The last step in the production is to post all transactions. The post will update inventory, serial/lot records and G/L accounts, as well as the following:
- If the transaction issues material, the system will
- Adjust Quantity on Hand and Quantity Allocated fields in the Item Master file or Item/Location file.
- Create Inventory Transaction records.
- Adjust quantity in the ATP records.
- Update the serial record for serialized items.
- Create temporary records for lot components. Use the “Issue Serial/Lot Component Items” function to issue lot numbers for these temporary records.
- Adjust the quantity of the components in the default production bin if Multi-Bin is utilized.
- If the transaction is for last operation, several functions will be performed for the parent item.
- The Quantity on Hand, Quantity Ordered, Average Cost and Last Cost fields in the Item Master file or Item/Location file will be adjusted.
- An Inventory Transaction record will be created.
- An adjustment will be made to the quantity in the ATP records.
- The serial/lot record will be updated for serial/lot items.
- If Multi-Bin is used:
- The parent item’s quantity in the default production bin will be adjusted.
- An Inventory Transfer Batch will be created with the appropriate Global Setup.
- Update “New Received Item” in COP if this order is not copied from COP.
- Update the Order Status and Reported Quantity in the Work Order file. If the Order Complete flag is “Y”, the system will close the order and change the order status to “Complete”.
- Update the time and quantity of the orders’ operation and bill of material.
- Create distributions in the B/M Distribution to G/L File. The distribution amounts are for each operation and components in the order.
- Each transaction will create distributions which credit the inventory account, labor absorbed account, burden absorbed account or outside process absorbed account. At the same time, each transaction will create offset distributions which debit the Work-In-Process Account.
- If the transaction is for the last operation, Y Count Point, it will create distributions which credit the Work-In-Process Account and debit the finished goods account. Based on control settings, variance distributions in G/L may be created as well;
- Standard Cost Variance, if I/M Setup is configured for Standard Cost.
- WIP Variance, if the system cannot handle the amount left in the WIP Account.
- Scrap Account, if scrap account is in use.
- If the transaction is for an outside process, the system may create PO Receiving Transactions with the appropriate BOMP Global Setup.
- The system will move the transaction record to history.
- The system will update the 12 Month record for BMOPERID, BMOPITEM, BMOPPCAT and BMLCDPWC.
Since posting will update multiple databases, we highly recommend printing a transaction edit list to review all transactions before posting them.
Elliott provides two options to post transactions, immediate posting after the transaction is created and batch posting.
If the transactions do not need to be reviewed, you can post the production immediately after creating it.
This needs to be enabled in BOMP Global Setup in fields 4, Enable Immediate Production Trx Posting, and 21, Immediately Post Completed Scan Trx for +WO. The first turns on the feature in the Production Transaction Processing screen and the second enables the feature in Work Order Production.
With this feature enabled, you will be prompted with “Do You Want To Post Immediately” once you have finished reporting a transaction. Selecting “Yes” will bring up the Print Options window for the post journal destination.
(Figure 48) Immediate Posting Confirmation
The system will provide a warning and solution if an exception occurs. If the exception is not handled, the system will not post the transaction immediately. Review the exceptions in the transaction edit list and correct them or override all exceptions before posting again.
If the transaction will close the order, the system will post all transactions of the order.
Transactions can be reviewed through the edit list before posting them as a batch. The post will allow you to select a range of work orders, dates, work centers and locations of the transactions, as well as the level of detail to print on the journal.
How to Access:
Main Menu è Distribution è Bill of Material Processor è Processing è Posting Production Transactions è Post è Plus Work Order
(Figure 49) Batch Post Transaction Routine
Type and Description
Starting/Ending Order No
6 numeric digits.
The start and end of the range of order numbers. Defaults to All.
Post Transactions Thru
A date in the standard date format.
Selects transactions with a transaction date on or before this date.
Defaults to the system date.
Starting/Ending Work Center
6 alpha-numeric characters.
The start and end of the range of work centers. Defaults to All.
2 alpha-numeric digits with wildcard support.
Select the production location.
“Y” or “N”.
Enter “Y” to print cost on the post journal. This flag is subject to several security flags and BOMP Setup. If the user is not authorized to view cost, this option will not be available.
Defaults to “N”.
Print Cost Detail?
“Y” or “N”.
Enter “Y” to print cost detail on the post journal. This cost details how the system calculates production cost in the Y Count Point. The system will list cost distributed from each operation and material.
Default to “N”.
Once a transaction is posted, it cannot be changed. However, WO+ provides a way to fix a bad transaction if it may cause serious problems. A transaction can be created with the opposite value of one posted. This transaction is called a Reverse Transaction and can be created in the Production Transaction Processing screen. This transaction will attempt to reverse most of the changes made by the bad transaction, including quantity, hours, distributions, and materials. However, it cannot recover 100% of the data to the status before the post due to the complexity of the transactions. For example, it cannot recover changed average cost and last cost, issued serial number or printed transfer batch. You should avoid using this often, but it can be used to deal with serious problems.
Normally, the work on an operation of a work order is called “production” in WO+. Each transaction is identified with a Production Number, which is usually hidden from view. Only the work order number and operation number are needed to report production and create a Production Transaction. So, one Production Number is related to one operation of a work order. Start the production by entering the order number and operation number. When the order number and operation number are entered again, the system ends the production and transactions are created.
Multiple work orders can be grouped together and processed at the same time in one work center. One example would be when a worker moves products from one production department to the packaging department for a group of work orders. The labor for the worker should be distributed to all work orders in the group. Instead of starting a production for each work order, you can create a Batch Production.
Batch Production is related to multiple operations from multiple work orders. These operations should share similar attributes, like if they are all moving steps in the same work center. All labor and machine time contributed to the Batch Production will be distributed to each work order based on quantity.
The most basic way to create a Batch Production is through the Work Order Production interface.
In the Work Order Production section, press the F1 function key to add a batch when the cursor is on the Order Number field. The system will bring up the Batch Production maintenance screen. From here, multiple operations can be added from different work orders through the Insert Key. Each operation is called a Production Detail of the Batch Production. You can also use the Delete Key to remove detail and use the F1 Key to change detail.
To add Production Detail, the Work Order Number, Operation Number and Plan Quantity need to be entered. The system will reflect the new production status at the top of the screen with total hours and total pieces.
(Figure 50) Press F1 to Add a Batch Production
(Figure 51) Create Batch Production Screen
(Figure 52) Add an operation to Batch Production
(Figure 53) Two work orders have been added to this Batch Production
(Figure 54) Start this Batch Production
Figure 42 shows where to start a Batch Production in Work Order Production. Figure 43 shows the initial screen to create a Batch Production. Figure 44 shows the screen to add a Production Detail. The Work Order Number, Operation Number and Planned Quantity need to be entered. Figure 45 shows two work orders have been added to this Batch Production and it will take 5 hours of machine time to complete all 20 pieces. Figure 46 shows Work Order Production after leaving the Batch Production Create Screen.
There are some limitations for all operations in the same Batch Production.
- All operations should have the same Operation Type.
- All operations should be in the same Work Center.
- All operations should use the same Machine Operation Mode (Setup Mode or Running Mode).
If these are satisfied, the Batch Work Order can have different work order numbers, different product numbers and different order quantity.
There are three ways to report production for the current Batch Production in Work Order Production:
- Start the next activity, except for breaks, meal breaks or end-of-day log off.
- Enter the order number and operation number of any Production Detail in the Batch Production.
- When cursor is on the Order Number field, use the F7 Key to enter a Production Number.
Any method will bring up the Production Reporting screen, which is usually seen in this interface. There are two options for reporting:.
- If the actual processed quantity matches the planned quantity, you can simply enter the total quantity. The system will automatically create a transaction for each work order in this batch.
- If the actual processed quantity does not match the planned, you will need to use Detail Reporting. Press F5 to bring up the Detail Reporting screen.
(Figure 55) Report Batch Production when Complete Qty matches Planned Qty
(Figure 56) Report Batch Production, Detail Reporting Screen.
In the Detail Reporting screen, the system will list all details required to be reported. An asterisk “*” will be displayed on the left side of any operation not yet reported. The following functions are available:
- Press the Enter Key to report for one Production Detail (Figure 49).
- Use the Insert Key or Delete Key to add or delete one Production Detail.
- Press the F1 Key to Auto-Report all Production Detail. The system will use Planned Quantity to populate Complete Quantity.
- Use the F2 Key to remove all reported transactions.
Every Production Detail must be reported before leaving this screen or the reporting will be aborted.
A change in Production Detail while reporting is considered an exception. Although anyone can handle this exception, an exception record will be created for future reference.
(Figure 57) Report for one Production Detail
(Figure 58) All Production Details are reported
Every work order production can be changed into a Batch Production. You can think of a work order production as a Batch Production with only one work order, so they are always interchangeable.
There are several methods to change a single order production into a Batch Production.
When reporting Complete Qty for the current production in Work Order Production, press the F5 Key to bring up Detail Reporting. If the production is for a single work order, the cursor should be on the Qty Complete field (Figure 51). An option will appear, “F1=Batch Mode”. Press the F1 Key and the screen will change into the Batch Production Reporting screen. You can add other work orders to this Batch Production.
(Figure 59) Detail Reporting for single order production.
(Figure 60) Change into Batch Mode.
In the Work Center Operation interface, which is described in another section, you can select Started Production List or Completed Production List and use Advanced Operation to maintain one production. If the production is started but not yet finished, it can be changed into a Batch Production as well. Also, the F1 Key can be pressed in the Order Number field to change the screen into Batch Mode.
If a Batch Production has only one work order, it will become a single order production and the reporting screen will be different.
(Figure 61) Maintaining a Started Production in Work Center Operation