Understanding Lean Completions
You use the Item Completions program (PF31011) to complete an item on a shop floor daily plan or Demand Flow daily plan, or complete an ad hoc (unplanned) item. You perform a completion based on an item number instead of a work order. There is only one Item Completions program, but there are three ways to complete an item based on the setup.
If you have set up the line using the Demand Flow line design process, you use the Daily Planning and Sequencing program (PF34S002) to plan the demand based on sales orders or finished goods orders. You select a Demand Flow daily plan against which to complete items using the Demand Flow Plans program (PF31013).
If you do not use the DFM system, you create a daily plan in the JD Edwards EnterpriseOne Shop Floor Management system and then use the Shop Floor Plans program (PF31012) to select a plan for completion.
An ad hoc completion completes transactions for any item that you did not plan through either daily plan program. You complete ad hoc items directly through the Item Completions program.
Once items on a daily plan are displayed, you specify this information for each item that you want to complete:
Actual completed quantity
Actual scrapped quantity
Location
Lot or serial number
Note: You can enter a lot or serial number manually only for end items.
After entering item completion information, you process the completion transaction by running the Multi-Level Item Completions program (RF31011B). This batch program creates the transactions related to completions, such as component issues and labor reporting.
You can set a processing option to use the preprocessed item data or have the system ignore it and perform preprocessing through Item Completions. You have the flexibility to define how the backflush transaction occurs during item completion:
Backflush the material and labor for the single-level item (including all phantoms).
Backflush the material and labor through any user-specified level in the BOM.
Backflush the material and labor for all levels in the BOM structure.
The Item Completions program backflushes all material and labor based on standard values from the bill of material and routing within the effectivity dates and user-specified level in the bill of material. Demand Flow principles require a flattened bill of material and routing for backflushing, but the system creates the flattened (multilevel) bill of material and routing automatically. This enables you to maintain the existing bills and routings in an easy-to-read format.
You can create the multilevel bill and routing before using Item Completions (preprocessing) or let Item Completions create the multilevel bill and routing. Creating the multilevel bill and routing before Item Completions improves processing time for Item Completions. Preprocessing is recommended for companies that have large stable bills and routings or quick manufacturing times. Companies that change their BOM and routing frequently may want to determine the multilevel BOM and routing at the time of completion. The system performs a backflush from a single raw-in-process (RIP) location that is defined in the Line Master program (PF30L912)and stored in the Work Center Master table (F30006).
When you run completions, the system:
Records the end items completed and creates a transaction ID in the Transaction ID Master table (FF31011).
Records routing detail in the Routing Transaction table (FF31112).
The routing does not contain rework or outside operations for Item Completions.
Records labor detail in the Lean Transaction Labor Detail table (FF31113).
Records part detail in the Lean Transactions Parts List table (FF31111).
Receives purchased items into inventory.
Issues components to the manufactured end item.
Updates the daily plan with actual completed quantities.
Updates the daily plan with actual scrapped quantities.
Updates end item inventory.
Updates the Item Ledger table (F4111).
Updates manufacturing accounting.
For consignment stock issues, you can set up purchased component items to be received into the system at the same time as they are issued to lean transactions. To enable this functionality, perform these three steps:
Set the Issue and Receipt field on the Additional System Info form in the Item Branch/Plant program (P41026) to 1. (The system receives an item when an inventory issue occurs).
Enter purchase orders.
Create a version of the Purchase Order Receipts program (P4312) that the system calls to receive components when creating issue transactions for lean completions.
When the system creates the lean parts list record in the Lean Transactions Parts List table (FF31111), it retrieves the value from the Issue and Receipt in the Item Branch table (F4102). If this value is 1, the system looks for open purchase orders for the item and matching branch. If open purchase orders exist, the system selects the purchase order with the lowest order number. You cannot manually select a different purchase order for the receipt. The receipt quantity is automatically the issue quantity. If the issue quantity is greater than the open quantity on the purchase order, the system still creates a receipt for the issue quantity. You can review the details of the receipt transaction in the Transaction Management program (PF31014).
If the receipt transaction fails or if there are no open purchase orders, the system sends a message to the work center, but continues issuing the material, thus driving inventory negative. You have to reconcile inventory manually. Reversing a completion transaction does not reverse the purchase order receipt. You have to perform a manual inventory adjustment after reversing the completion transaction.
Because the transactions are processed blindly, you cannot use lot or serial numbers.
You can track the completion on a daily plan based on the production ID used in the daily plan or the transaction ID created with each completion. The transaction ID records have associated parts, routing, hours, and quantity information that you can review. The records can include both open and closed daily plans.
Once accounting is completed through variances and the processing option in variances has been set to close the transaction to further processing, the transaction status is set to Closed so that no further processing is enabled.