What's the best way to keep track and handle "Rework" Operations

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1
Why not add Operation 031 to do the operation 20 rework, then add
operation 032 to do the operation 30 rework. The rule being all
operations not ending in a zero are rework and easily identifiable.



Hope this helps.



Patrick Winter



From: vantage@yahoogroups.com [mailto:vantage@yahoogroups.com] On Behalf
Of Mike Tsoi
Sent: Friday, October 31, 2008 3:29 AM
To: vantage@yahoogroups.com
Subject: [Vantage] What's the best way to keep track and handle "Rework"
Operations ini Vantage?



Let's say we have a job assembly ABC that having 5 operations in
sequence. They are Opr 10; Opr 20; Opr 30; Opr 40 and Opr 50. We
require to produce qty 1000pcs for ABC and start from Opr 10. The
Qty/Parent between each operations are 1:1. Each of the operation are
to be done in difference work center (wc).

Assumed that we report completed qty for Opr 10, Opr 20, and Opr30
1000pcs. When the production labor go to start to do Opr 40, they
found that the WIP was bad and require to go back Opr 20 to rework.
In this case, what we have to do in Vantage in order to:
1.) Send the WIP (Completed by Opr30) of 1000 back to Opr 20 for rework?
2.) Tell Opr 20's work center that there is a 1000qty WIP, returned
from Opr 40, requiring to be rework by Opr 20?
3.) Keep track the WIP transaction history? For example:
Opr 40's wc returned 1000 WIP Qty to Opr 20's wc for rework on date
XX-XX-XX.
Opr 20's wc reworked 1000 and pass to Opr 30's wc on date XX-XX-XX.
Opr 30's wc reworked 1000 and pass to Opr 40's wc on date XX-XX-XX.

Do anyone has experience or idea on it?
I am not considering to use "Rework Activities" as it keep track for
rework time only, but not the WIP qty and its movement.

Thank you.
Regards,
Mike
TTG





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2
Let's say we have a job assembly ABC that having 5 operations in
sequence. They are Opr 10; Opr 20; Opr 30; Opr 40 and Opr 50. We
require to produce qty 1000pcs for ABC and start from Opr 10. The
Qty/Parent between each operations are 1:1. Each of the operation are
to be done in difference work center (wc).

Assumed that we report completed qty for Opr 10, Opr 20, and Opr30
1000pcs. When the production labor go to start to do Opr 40, they
found that the WIP was bad and require to go back Opr 20 to rework.
In this case, what we have to do in Vantage in order to:
1.) Send the WIP (Completed by Opr30) of 1000 back to Opr 20 for rework?
2.) Tell Opr 20's work center that there is a 1000qty WIP, returned
from Opr 40, requiring to be rework by Opr 20?
3.) Keep track the WIP transaction history? For example:
Opr 40's wc returned 1000 WIP Qty to Opr 20's wc for rework on date
XX-XX-XX.
Opr 20's wc reworked 1000 and pass to Opr 30's wc on date XX-XX-XX.
Opr 30's wc reworked 1000 and pass to Opr 40's wc on date XX-XX-XX.

Do anyone has experience or idea on it?
I am not considering to use "Rework Activities" as it keep track for
rework time only, but not the WIP qty and its movement.

Thank you.
Regards,
Mike
TTG
3
You don't mention utilizing OP Inspection & DMR disposition so I'm assuming you it either isn't process friendly for you or you don't have the module license.

If you DO have the module (and it hasn't proved intrusive in your process) you can simply edit the already completed OP 20 labor entry and adjust the OP Qty completed down, putting the remaining problematic discovered qty into Non-conforming Qty. (Also manually uncheck the labor record so it is no longer indicating the OP as complete... Some v8 versions do this automatically, some don't - so force it to be sure). This will put the non-conforming qty in the inspection Queue.

Inspect Fail this qty & generate the DMR. Under DMR disposition, create an Acceptance Reason Code called "OP Rework Req'd" (or something like that meaningful to you).

DMR Accept Dispositioning returns the WIP to the OP but you still need to do the rework.

Now, because your labor entries, OP Inspection & DMR Disposition all indicate the qty requiring rework at OP 20, you CAN use Rework Labor Entry to simply capture the time/cost of that rework.

If you don't use OP inspection, you still have options:

You can add an OP after OP 30 (call it OP 35) that details the rework required for the problematic work done at OP 20.

I'd actually mark the OP as an 'Added Operation' so that (if you aren't using Added Operations for other reasons) you will know (for later process QC and/or cost related report generation purposes) that Added OP's are rework OPs in your general job method OP schema. (If you use 'Added OP's for other reasons, perhaps come up with a reliable rule of significant meaning to OP numbering so that OPs numbered '##1" are reworks - or something to that effect that works for you.)

At this point, the remainder of this process is dependent upon whether you use the Op Yield Recalc (job) Qty process.

If you do: IMMEDIATELY labor report the good qty from OP 20 at your newly Added OP 35 as a zero time consumed entry. (This is just to prevent the Yield recalc process from eventually reducing your job prod qty.)

Whether you use OP Yield Recalc (job) Qty or not - then Start activity for Added OP 35 on the remaining problematic qty requiring rework & End Activity when done. (Make sure this final end activity reported qty sets the OP as complete. Manually check it off as complete if needed.)

Which ever path you choose, your WIP qty should be good & you will have a way to gather stats/costs on OP rework.

Piece of advice though?

Unless this is a common occurrence (which means your process is broken & you should be redesigning it to be more reliable anyway) REALLY consider whether you need this info processed through Vantage.

It may be sufficient to handle these (hopefully rare) exceptions via a form and then track them offline.

Don't get caught in the mental paradigm trap of feeling you HAVE to do everything in the system just because it is there.

Sometimes a piece of paper and a pencil (under good supervision) is the best way. You can always (post OP rework processing and prior to inventory receipt) do a job cost adjustment (if you are on actual cost) to cost account for the activity.

Think it through and decide if all that additional system processing adds any value in the eyes of your customer: Are they willing to pay more for your product because you chose to incur the additional time/cost of doing the extra system activities & transactions? (I doubt it unless it is some product certification requirement to include process result documentation.)

Good luck.

Rob

--- On Fri, 10/31/08, Mike Tsoi <ddc443@...> wrote:
From: Mike Tsoi <ddc443@...>
Subject: [Vantage] What's the best way to keep track and handle "Rework" Operations ini Vantage?
To: vantage@yahoogroups.com
Date: Friday, October 31, 2008, 4:28 AM











Let's say we have a job assembly ABC that having 5 operations in

sequence. They are Opr 10; Opr 20; Opr 30; Opr 40 and Opr 50. We

require to produce qty 1000pcs for ABC and start from Opr 10. The

Qty/Parent between each operations are 1:1. Each of the operation are

to be done in difference work center (wc).



Assumed that we report completed qty for Opr 10, Opr 20, and Opr30

1000pcs. When the production labor go to start to do Opr 40, they

found that the WIP was bad and require to go back Opr 20 to rework.

In this case, what we have to do in Vantage in order to:

1.) Send the WIP (Completed by Opr30) of 1000 back to Opr 20 for rework?

2.) Tell Opr 20's work center that there is a 1000qty WIP, returned

from Opr 40, requiring to be rework by Opr 20?

3.) Keep track the WIP transaction history? For example:

Opr 40's wc returned 1000 WIP Qty to Opr 20's wc for rework on date

XX-XX-XX.

Opr 20's wc reworked 1000 and pass to Opr 30's wc on date XX-XX-XX.

Opr 30's wc reworked 1000 and pass to Opr 40's wc on date XX-XX-XX.



Do anyone has experience or idea on it?

I am not considering to use "Rework Activities" as it keep track for

rework time only, but not the WIP qty and its movement.



Thank you.

Regards,

Mike

TTG