Production Transaction Processing

Application Overview

The Production Transaction Processing application allows for reporting progress made toward completing production work orders.  Transaction information will reside in a transaction file until it is posted through the Post Production Transactions application.

This application has been designed to provide the user with solutions to many common mis-reporting problems that may occur.

If over-production of an order occurs, components will be automatically deallocated and have quantity on-hand reduced.  Also, finished goods will have quantity on-hand increased by the reported amount.  This will take place regardless of whether the Work In Process (WIP) feature was selected when work orders were printed, or if the order was flagged as "complete" by a previously posted transaction.

Under-production, even to the extreme of reporting zero (0) items produced, can be handled by flagging the order as complete and posting the transaction.  The technique commonly referred to as "back-flushing" will then be implemented by the system in this situation.  Any transactions entered against the order after it is flagged as complete will be treated as over-production (see above).

Negative quantity transactions are also allowed by the system.  You may enter negative quantities up to but not greater than the total quantity reported for the order to date.  Regardless of the order's status, all quantity allocated and on-hand adjustments will be made automatically.

When processing Production Transactions for serialized end items, records are written to the Production Transactions and Serial/Lot Files simultaneously when answering N to the Any Changes? question at the bottom of the screen.  If the ESC key is pressed at the Any Changes? question, these files are still updated.  If the transaction is not desired, it must be deleted.

Run Instructions

Select Production Transaction Processing from the pull down BOMP Processing window.  The following screen will then be displayed:

Production Transaction Processing Entry Screen

The following options are available:

      To return to the menu bar, press the ESC or F10 key. To leave this application, press X for EXIT when positioned at the menu bar.

Entry Field Descriptions

The following entry will be requested when lot items are being produced.

The following entry will be requested when serial items are being produced.

Production Transaction Edit List

Transaction Processing

Production Transaction Edit List

Plus Work Order Production Transaction Entry

How to Access:

Main Menu è Distribution è Bill of Material Processor è Process è Production Transaction Processing è Process è Plus Work Order

(Figure 1) Production Transaction Processing for Plus Work Order

This is the traditional way to create, edit and delete production transactions.  The operator needs to enter all the data of a transaction and is allowed to edit most of the fields, in most cases.  If you are not planning to adopt the time clock system WO+ provides, you can always report production through this interface.  Also, the Transaction Edit List can print out all the details of each transaction before they are posted.  The list will print all warnings and errors a transaction would encounter during posting so a manager can correct them.  Only some exceptions can be handled through this screen, like reversing a transaction or overriding a post exception.

What can be done here?

• Add a transaction.
• Edit a transaction.  If the transaction was created through scanning, thus contained a production number, only certain fields can be modified.
• Delete a transaction.  If the transaction was created through scanning, thus contained a production number, it cannot be deleted.
• Print the Edit List.
• Import transactions from a CSV file (not implemented yet).
• Create a reverse transaction from a posted transaction.
• If a transaction cannot be posted due to an exception, you can flag the transaction so the post program will override the exception.
• Change operation data.

Field Description

Transaction Edit List Selection

(Figure 2) Production Transaction Edit List Selection

The Transaction Edit List can print out detailed information for each selected transaction. This includes any warnings or errors.  You can print an edit list before posting and examine the statistics for any exception that might happen.

Print Label

If labels are needed for the finished products, this program outputs an item number for the completed pieces in the selected range of work orders to a CSV file.  For example, if 10 pieces of product in a work order are finished, this program will create 10 records in the CSV file.  A barcode printing program, like Bartender, can be used to print the barcode labels from the CSV file.  You can enable this feature and fine tune the parameters through the Barcode Printing Global Setup.

Report Additional Information

Issued Material Reporting

Materials will be used to manufacture parent items and they can be issued in certain operations based on the definition in each work order.  Those operations which issue material are called Material Issue Points.  In WO+, more than one operation can be a material issue point.  For flexibility, even if an operation is not defined as a material issue point in the work order, you can still issue material in the operation.  This might be a situation where the operator needs to return some materials when the order is complete. Also, material usage may be different between planning and production, therefore the operator can change the issued quantity or substitute material when reporting.

There are two modes to report material, Material Verification Mode and Material Confirmation Mode.  You can switch from one mode to another though the BOMP Global Setup field 51, Enforce Material Verification in Production.  The reporting screen will have two different modes.

(Figure 3) Issued Material Reporting Screen

How to Bring Up Issued Material Reporting

Elliott will automatically pop up the Material Reporting screen when an operator is reporting for a material issue point.  The screen will display all materials which are planned to be issued for this work order.  At this point you can verify if the item number and quantity are correct.

Extra steps are required to bring up this screen if the operator wants to report issued material for an operation which is not a material issue point.  This is available in Production Transaction Processing and Work Order Production.

If the operator is reporting production through Production Transaction Processing, the following steps are required:

1. In Add mode, populate every field for a transaction.
2. Select field 5, Qty Complete/Qty Received.
3. Press the F2 Key to bring up the Issued Material Reporting screen.

The following are required if reporting production through Work Order Production:

1. Enter a non-zero number in the Qty Completed field.  The system will display “Production Reported” to the right of the quantity and prompt “Any Change?”
2. Answer “Y” to the question and cursor will move back to the Qty Completed field.
3. Press the F5 Key to bring up the Detail Reporting screen.
4. In the Qty Completed/Qty Received field, press the F2 Key to bring up the Issued Material Reporting screen.

Even if the operation is a Material Issue Point, the operator can use the same steps to bring up the Issued Material Reporting screen.

Depending on the BOMP Global Setup, the Issued Material Reporting screen can be one of two modes.

Material Confirmation Mode

(Figure 4) Issued Material Reporting. Confirmation Mode. Changing Material.

Setting BOMP Global Setup field 51, Enforce Material Verification in Production, to “N” will set this screen to Confirmation mode.  In this mode, the system will display all materials based on the planned quantities in the work order bill of material and prompt, “Any change?”  Respond with “N” to issue material based on this list.  Otherwise the system will bring up the next stage, Change mode.

In Change mode, you can change the actual issued quantity and add substitute components.  The first prompt is for an item number.  Now the following can be performed in this screen:

• Press the Up or Down Arrow Keys to move the highlight bar.  Press Page Up or Page Down to change to scroll a page at a time.
• Press the Enter Key to change Actual Issued Quantity for the highlighted component.
• A positive quantity means issue material with this amount.
• A zero quantity means the material is not used.
• A negative quantity means the components are being returned to stock. This is useful when the order is complete and there are some components left.
• Press the F1 Key to view and change the material detail.  The detail includes material location and actual issued quantity.
• Press the F2 Key to add substitute material.
• Press the F7 Key or F8 Key to search the Item file.
• Enter a valid Item Number, UPC or GTIN.
• If the item is in the list, the system will move the cursor to that item and ask the operator to change the actual issued quantity.
• If the item is not in the list, the system will allow the operator to add the item as substitute material to the list.

Press the Escape Key to exit the screen.

Material Verification Mode

(Figure 5) Issued Material Reporting. Verification Mode.

Setting BOMP Global Setup field 51, Enforce Material Verification in Production, to “Y” will bring up this screen in Verification mode.  In this mode, the operator needs to enter through every component required for this work order before exiting the screen. Therefore, the Confirmed Quantity of each component defaults to zero.

Verify through Accumulation

Each time an operator enters an item number, the system will accumulate the confirmed quantity of that component.  If 10 pieces of one component are used during the production, the operator can enter the item number 10 times.  The system not only accepts the Item Number, but the UPC or GTIN can be entered if they are defined.

Quantity to Accumulate

Each time the item number or UPC is entered, the system will accumulate the confirmed quantity by one.  However, you can define this quantity to be the product of the Package/Box Quantity and Quantity in Advance for each entry. Package/Box Quantity is the quantity of a component packaged in one box.  For example, the component TUBE in Figure 32 is packaged 5 per box (see Box Qty: 5) and scanning the barcode on the box confirms 5 pieces.  The Package/Box Quantity is defined in the Item Master file and a BOMP Global Setup defines which field represents the package/box quantity.  If the GTIN is scanned, the system will use the package quantity defined in the GTIN. Quantity in Advance is the number of component units to report.  Figure 32 is configured to report 2 boxes of TUBE (see X This Qty: 2), so when the item is scanned the confirmed quantity of this component will accumulate 10 pieces.

(Figure 6) Issued Material Reporting. Verification Mode. Reporting

Scan and Manual Entry

The system will record which input method is used to verify these components, Scan or Manual Entry.  If the barcode tag on each component is scanned for a component, the system sets entry method for that component to Scanned and an “S” will be displayed on the right side of the line (see the FLANGE line in Figure 33).  If the confirmed quantity is modified, the line is considered a Manual entry and an “M” will be displayed on the right side of the line (see the TUBE line in Figure 33).  When a UPC or GTIN is used, the system always considers it as scanned.  Overriding the quantity is always considered a manual entry.  Whether the item number is manually entered or scanned is defined in the BOMP Global Setup.

Exceptions

Exceptions can occur when verifying materials.  Verifying too few or when a substitute material is to be used, the system will prompt for a supervisor password.  Enter the correct password to override this exception.  The BOMP Global Setup defines which actions are exceptions.

Functionality

During verification, the cursor always begins at the Item Number field.  Several options are available:

• Press the Up or Down Arrow Key to move the highlight bar.  Press Page Up or Page Down to scroll a page at a time.
• Scan an UPC or GTIN Barcode.  The system will accumulate the confirmed quantity of the corresponding component.  The system always considers this action as a scan.
• Scan or type in the Item Number.  The system will accumulate the confirmed quantity of the corresponding component.  The system will consider this action as a scan or manual entry based on the BOMP Global Setup.
• If the BOMP Global Setup field “Enter Qty Before or After” is set to “A” for After, the Qty in Advance field can be changed after the item number has been entered.
• If the BOMP Global Setup field “Enter Qty Before or After” is set to “B” for Before, the quantity can be entered in the Item Number field.  If a quantity is entered, the system will use the quantity as Qty in Advance.  This quantity can only be a limited length integer.
• Press the F7 Key or F8 Key to search the Item file.
• Press the F1 Key to view component detail.
• Press the F2 Key to add substitute material.  When substitute material is added, the confirmed quantity will be set to zero and a quantity needs to be confirmed for this material.
• Press the F3 Key to directly accumulate for the highlighted component.  This is always considered a manual entry.  It may be an exception if defined as so in the BOMP Global Setup.
• Press the F4 Key to change Quantity in Advance.
• Press the F5 Key to directly change the confirmed quantity.  This is always considered a manual entry.  This is the only way to enter a negative quantity for the confirmed quantity.
• A positive confirmed quantity means you are issuing material.
• A quantity of zero means the material is not used.
• A negative quantity means the components are being returned to stock. This is useful when the order is complete and some components are left.
• Press the Escape Key to exit verification.  If any component is under-verified or over-verified, the system will display a warning.

PO Information

If an operation is an outside process, the system will prompt for PO related information about the production.  This will happen in the Work Order Production interface when production starts and when production is reported.

(Figure 7) Outside Process Information

Field Description

If the PO package is on, there are some benefits to linking a BOMP transaction to a PO line item.

• You can reference the data in BOMP back to Purchase Order.
• If the BOMP Global Setup field 36, Copy PO FOB Cost to WO+ Outside Process, is “Y”, the system will use the FOB cost in the PO to calculate the outside process cost instead of that defined in order routing.
• If the BOMP Global Setup field 37, Update PO Receiving thru WO+ Outside Proc Rpt, is “Y”, the system will automatically create a PO Receiving Transaction for the PO when the BOMP transaction is posted.  However, the system will not allow a greater quantity to be received for the item than listed on the PO.

Follow the instructions below to change this information after the transaction is created.

Use the following steps when reporting production through Production Transaction Processing:

4. In Add mode, populate every field for the transaction.
5. At Field Number, enter 5 for the “Qty Complete/Qty Received” field.
6. Press the F3 Key to bring up the Outside Process Additional Information screen.

Use the following steps when reporting production through Work Order Production:

5. Enter a non-zero number in the Qty Completed field.  The system will display a “Production Reported” literal to the right of the quantity and prompt “Any Change?”
6. Answer “Y” and the cursor will move back to the “Qty Completed” field.
7. Press the F5 Key to bring up the Detail Reporting screen.
8. In the “Qty Completed/Qty Received” field, press the F3 Key to bring up the Outside Process Additional Information screen.

All fields can be left blank for this transaction.

Serial Number

A serial number will need to reported for serialized parent items or components when the serial number system is in use.

Serial Number for a Parent Item

(Figure 8) Parent Item Serial Number Report

After every field of the transaction has been entered for the last operation, the system will pop up a screen to let the operator enter the serial numbers for the newly created serialized parent items.  They will need to be entered one by one.  If 10 pieces are reported, 10 serial numbers should be entered as well.  The transaction will be aborted if enough serial numbers are not reported.

Serial Number for Components

The Issued Material Reporting screen is used to report a serial number for an issued serialized component.  The screen appears different for Confirmation mode and Verification mode.  In Confirmation mode, the system will display an asterisk (*) for components in which serial numbers have not been reported (see Figure 36).  Press Enter on this item and the Serial Number Reporting screen will pop up after entering the actual quantity.  In Verification mode, the system will pop up a screen to enter serial numbers one by one after a valid item number has been entered.  The quantity of issued materials is always the same as the number of serial numbers reported.

(Figure 9) Component Serial Number Report, Confirmation Mode

(Figure 10) Component Serial Number Report, Verification Mode

Lot Number

Lot Number for Parent Item

Reporting production for a parent lot item on the last operation will prompt for lot information.  In the Work Order Production interface, the system will pop up a Lot Information screen after entering an amount in the Qty Completed field.

(Figure 11) Lot Number reporting in Work Order Production

Lot Number for Components

The lot number of issued lot items needs to be reported.  It does not need to be reported immediately when reporting material.  Another process is used to report these lot numbers: Issue Serial/Lot Component Items.

How to Access:

Main Menu è Distribution è Bill of Material Processor è Processing è Issue Lot/Serial Component Items

(Figure 12) Issued Serial/Lot Component Items

Each time a work order is selected, the system will bring up one component issued for the work order and the lot number for the component can be reported.