1 / 44

WIP/LOT TRACE

WIP/LOT TRACE. GEORGE SCHULCZ. Agenda. Overview Terminology Business Requirements Scope Functionality. What is WIP Lot Trace (WLT) Why Was it Developed. Overview. WLT-020. Overview. What is WIP Lot Trace? The Capture and Reporting of: Lot Composed-Of Information

gerd
Download Presentation

WIP/LOT TRACE

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. WIP/LOT TRACE GEORGE SCHULCZ

  2. Agenda • Overview • Terminology • Business Requirements • Scope • Functionality

  3. What is WIP Lot Trace (WLT) • Why Was it Developed Overview WLT-020

  4. Overview What is WIP Lot Trace? • The Capture and Reporting of: • Lot Composed-Of Information • Lot Where-Used/Shipped Information

  5. Why it was developed? • Automotive Development Group Customers needed it • Legal Requirements • Other Customer Requirements

  6. Terminology • Lot Number • Serial Number • Lot Traceability • WIP • Queue • Reference • Lot Splitting • Lot Combining WLT-030

  7. Terminology • Lot Number - A unique id assigned to a homogeneous quantity of material • Serial Number - A unique id assigned to a discrete single piece of material • Lot Traceability - Lot consumption and production information sufficient to trace material lots through the manufacturing and distribution process • WIP - Work In Process

  8. Terminology • Queue - A factory location containing material awaiting processing by an operation • Reference - An additional, optional identifier that can be assigned to lot-controlled material • Lot Splitting - Creating several lots of processed material from one input lot • Lot Combining - Creating one lot of processed material from several lots of input material

  9. Business Requirements • Safety Issues • Recalls • “Crisis Containment” • Sources of quality problems • Effects of quality problems • Applicable Industries • Automotive • Medical • Etc, etc.

  10. Scope • MFG/PRO Release eB • Modifications to modules • Work Orders • Standard Repetitive • Advanced Repetitive • Shop Floor Control • Inventory Control • Purchasing • New menu “Pro/Plus WIP Lot Trace”

  11. Scope (cont.) • Work Orders • Issues • Receipts • Operation Backflush (new)

  12. Scope (cont.) • Standard Repetitive • Setup Transaction • Labor Transaction • Reject Transaction • Rework Transaction • Scrap Transaction • Transaction Inquiries

  13. Scope (cont.) • Advanced Repetitive • Setup Transaction • Labor Transaction • Backflush Transaction • Reject Transaction • Rework Transaction • Scrap Transaction • Adjust Transaction • Move Transaction

  14. Scope (cont.) • Advanced Repetitive (cont.) • Cum Order Close • Sub Shipper Maint • Sub Container Maint • Sub Shipper Confirm • Sub Shipper Issue • Reports and Inquiries

  15. Scope (cont.) • Shop Floor Control • Labor Feedback by Work Order • Labor Feedback by Employee • Labor Feedback by Work Center • Operation Move Transaction • Operation Scrap Transaction (new) • Reports and Inquiries

  16. Scope (cont.) • Inventory Control • Transfer With Lot/Serial Change • Batchload Transfer With Lot/Serial Chg • Transaction Detail Inquiry • Purchasing • PO Maint • PO Receipts • PO Print • PO Returns

  17. Scope (cont.) New menu “Pro/Plus WIP Lot Trace”

  18. Enter Yes to activate the WIP Lot Trace (WLT) module. • When WIP Lot Trace is active, new fields and frames display in several programs such as Backflush Transaction, Reject Transaction, and Rework Transaction. • Use this module to monitor and trace work in process (WIP) inventory at each operation in the manufacturing process. It facilitates tracking of WIP material lot/serials sent out to multiple subcontractors and supports detailed tracking of any WIP material, as needed. This module also maintains detailed historical records.

  19. Functionality • Traceability (capture and reporting of as-built data) • WIP Lot Inventory (maintenance and reporting of QOH balances for WIP lot/serials) • Subcontract (handling of WIP lot/serials for subcontract processing) • Setup and Control

  20. Traceability • Data Capture • By functions that record material conversion events • Data captured: • Material conversion event record (labor, burden, scrap, etc.) (Operation History [op_hist]) • Material consumption and production records (WIP Lot Trace Master (wlt_mstr) [new table])

  21. Traceability Example Defective Material Discovered Determine Cause Of Defect Component Problem? Component Material Is Defective Yes No Determine Material Locations Quarantine Materials And Parents

  22. Traceability (cont.) Backflush: Enter WIP lots to consume

  23. Traceability (cont.) Backflush: Enter WIP lots to produce

  24. Traceability (cont.) • Data Reporting • Lot Where-Used Report (new) • Lot Actual Bill Report (new) • Transaction Detail Reports and Inquiries (new and modified)

  25. This program is used to create a multilevel report showing where WIP or component item lot/serials were consumed.

  26. 3.22.13.19 WIP Lot Where-Used Report Level Type Prod ID Prod Op Item Number Lot/Serial Ref Qty UM Qty On Hand UM-------- ------------ -------- ------- ------------------ ------------------ -------- ---------- -- ------------ --1 Item gas-craig-c2 craig-c2 70.0 EA 430.0 EA.2 WIP 4537 10 gas-craig gas-wip01 10.0 EA 0.0 EA..3 WIP 4537 20 gas-craig gas-wip01 10.0 EA 0.0 EA...4 Item gas-craig gas-wip01 10.0 EA 10.0 EA.2 WIP 4537 10 gas-craig gaswip02 40.0 EA 15.0 EA..3 WIP 4537 20 gas-craig gaswip02 25.0 EA 0.0 EA...4 Item gas-craig gaswip02 25.0 EA 25.0 EA.2 WIP 4537 10 gas-craig gaswip03 20.0 EA 20.0 EA End of Report • To report WIP material, set material type to WIP. The produced by operation and work order ID must be specified. The item indicated is the finished item number for which the WIP material was produced or consumed. The lot/serial and reference selection ranges apply to WIP material. • To report component item material, set Material Type to Item. The component item number must be specified. The lot/serial and reference selection ranges apply to component material.

  27. This program is used to create a multi-level report showing the traced WIP and component item lot/serials used to manufacture a specific finished parent item.

  28. 3.22.13.20 WIP Lot Actual Bill Report wlrp03.p b+ 3.22.13.20 WIP Lot Actual Bill Report Page: 1 qad.inc Level Type Prod ID Prod Op Item Number Lot/Serial Ref Qty UM Qty On Hand UM-------- ------------ -------- ------- ------------------ ------------------ -------- ---------- -- ------------ --1 WIP 4537 20 gas-craig gas-wip01 10.0 EA 0.0 EA.2 WIP 4537 10 gas-craig gas-wip01 10.0 EA 0.0 EA..3 Item gas-craig-c1 craig-c1 10.0 EA 430.0 EA..3 Item gas-craig-c2 craig-c2 10.0 EA 430.0 EA1 WIP 4537 20 gas-craig gaswip02 25.0 EA 0.0 EA.2 WIP 4537 10 gas-craig gaswip02 25.0 EA 15.0 EA..3 Item gas-craig-c1 craig-c1 25.0 EA 430.0 EA..3 Item gas-craig-c2 craig-c2 25.0 EA 430.0 EA End of Report • When reporting for WIP material, The produced by operation and work order ID must be specified.

  29. WIP Lot Inventory • Data Maintenance • QOH balances maintained by WIP lot/serial, operation, queue, work center, and machine • Similar to inventory QOH balances • Updated by material conversion functions e.g. Backflush, and other functions e.g. Scrap, Reject, Rework, Adjust • Data Reporting • WIP Lot Inventory Status Report (new) • Advanced Repetitive WIP Status Inquiry/Report (modified)

  30. 3.22.13.13 WIP Lot Inventory Status Report wlrp01.p b+ 3.22.13.13 WIP Lot Inventory Status Report Date: 03/19/02 Page: 1 qad.inc Time: 15:57:45 Item Number Site Location Line ID Op Queue Work Ctr Machine Lot/Serial Ref Qty On Hand UM ------------------ -------- -------- -------- -------- ----- -------- -------- -------- ------------------ -------- ------------ -- gas-craig gassite gas-crai 4537 20 Input gas-wc1 gaswip02 25.0 EA End of Report • Use WIP Lot Inventory Status Report to generate a report showing WIP material and component quantity-on-hand (QOH) information. • When you report WIP material, the report shows the production line, ID, operation, operation queue, work center, and machine where each lot/serial resides. This information is not available for component items. • When reporting for WIP material, Item Number refers to the finished item number, and Lot/Serial refers to the WIP lot/serial. When reporting for component items, Item Number and Lot/Serial both refer to the component. The report shows both material types if they conform to the selection criteria, and Include WIP material and Include Item material are Yes.

  31. 18.22.4.11 Wip Status Report reworp05.p b+ 18.22.4.11 Wip Status Report Date: 03/20/02Page: 1 qad.inc Time: 08:13:58 ID: 4537 Routing Code: Site: gassite BOM/Formula: Item Number: gas-craig test for 18.22.13 error Start Eff: 03/01/02 Production Line: gas-crai End Eff: 03/31/02 Order Qty: 1.0 Status: Active Mile- Op Description stone Input Queue Quantity Output Queue Quantity Reject Queue Quantity------ ------------------------ ----- ------------- ------------- ------------- ------------- ------------- ------------- 10 yes Begin Qty 0.0 Begin Qty 0.0 +Processed 70.0 +Rejected 0.0 +Reworked 0.0 -Reworked 0.0 -Rejected 0.0 -Scrapped 0.0 -Moved Out 70.0 -Adjusted 0.0 -Scrapped 0.0 Current Qty 0.0 -Adjusted 0.0 Current Qty 0.0No WIP lots were found at this operation Mile- Op Description stone Input Queue Quantity Output Queue Quantity Reject Queue Quantity------ ------------------------ ----- ------------- ------------- ------------- ------------- ------------- ------------- 20 yes Begin Qty 0.0 Begin Qty 0.0 Begin Qty 0.0 +Moved In 70.0 +Processed 35.0 +Rejected 0.0 -Processed 35.0 +Reworked 0.0 -Reworked 0.0 Current Qty 35.0 -Rejected 0.0 -Scrapped 0.0 -Moved Out 35.0 -Adjusted 0.0 -Scrapped 0.0 Current Qty 0.0 -Adjusted 0.0 Current Qty 0.0 WIP Lot Inventory Work CtrQueue Prod Op Machine Lot/Serial Ref Qty On Hand UM-------- ------- -------- ------------------ -------- ------------ --Input gaswip02 15.0 EAInput gaswip03 20.0 EA

  32. Subcontract • Facilities for users who use external subcontract processors • Traceability data captured/WIP lot QOHs maintained • PO Maint: Entry of a WIP lot/serial on each subcontract-type line • PO Print: Print entered WIP lot/serial • Adv Rep Sub Shipper/Container Maint: Entry of a list of WIP lot/serials to ship

  33. Subcontract (cont.) • Adv Rep Sub Shipper Print: Print WIP lot/serials entered • Adv Rep Sub Shipper Confirm: Moves WIP lot/serials to next operation • PO Receipts: Backflushes the referenced operation; entry of WIP lot/serials consumed and produced

  34. 18.22.4.11 Wip Status Report 15 yes Begin Qty 0.0 Begin Qty 0.0 Begin Qty 0.0 +Moved In 100.0 +Processed 100.0 +Rejected 0.0 -Processed 100.0 +Reworked 0.0 -Reworked 0.0 Current Qty 0.0 -Rejected 0.0 -Scrapped 0.0 -Moved Out 100.0 -Adjusted 0.0 -Scrapped 0.0 Current Qty 0.0 -Adjusted 0.0 Current Qty 0.0No WIP lots were found at this operation Mile- Op Description stone Input Queue Quantity Output Queue Quantity Reject Queue Quantity------ ------------------------ ----- ------------- ------------- ------------- ------------- ------------- ------------- 20 subcontract op yes Begin Qty 0.0 Begin Qty 0.0 Begin Qty 0.0 +Moved In 100.0 +Processed 0.0 +Rejected 0.0 -Processed 0.0 +Reworked 0.0 -Reworked 0.0 Current Qty 100.0 -Rejected 0.0 -Scrapped 0.0 -Moved Out 0.0 -Adjusted 0.0 -Scrapped 0.0 Current Qty 0.0 -Adjusted 0.0 Current Qty 0.0 WIP Lot Inventory Work CtrQueue Prod Op Machine Lot/Serial Ref Qty On Hand UM-------- ------- -------- ------------------ -------- ------------ --Input gaswip-11 100.0 EA

  35. Setup and Control Control file

  36. Setup and Control (cont.) Routing Registration

  37. This program is used to override the WIP Lot Trace Control File settings for a particular routing code. • When a routing code must have information other than what is specified in the control file, indicate the routing code and those exceptions here. When you use the specified routing code to register manufacturing events, WIP Lot Trace uses the settings you indicate here, not the control file settings.

  38. The first frame is used to register control information for the routing code. Indicate whether to trace parents, lot size, splitting, numbering details, and starting and ending dates. The values defined in the first frame are used for all operations for the indicated routing code.

  39. The second frame is used to indicate information specific to an operation within the routing.

  40. Setup and Control (cont.) BOM Registration • This program is used to override the WIP Lot Trace Control File settings for a particular BOM code. • When using the specified BOM code, WIP Lot Trace accesses the information set up here, not the control file settings.

  41. Use the first frame to register control information for the BOM code. Indicate whether to trace components and references, and whether component lots can be combined. The values defined in the first frame are used for all component items for the indicated BOM code.

  42. The second frame is used to indicate the information specific to a component of the BOM code.

  43. QUESTIONS ? ? ?

More Related