Re: shop floor posting -- BPCS-L

I can explain how this works in 405 CD

What causes the entire order to be coded as closed is EITHER someone goes into shop order maintenance and force closes it, or the combined labor and inventory reporting equals or exceeds what is needed to make the part. If you have an almost finished order, and you decide that any more quantity needs to be in a later shop order, then you have a choice of methods to tell BPCS that you are now done with that order. * You can force close the order, which can cause labor variance depending on how big the difference between ordered and made. * You can alter the order quantity to what was really made, then report a zero transaction to force BPCS to rethink all the flags. What causes operations to be coded as closed is EITHER someone reports the finished flag, or the quantity posted equals or exceeds what is to be made, at the time of the labor being posted. If you have a requirement for 100, and you post 98, THEN change the requirement to 98, that does not cause BPCS to recognize that the order is done, but you can then post a transaction for zero hours, zero made, zero scrap ... BPCS will process the whop order using the done nothing transaction, and conclude "aha" we are all done here.

We have a shop order for 100 ... we report 98 MADE and 2 SCRAPPED BPCS consumes the material for 100, receives the inventory for 98, and codes the order as closed. Our people not like that because at the moment of scrap, our shop floor REPAIRS the 2 that had to get scrapped, or makes 2 REPLACEMENTS, so we end up reporting 100 made ad 2 scrapped on an order to make 100, and if we have more than one shop order open, BPCS tries to post the excess reporting to some other one, and often as not gets it messed up.

We have a shop order for 1000 ... we get 800 done and due to change in requirements, we only need 800 now, so * We use SFC540 to change the shop order to only need 800 (what was made) * We then post a zero transaction via SFC600 ... zero hours, zero made, zero scrap, using a dummy employee # like 99999 to the shop order It is the act of reporting labor against a shop order, that causes the shop order to be coded finished by BPCS 405 CD and earlier versions, when that reporting process observes that what has been reported so far equals or exceeds the quantity that is to be made.

It is very important in this scenario to down size the shop order to exactly what was made, then post the zero transaction. Suppose in the above example the order was down sized to 100, some arbitrary # by someone who just wanted the order closed without having to look up how much has been made, or track down all labor tickets in process of being posted. When the shop order purges ... the standard would say "We needed to make 100" but the Actual would say "We used enough materials to make 800" which would cause a labor cost variance of that part eight times standard, and if that part later used in higher parent parts, they too get contaminated.

We use last cost ... if you use weighted averaging you may be better off in my last scenario.

There's also such a thing as having a modification to get direct access to individual flags, such as reopening closed operations.

Pull through can also complicate this ... look in ITH ... do you have any WF WT transactions?

, you wrote:

version 6.1

i need some help understanding how SFC650 works. suppose we cut a work
order for 100 pieces and suppose somewhere along the way we lose a
couple so we are only going to get 98 pieces. if we post 98 good the
operations do not get closed and we only get 98 posted complete to
inventory leaving a balance of 2 remaining due on the work order. to
reflect that there are no more coming we change the work order qty to 98
to match the qty actually produced. but this does not 'close' the work
order and the operations are still open and show on the capacity and
dispatch reports.

we tried to post 98 at each operation with the complete flag set to yes
with each posting. this completed each operation and removed the
remaining load associated with that operation fro the dispatch reports.
but it posted 98 to inventory at the last operation but it did not close
the work order (even though we said the last operation was complete).
the only way i can see to get the remaining balance of 2 out or mrp is
the manually close the work order also (SFC500 action 21).

is there any way to automatically close the work order using the
information posted via SFC650 when you are going to get less than the
required qty?
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