WIP Over Completion Training Documentation

Table of Contents WIP Over Completion Tolerance ................................................................................................................ 2 Over Completion Tolerance Feature....................................................................................................... 2

Page 1 of 12

WIP Over Completion Tolerance

Over Completion Tolerance Feature
Over Completion refers to completing an assembly quantity into inventory that is greater than the Discrete job or Repetitive schedule start quantity, whether or not the assemblies have a routing. If you want to over complete assembly quantities in the manufacturing process, you must setup a tolerance level for the quantity of assemblies that can be overcompleted on a job or schedule. The tolerance level which is either a number or a percent, is used to validate the quantity being overcompleted. If the quantity is greater than the tolerance allows, the transaction will fail. You can set up tolerances at these levels: Organization Level, Item Level, or Job (and Schedule) Level. We will review the setup screens used for setting these tolerances at the Organization Level and Item Level.

However, for this exercise we will only enter the actual tolerances at the job level.

To review setup for entering Over Completion Tolerances at the Organization Level: Navigation: WIP Setup Parameters. Choose Other Tab.

Note that the field for entering the Inventory Organization Default Over Completion Tolerance Percent can be entered on this form. When you set this parameter at the Inventory Organization level, this value will be the default over-completion tolerance percent for all items in the Inventory Organization. If you do not set a tolerance level, the default over-completion tolerance percent will be null, which in effect is equal to zero percent or no tolerance. If you then try to over-complete assemblies, you receive a message telling you that you cannot over-complete the assemblies because there is no tolerance. For the purposes of this review, do not enter a value. Close the form.

Page 2 of 12

To review setup for entering Over Completion Tolerances at the Item Level: Navigation: INV Items Organization Items. Query any item. Choose the WIP Tab.

Note that the field for entering the Inventory Organization Tolerance Type (either Amount or Percent) and the Tolerance value (a number for Amount Tolerance Type and percent for Percent Tolerance Type) can be set on this form. The tolerance you set at the item level overrides the tolerance that you set up at the organization level. For the purposes of this review, do not enter any values. Close the form.

Page 3 of 12

In order to setup Over Completion Tolerances at the Job Level, we will first create a discrete job.

Set up Discrete Job in Work In Process Step PreReqs Prerequisites Define Discrete Job in Work In Process OC 1

Setup Required Required

Org Setup

Responsibility: Work In Process Navigation: WIP Discrete Discrete Jobs [New]

Discrete Jobs form opens.

If the job number defaults, record the Job Number. Otherwise, enter Job Number for this Discrete Job. Type = Standard (Standard Discrete Job)

Assembly = Assembly to be built using this Discrete Job. Class = Discrete (The Discrete WIP Accounting Class will be used.)

Page 4 of 12

Status = Released Quantites:

(The job will be released to the shop floor.)

Start = e.g., 20 MRP Net = e.g., 20 Start Date = e.g., todays date Completion = leave blank Enter Tolerance Type = Percent Enter Tolerance Value = 10 Enter a Default Completion Subinventory e.g., FGI Accept default values

Dates:

More Tab:

Routing Tab: Other Tabs:

Save the record. Note the Discrete Job form allows you to enter either: 1. A Tolerance Type of Percent and a Tolerance Value percent, or 2. A Tolerance Type of Amount and a Tolerance Value amount.

Repeat the job creation process one more time so that a total of two discrete jobs have been created.

Step

Transact Discrete Jobs Using Over Completion.

Page 5 of 12

PreReq OC2

Create Discrete Jobs Transact a Discrete Job in the Move Transaction Form Using Over Completion

Required Required

Completed in OC1

Navigation: WIP Move Transactions Move Transactions. Query the first Discrete Job created in Step OC1. Click the Complete check box. In the From Operation Sequence field, select the first Operation Sequence Step from the List of Values, e.g., 10. Click the Over Completing check box. Note: You must select the Over Completing check box before entering the over completing quantity. Enter the over completing quantity in the Quantity field, e.g., 22. Save the record.

Important Note: If you are attempting to uncheck the over-completion check box, remove the quantity from the Quantity field or you will not be able to make the change to the over-completion check box.

Page 6 of 12

Step PreReq OC3

Transact Discrete Job Using Assembly Over Return OC1 Transact a Discrete Job in the Move Transacton Form Using Assembly Over Return

Required Required

Over Complete Discrete Job

Navigation: WIP Move Transactions Move Transactions. Query the Discrete Job that was over completed in Step OC2. Click the Return check box. In the To Operation Sequence field, select the To Move Operation Sequence Step for the next to last operation from the List of Values, e.g., 30. Note: The Over Completion check box is disabled if you are performing a Return transaction or a reverse move transaction. You cannot return more assemblies than you have completed to standard discrete jobs. However, you can return more assemblies than you have completed to non-standard discrete jobs. Enter the Assembly Over Return quantity in the Quantity field, e.g., 22. Note that the quantity available to return is the quantity that you over completed in step OC2.

Save the record.

Page 7 of 12

Step PreReq OC4

Transact Discrete Jobs Using Over Completion. Create Discrete Jobs Transact a Discrete Job in the Completion Transactions Form Using Over Completion

Required Required

Completed in OC1

Navigation: WIP Move Transactions Move Transactions. Query the second Discrete Job created in Step OC1. Click the Move check box. In the From Operation Sequence field, select the first Operation Sequence Step from the List of Values, e.g., 10. In the To Operation Sequence field, select the last Operation Sequence Step from the List of Values, e.g., 40. Enter the full job quantity in the Quantity field, e.g., 20. Save the record.

Page 8 of 12

Navigation: WIP Material Transactions Completion Transactions. Query the second Discrete Job created in Step OC1. Click the Over Completion box. Click the [Continue] button.

Page 9 of 12

Enter the over completing quantity in the Quantity field, e.g., 22.

Page 10 of 12

Click the [Done] button.

When using Over Completion functionality, it is important to note: Resources for over-completed assemblies are automatically charged and any backflush components are backflushed. If you complete more than the available quantity in To Move, any extra quantities will be moved through each operation. For example, if you start a quantity of 100 but complete 160, the process will go back to the beginning operations and compute at 160. Cost implications: For backflush components and WIP move resources, cost will be re-figured based on what you put in To Move. For example, if you start a job for 100 and move 120 into To Move then cost will be incurred against the 120. The job, as before, will relieve cost based on quantity complete. If your components are Push and your resources Manual move, then costs will be incurred for only what components you issue to the job and resource charges you record. If you issue the components for 100 but complete 120, unless you issues the additional 20 components to the job only the 100 will be calculated in cost incurred.

Also note that the system administrator must setup user access privileges that identify who has permission to perform over-completion transactions. If the user does not have permission, the Over Completion check box will not be accessible on the Assembly Completion and Move Transaction forms.

Page 11 of 12

This is the end of the Over Completions training.

Page 12 of 12