing or Issuing Components

Access the Edit Components - Production Selection page (Production Control, Process Production, Issue Materials, Edit/Issue Components, Production Selection. Select the production ID or production schedule for which you want to edit or issue components. Components must have an issue method of Issue or Replenish to use this page).

See Also

Defining Production Options

Editing or Issuing Component Summaries

Access the Edit/Issue Components Summary page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Edit/Issue Components Summary).

Print at Save	Select this check box if you want to print production documents for a particular production ID at save time.
Setup Print Options	Click this link to access the Process/Output Options page to select different print criteria for the production documents.
	Click the Express Page button to access the Edit/Issue Express page to view or assign serial and lot numbers.
	Click the Detail button to access the Edit/Issue Component Detail page.
	Click the Item Search button to access the Item Search, Item Availability, or Item Substitution pages.
Op Seq (operation sequence)	Determines the WIP inventory location to which the components are issued and from which they are consumed. When you add a new component to the component list, the operation sequence defaults to zero. When recording end item completions and scrap, the system consumes a component with an operation sequence of zero at the first operation and decrements the component quantity on hand in the production area's default WIP location. You can change the operation sequence to any valid operation on the end item's operation list. When you select an operation sequence, the component must be issued to and is consumed from the WIP location associated with the operations work center.
Per	Indicates whether the quantity required is per assembly (Asy) or per order (Ord). Per assembly indicates the quantity required to complete one end item. Per order indicates the amount required, regardless of the end items that will be produced. If the component is per assembly, the system calculates the consumed quantity by multiplying the quantity per by the end item completion and scrapped quantity. If the component is per order, and you're recording completions for a production ID, the system consumes the full order quantity during the first recorded backflush. Once consumed, it will not be consumed again during any subsequent backflushes. If you're recording completions for a production schedule, the consumption of a per order quantity depends on the Manufacturing Options setting for Calc Per Order for Production Schedules.
Pending Issue Qty (pending issue quantity)	The system calculates this value for those components whose operations have had end item completions or scrap reported. Enter a new pending issue quantity if you consumed more or less than the quantity calculated. The pending issue quantity is based on the quantity completed plus the quantity scrapped multiplied by the quantity per assembly. If the quantity on the component list is expressed in terms of quantity per order, the full quantity appears. This quantity is consumed only at the time of the first backflush for production ID. For production schedules, the Calc Per Order for Production Schedules option on the Manufacturing Business Unit Option page determines how the quantity is displayed. If you have enabled PeopleSoft Workflow, the system sends a notice to the production supervisor that there is a nonzero quantity for this component. PeopleSoft Manufacturing uses the Identify Production with Pending Quantities workflow for this notification. If the option is set to Calc Per Order for Prdn Sched, the system displays the per order quantity for every production schedule completion. If you have already consumed the order quantity for the production run, you must zero out this amount. If the option is set to do not Calc Per Ord on Prdn Sched, the system doesn't display any per order quantity for any production schedule completion. In this instance, you must enter the order quantity when the material is consumed for the production run.
Pending Yield Loss Qty	If the quantity of components lost is more or less than planned, indicate the new pending yield loss quantity here. If the item's yield loss is set to calculate the pending yield loss quantity, then the system calculates the pending yield loss for those components whose operations have had end item completions or scrap reported. You define whether or not you want the system to calculate pending yield loss quantity at the business unit or item level. If you do not want the system to calculate pending yield loss quantity, then you manually record the yield loss at the appropriate times. The system uses this formula to calculate the pending yield loss quantity: (Quantity Completed + Quantity Scrapped) x Expected Yield Loss Percentage Expected Yield Loss Percentage = (1 - Component Yield / 100)

Adding or Substituting Components

Allowing Negative On Hand Inventory

If the PeopleSoft Inventory business unit parameter allows negative inventory balances and there is not enough material in the WIP location to cover the pending issue or pending yield loss quantity, the quantity on hand in the WIP location will become negative. Another business unit parameter determines when the system issues a warning message prior to driving quantity on hand negative. This message allows you to decide whether to continue with the completion transaction or to wait until the inventory is moved into the WIP location before continuing. If you do not allow the inventory to go negative, the quantity that couldn't be consumed remains in the pending issue or pending yield loss fields. These must be reconciled once the WIP location has sufficient quantity on hand.

Note. If the item that you're consuming is serial-controlled, you cannot drive the quantity on hand negative, regardless of the PeopleSoft Inventory business unit setting.

Using the Edit/Issue Express Page

Access the Edit/Issue Express page (Production Control, Process Production, Issue Materials, Edit/Issue Components, Edit/Issue Express. Click the Edit/Issue Express link).

Component Details

You can change any of this information on this page: Component ID Pending issue quantity Operation sequence Pending loss

Consuming Serial-Controlled Components

Access the Lot/Serial Number Selection page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Edit/Issue Express. Click the Select Lot/Serial link).

Consuming Lot-Controlled Components

Access the Lot/Serial scroll area on the Edit/Issue Express page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Edit/Issue Express).

See Also

Automatically Consuming Lot-Controlled Stock During a Backflush

Editing or Viewing Component Detail

Access the Edit/Issue Components Detail page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Edit/Issue Components Detail).

Component Details

Note. Quantities of an item that are stored in a nettable, available WIP location and reserved for production use are not available for other purposes.

Identifying Material Shortages

An Application Engine process queries the production component table for any outstanding pending component quantities for production with a status of In Process or Pending Complete. If the system finds outstanding quantities, the system issues a worklist notification for each of the qualified production orders to relieve the component. When you work the worklist entry, you're transferred to the Edit/Issue Components Summary page. Once you consume material to relieve the shortages, the worklist entry is marked as completed.

Running the Completions Update COBOL/SQR Process (SFPDCDRV)

The Prdn Compl/Scrap (SFPDCDRV) process (Production Completions and Scrap process) updates completions transactions that are staged by other processes, such as Edit Components updates, production completions, or subcontracted completions recorded through electronic data collection. In addition, you run this process to update production quantities for production schedule completions and scrap. You run this process if you selected Stage Compltns/Putaway on Save as the completions action on the Record Completions/Scrap page.

Page Used to Run the Completions Update COBOL/SQR Process (SFPDCDRV)

Running the Completions Update Process

Access the Prdn Cmpl/Scrap page (Production Control, Process Production, Complete Production, Process Completions and Scrap, Prdn Cmpl/Scrap).

Creating Reversing Entries to Correct Data Entry Errors

Use the Record Completions/Scrap component to create reversing entries to correct data entry errors made when recording end item completions or scrap.

Enter a negative number to reverse the completion or scrap entry. For example, suppose that an entry was made to record a completion of 8 end items at operation 20, but only 6 end items were actually completed. You can enter a -2 in the Completed Qty (completed quantity) field to reverse the original entry of 8. This brings the completed quantity balance for that operation to 6.

This reversing entry:

• Rebalances the completions or scrap count.

• In the case of a production schedule, rolls back the reversing entry through all prior operations.

• In the case of a production ID, rolls back the reversing entry through the specified prior operation, or back to the previous count point.

• Automatically returns any components that were consumed at the current operation to the appropriate WIP location.

• Creates a reversing entry for earned labor, machine, and overhead costs.

Pages Used to Create Reversing Entries to Correct Data Entry Errors

Identifying Production for Data Entry Error Corrections

Access the Record Completions/Scrap - Production Selection page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Production Selection).

Note. If you attempt to perform negative completions and you haven't recorded any positive completions, the system displays an error message. If you click Yes to continue, you are able to record positive completions. If you click No, the system returns you to the Production Selection process page.

If you attempt to perform negative completions and you cannot find the quantity in the location you expected, you may not have run the Completions Update process and the putaway process.

Entering Negative Completions Quantities

Access the Record Completions/Scrap page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completion/Scrap).

Completed Qty (completed quantity)	Enter a negative return quantity in this field. Note. If you enter a negative quantity in the Completed Qty (completed quantity) field, and you didn't select the negative completion on the Record Completions/Scrap - Production Selection page, you receive a message asking if you're doing a negative transaction. If Yes, then the transaction automatically selects the Negative Completions option for you, and you do not have to return to the Production Selection page and select the Negative Completions check box.
Enter Scrap Data	Click this link to correct the scrapped component quantities.
Quality	Click the Quality link to initiate a data entry session and to transfer to either the Data Entry - Subgroup Method page or the Data Entry - Sample Method page in PeopleSoft Quality, depending on the data entry method that you specified when creating the quality control plan. Note. The Quality link is available for each end item in the Output Details scroll area. You can transfer completions data to PeopleSoft Quality for each end item.
Update Prior Operations and Back Thru Operation	You can enter values for these fields if you're creating a reversing entry for production IDs.
Lot ID	Select a value if you're creating a reversing entry for lot-controlled end items.
Area	Specify the storage area and inventory locations from which you want to pull the completed end items.
Return Qty (return quantity)	Enter a negative number in this field.
Serial IDs	Click this link if you're correcting data entry errors for serial-controlled components. Select each serialized item that you want to move back into production by selecting one or more serial IDs.

Note. Reversing entries are processed when you save the Record Completions/Scrap page.

Creating a Reversing Entry for the First Operation, an Intermediate Operation, a Count Point, or for Scrap at Any Operation

If you're creating a reversing entry for the first operation, an intermediate operation, count point, or for scrap at any operation, the system reverses the earned production costs or the scrap costs for those end items at that operation and moves them back to the specified prior operation or count point. In addition, the system returns all consumed components to the WIP location.

Example: Negative Completions When Using Count Points

Count point operations: 30, 50

Production start quantity: 10

Step 1

Production start quantity completed: 10

Completing at operation sequence: 30

Back through operation sequence: 10

In this example, you're completing operations and scrap for a quantity of 10 at operation sequence 30, which is a production ID count point. You selected the Update Prior Operations check box on the Record Completions/Scrap page, and indicated that you wanted to update previous operations back to operation sequence 10. The system calculates the production completed at operation sequences 10, 20, and 30:

Step 2

Production start quantity issued or returned: -5

Reversing end item completions at operation sequence: 3

Update previous back through operation sequence: 10

In this example, you're returning a quantity of 5 at operation sequence 30, which is a count point. You selected the Update Prior Operations check box on the Record Completions/Scrap page, and indicated that you wanted to update previous operations back to operation sequence 10. The system recalculates and reverses the quantity issued to the operation at operation sequence 40:

Example: Negative Completions When Not Using Count Points

Production start quantity: 10

Step 1

Production start quantity completed: 10

Completing at operation sequence: 30

Back through operation sequence: 10

In this example, you're completing operations and scrap for a quantity of 10 at operation sequence 30. You selected the Update Prior Operations check box on the Record Completions/Scrap page, and indicated that you wanted to update previous operations back to operation sequence 10. The system recalculates and reverses the production completed at operation sequences 10, 20, and 30:

Creating a Reversing Entry at the Last Operation for Completed End Items

If you're creating a reversing entry for the last operation, the system reverses the earned production costs for those end items at the last operation.

To create a reversing entry for the last operation, you must specify the storage area or production area from which you're removing the previously completed end items. You also must complete these:

• For completed end items, select the inventory or WIP location from which you want to remove the items.

• Select which serial- or lot-controlled items need to be moved back into production, if the completed end items are serial-controlled or assigned to a lot.

Completing Production

For production IDs, use the Complete Production page to indicate that:

• Setup has been completed at the operation even though you are not recording any end item completions.

  This enables you to earn the setup costs for the production run. Setup is automatically earned when the first end item completion or scrap is recorded.

• Post production work has been completed at the operation.

• Production for all operations has been completed.

Pages Used to Complete Production

Running the Complete Production Process

Access the Complete Production page (Production Control, Process Production, Complete Production, Record Completions and Scrap, Record Completion/Scrap. Select the Complete Production link).

Moving Excess Inventory Back to a Stores Location

When the last end item is completed or the production run is finished, move any excess WIP components with an issue method of issue or replenish back to their appropriate stores location. Once you've identified the excess WIP inventory, run a transfer transaction using PeopleSoft Inventory. The transfer process moves the excess WIP components from the WIP location back to the stores location.

Use Kit Issues/Return to return excess components whose issue method is Kit.

Viewing and Reporting Material Shortages

PeopleSoft Manufacturing provides a shortage report, which enables you to view, at a glance, the shortages for each production order or production run sorted by production ID or components. The system tells you where shortages exist, so you can move inventory to those areas to relieve production shortages.

Pages Used to View and Report Material Shortages

Viewing Scrap and Earned Conversion Cost Information

On a periodic basis, you want to monitor scrap and earned conversion costs associated with production. Viewing this information gives you a good idea of how the manufacturing floor is performing. PeopleSoft Manufacturing provides you with the ability to view scrap and earned conversion costs for production IDs and schedules in the production environment.

Pages Used to View Scrap and Earned Conversion Cost Information

Recording and Viewing Actual Machine and Labor Hours

PeopleSoft Manufacturing provides you with the ability to record and view actual labor and machine hours incurred during the manufacturing process.

Pages Used to Record and View Actual Machine and Labor Hours

Entering Actual Hours Information

Access the Record Actual Hours page (Production Control, Process Production, Complete Production, Record Actual Hours, Record Actual Hours).

Op Seq (operation sequence) and Work Center	Select values for either field. If you select the operation sequence, the work center, crew, and machine information associated with the operation sequence appears on the page. You can, however, change these values. For production IDs, the operation sequences listed are from the production ID's operation list. The operation sequences for production schedules are the item's routing for the routing code specified for the area or item. If you select the work center, you can select from all available work centers to accommodate any changes that might have occurred on the routing during production. Once you select the work center, the default crew and machine information appears based on the work center information. You can accept or change these defaults. Note. If you then enter an operation sequence, the work center information is changed to the work center associated with the operation sequence, if it is different.
Crew Reporting	If you select this option, the system multiplies the actual labor hours that you record by the crew size to determine the total number of actual labor hours for performance reporting.
Machine Reporting	If you select this option, the system multiplies the actual machine hours that you record by the number of machines to determine the total number of actual machine hours for performance reporting.
Labor Hours or Machine Hours	Enter the number of hours based on: Setup Run Fixed run Post production Note. Enter negative hours in these fields to correct data entry errors.
Scheduled	Enter any number of scheduled hours when there is known downtime for the work center. Scheduled hours are used to calculate labor and machine utilization. If no scheduled hours are entered, the system calculates the available hours based on either the work center or production calendar.

Note. You can enter actual hours for any labor or machine time type even if the time type wasn't included for planning or costing purposes. For example, if no costing postproduction time was specified for the operation, but actual time was spent cleaning up the work center once production was completed, you can still enter those actual hours.