Hi,
A little involved this one, so stick with it:
A works order has a BOM with 4 items (A,B,C,D) and a route with 4 operations (10,20,30,40). The BOM and setup are configured to consume at each stage of the route: A at 10, B at 20 etc.
Production progress is recorded at end of each day, and/or whenever the order is complete. We start 10 units and at the end of day 1, x10 have completed operation 10, and x5 finished goods have passed through operation 20, so we record a route journal for that. Operation 10 only is marked ‘Operation complete’.
The production is completed on day 2 when all 10 reach the end of production. An RAF journal for 10 good quantity is done, and auto-consumes the BOM elements.
Problem: Operation 10 is fine as it’s already complete, operation 30 and 40 are consumed OK also. But operation 20 is over-consumed becuase the line in the original route journal was not marked ‘operation complete’. So we get the original 5 consumed on the route journal, and a further 10 consumed in the RAF journal.
Is there a way that the RAF journal can just consume outstanding quantities against the BOM estimate when some items are already registered on a route journal, and some are not.
Many thanks for any steer…
Hi Adam
Which version?
Why are you operation linking consumption?
What are the RAF parameters you are using? If flushing method what are the flushing methods of the items?
I presume the route card journal is manually entered rather than being produced at the start?
Hi, thanks for the quick reply.
AX2009. The main reason for linking consumption is to keep shop floor raw material consumption up to date on a daily basis based on the stage that the production order has reached at the end of each day.
There are lot of parameters to list, but in general we’ve tried just about every combination without sucess. The items are set to backflush i.e. when the route journal is done.
However, you have hinted at an idea, that the route cards could be created at the start of production and then just posted depending on where the production gets to? However I don’t think I found a way to create the job cards at ‘Start’ but not post them - they were either not created, or created and posted. If that is possible it could be a good solution. We could then use the RAF journal to just post the good quantity and not consume the BOM materials??
I’ll have a play with the demo and see if I can achieve that.
On second thoughts it still leaves the partial completion problem - if the created journal is part posted, you would have to remember to go back and complete it, which is why we were trying to use the RAF journal as a ‘clean-up’ function.
Thanks,
Hi Adam
You cannot configure this having had a look at it.
The RAF is presumably posting by Flushing principle, so as they are all set to Finish it looks solely at the requirements, not the current position. You are manually creating the journal whilst configuring the system to not create it at start and then post as per the flushing principle. The closed op is fine, it is the open one as you can tell that is the issue, the system does not verify any part posting processed manually, so at your finish you get an over consumption.
Do you inneed to consume them on the route card when the operation is not complete at the end of the day? You could not select the BOM Consumption and then the RAF journal reports all of the remaining operations (assuming you RAF by operation number) and will then not over consume. This is probably the only way I can see you achieving it. The downside is the consumed quantity is not recognised at the end of that day but this is better than the over consumption. However your operation linking is to keep the shop floor consumption up to date on a daily basis - if this is your driver it is the RAF auto-consumotion that is the issue and I would suggest you put a control in place not to let this be posted without the route card being processed, so do not RAF by flushing method, do it as never forcing the route card to be posted to complete the production, but this is then a lot more work.
As you probably understood as you wrote the forward or backwards consumption make no difference to the issue, partial completion will still be the issue, the forward flush would consume all of the components, but because you part report the quantity and leave the operation open the RAF would over consume, but in this instance it would make your situation worse.
Did you use to work at Columbus?
Many thanks for the feedback, that really helps to clarify our thoughts. I think my initial thoughts and understanding of the limitations were correct but it is good to have a second opinion to support that.
I was at Columbus 2001-2005, but worked independently since then. You can get my full profile via the Seaton Partners web site.
Thanks again.