WIP- Discrete Job Creation Process (Manual)

Production

Identify the item to Build

StandardAssembl

y?

Select BOM and Routing

Enter Assembly and Quantity

Attach a document if

required

NOYES

Determine the Job Number

Create Discrete Job

Select type as

‘Standard’

Select type as

‘Non Standard’

Release a Discrete Job

Create Discrete Job

Overview

• Discrete jobs may be created from Planner Workbench through the WIP Mass Interface, or they may be created using the Discrete Job form.

• Non-standard discrete jobs for repair, engineering prototypes, and released new build jobs using optional bills of materials or routings may be created using the Discrete Job form.

• A standard job is for items that have a standard released bill of material.

• Non-standard jobs are more flexible than standard jobs. They can be used for rework, field service repair, upgrades, disassembly, maintenance engineering prototypes, and other miscellaneous projects

• For a standard job, if a primary BOM and/or routing exist for the assembly they will be defaulted. You can also enter an alternate BOM and/or routing.

• You can attach illustrative or explanatory files-in the form of text, images, word processing documents, spreadsheets, video, etc. to discrete jobs.

• Change the Status on the job from Unreleased to Released.

Modify Discrete Job

Overview:

• You can change discrete jobs using the Discrete Jobs and Discrete Jobs Summary windows.

• What We Can Change?

Date changes: For date changes, it is only necessary to change either the start date or the completion date. If the start date is changed, the system will forward schedule and recalculate the completion date. If the completion date is changed, the system will backward schedule and recalculate the start date. These changes can be made through the Define Discrete Job form.

Quantity changes: Quantity changes can be done with no restrictions if the job is unreleased. You can also increase the quantity as a job is released. If the job is released and work has begun on the assembly, you cannot decrease the job quantity lower than the number of assemblies that have already passed the Queue intraoperation step of the first operation. If a sales order is linked to the job, you cannot decrease the job quantity lower than the order quantity.

Comments: The text of one-time comments can be amended. Standard comments can either be added or deleted.

Modify Discrete Job

Status: Jobs can have the following statuses: Unreleased, Released, Complete - Charges Allowed, Complete - No Charges Allowed, On Hold, and Cancelled.

Firm: Unreleased schedules or jobs may be firmed to prevent MRP date changes from being reflected automatically on the schedule or job.

Note: Changes cannot be made on components and operations in the Discrete Job form.

WIP-Component Issue Process

Production

Stores

Identify Discrete Job

Pending Material

Requirement ?

Print Move Order Pick Slip

Run ‘Component Pick Release’

View and allocate material

YES

Check the material

requirement

Transact Move Order

WIP-Change Material Requirement Process

Production

Planning

Check Discrete Job for which

additional material required

Query discrete job where

changes are required

Identify the changes in

item/Quantity/dates/comments/status/

firm fields

Enter and Save the changes

Open Material Requirement form

Modify Material Requirement

Once a discrete job has been created you may modify material requirements if they differ from the BOM. You may also use this form to add requirements for a non-standard discrete job.

This responsibility is majorly provided to Planner or Shop Floor In charge as this will cause audit issue when “ Require Qty in BOM V/S Actual Consumption” is calculated.

Caution:

• Major changes in the Material Requirement are done through BOM revision.

• Change the material requirement when the Job is in ‘Release or Un-release’ State

• Changes in material requirement after JOB completion may cause variance.

WIP-Move Transaction Process(Inter-Operation Moves)

Operation 10 QUEUE

QUEUEOperation 20

RUN TO MOVE REJECT SCRAP

RUN TO MOVE REJECT SCRAP

Operation 30QUEUE RUN TO MOVE REJECT SCRAP

Operation N

WIP-Move Transaction Process(Intra-Operation Moves)

Operation 10 QUEUE

QUEUEOperation 20

RUN TO MOVE REJECT SCRAP

RUN TO MOVE REJECT SCRAP

Operation 30QUEUE RUN TO MOVE REJECT SCRAP

Operation N

Move Transaction

Overview:

Using the Move Transactions form, you can move the assemblies you are building from one operation and/or intraoperation step to another.

You can move assemblies forward and backward within and between operations.

Moving assemblies into the To Move, Reject, or Scrap intraoperation step of an operation completes those assemblies at that operation.

When assemblies are completed at an operation, the system automatically backflushes Operation Pull components and charges resources.

Interoperation Moves: Moving assemblies from one operation to another is an interoperation move. Moves usually follow the forward sequence defined by the routing, but you can move assemblies from any operation to any other, even preceding operations.

Intraoperation Moves: Moving assemblies from one intraoperation step of an operation to another intraoperation step of the same operation is an intraoperation move. You can move assemblies from any enabled intraoperation step, (Queue, Run, To move, Reject, or Scrap), as required.

Things to Check

View Pending Jobs 

Use the Pending Jobs and Schedules form to view, update, delete, and resubmit records that have failed validation and remain in the Open Job and Schedule Interface table.

You cannot close a job if pending transactions exist. If no pending transactions exist on a job then the results of the search will return nothing.

Navigate to: Discrete > Pending Jobs and Schedules

Pending Move Transactions 

You can view, update, delete, and resubmit move transaction records that have failed validation and remain in the Open Move Transaction Interface table.

You can view error messages associated with failed records. Error messages can assist you in updating failed records before resubmission.

 Navigate to: Move Transactions > Pending Move Transactions

Things to Check

Pending Resource Transactions 

You can view, update, delete and resubmit resource transactions that have failed validation or processing and remain in the Open Resource Transaction Interface table.

You can view error messages associated with failed records, which can help you in updating the failed records before resubmission.

At period close this table should be reviewed prior to closing the period to make sure all resource transactions have cleared.

Navigate to: Resource Transactions > Pending Resource Transactions

WIP Value Summary

View A WIP Value Summary

Use the WIP Value Summary form to view the current value of open and closed jobs.

Navigate to: Discrete > WIP Value Summary

How to Understand the form output:

Periods From/To: This field will display the current period unless you entered a range into the previous form.

Quantities: This area will display the quantity information related to the discrete job selected.

Cost Element: Displays the cost element associated with the cost information listed.

Account: Displays the account associated with the cost you are viewing.

Cost Incurred: Displays the current cost incurred on the discrete job by element.

Cost Relieved: Displays the current cost relieved on the discrete job by element.

Variances Relieved: Displays the current cost variance relieved on the discrete job by element.

WIP Value Summary

Variance Relieved= Costs Incurred - Costs Relieved

COST INCURRED >> (Production Cost) Term used to indicate the total amount spent to produce an assembly by using/consuming applicable MATERIALS (sub assembly & components) & RESOURCES (such as machine, man power, consumables, tools etc.)

COST RELIEVED >> (BOM Cost) Cost or Rate of the assembly item produced by the manufacturing process, which is defined as Item standard cost at Item Costs form of costing module

WIP Material Transactions

When Material Transaction is used:

• Excess material may have been issued in error to a job. • The bill of materials for an assembly may be incorrect and may call for too many or

too few components. • A component may have been damaged during assembly and it is decided to issue

another component to the schedule or job, while leaving the damaged component charged to the schedule or job also.

 • Components may be consumed during assembly set-up and it has been decided to

leave the loss charged to the schedule or job and replace the components. • One WIP supply subinventory may have a short-term oversupply and it may be

decided to transfer the components to another WIP supply subinventory requiring them.

WIP Material Transactions Types

WIP Material Transaction Types:

• WIP Component Issue-Issues components from inventory to jobs and schedules to fulfill positive material requirements.

• WIP component Return-Returns components from jobs and schedules to inventory.

• WIP negative component issue-Issues components from jobs and schedules to inventory to fulfill negative material requirements. (WIP negative component issue is to return material into stock, material requirement should be – yes)

• WIP negative component return-Returns components to jobs and schedules from inventory to fulfill negative material requirements. WIP negative component returns reverse WIP negative component issues.

• Replenishment supply subinventory-Replenishes the supply subinventories of Operation Pull or Assembly Pull supply type components. This transaction works the same as performing a subinventory transfer in inventory.

• Inventory sub transfer-Performs a subinventory transfer of one subinventory to another. This is similar to the replenishment supply subinventory type.

WIP-Complete Discrete Job Process

Production

Check Discrete Job which needs to be complete

Pending Material

Requirement?

Pending Move

Transaction ?

Use ‘Completion Transaction’ and complete desired assembly units

Complete move transaction

Is it a last operation?

To component Pick Release

Process

YES

NO NO

YESYES

NO

Complete Discrete Job

Overview

• A job must have a status of “Released” in order to have completions transacted against it.

• When the last assembly on the job is completed, Materials or Manufacturing will process the final completion transaction and change the status of the job to “complete charges allowed”.

• The job will remain open for a determined amount of time in this state in order to allow for all appropriate charges to be made against it.

• At the end of that time, Cost Accounting will change the status of the job to “complete no charges allowed”.

• At the end of the accounting period, Cost Accounting will change the status of all jobs currently at “complete no charges allowed” to “closed”.

WIP- Discrete Job Close Process

Production

Cost Accounting

Identify the Discrete Job to complete

Is it a serialized item ?

Charge the Job with

appropriate charges

Change the job status to “

Complete-No Charge Allowed”

Close Discrete Job

NO

YESMove

assembly to FG or

Shipping

Enter completion

data

Enter serial

numbers

Partial quantity

?

NO

YES

Close Discrete Job

Overview

• A job must have a status of “Released” in order to complete quantities against it.

• When the last assembly on the job is completed and transacted, Materials or Manufacturing will change the status of the job to “Complete-Charges Allowed”.

• The job will remain open for a determined amount of time to allow all transactions to be done against the job and variances to be researched and resolved.

• Materials or Manufacturing will change the status to “Complete-No Charges Allowed”. Cost Accounting will review all jobs in this status and then close the jobs.