ITEM REWORK PROCEDURE

Must be Updated to VERSION 604N or 701N

Test in Demo First

 

A method of controlling items that do not pass QC or are returned by customers.

 

Ø      In PT-2 add the following record to PPCTRL:

 

Key:    PPINA1S

 

 Data:   Y

              12345678901234567890123456789012345678901234567890123456789012345

 

Ø      Add a new account number to FM-1 for Rework Items.

 

Ø      In FM-7, set up items records to identify items requiring rework. This can be done by copying existing records.

 

Example: Manufactured item AX55 was returned from a customer or did not pass QC. In FM-7, copy AX55 and name it AX55-R. 

 

In the "G\L Account" number field, add the new account number. Change the "Mfg or Purchase" field to "P".

 

Ø      Create a new structure for the Item with a VERSION ID of "RW". Enter common labor functions and parts that could be required in the rework process. The first line of the structure would contain the rework item with a quantity of 1 (this will remove the appropriate quantity from the rework item.)

 

Example: AX55 with a version code of "RW". The first line of this structure would contain AX55-R with a quantity of 1.

 

Ø      When an item fails QC or is returned by a customer, enter the quantity in IC-91 or a credit memo in   Order Entry using the item number containing an "-R" suffix.

 

Ø      When ready to begin the rework process, enter a production order. Use the "RW" version ID. You will  notice a field that will allow you to add "RW" version code. 

 

Ø      Complete the production as usual. If different materials or operations are used than what were initially set up in the "RW" structure in SC-6, add transactions in PC 20 and 21.

If using "Backflush" ,all materials and operations must be added to the "RW" structure prior to production completion.

 

After completing the Order in PC, inventory will increase by the reworked quantity. The rework item will be removed from inventory.

 

Things to look for in IC-1 while testing:

 

"-R" item

 

A completed Credit Memo in Order Entry or IC-91 transaction will increase "On Hand" and "Available" quantities.

 

A completed production order will reduce inventory On Hand and Available quantity for the "-R" item.

 

The reworked item "On Hand" and "Available" quantity will be increased by production completion.

 

 

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