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Evo-ERP and DBA Classic >> Manufacturing >> Work Order Issues -Deja Vu
http://www.istechforum.com/YaBB.pl?num=1099414624

Message started by mtopich on 11/02/04 at 08:57:04

Title: Work Order Issues -Deja Vu
Post by mtopich on 11/02/04 at 08:57:04

Lynn,
I know the issue of the automatic backflush not accurately backflushing BOM material has been a long standing topic. I am looking for a one-stop comprehensive explanation of the problem and solution.
We routinely have work orders that have over issues, under issues, and mixed errors (that is both over issues and under issues on the same work order.)
We have 2004.1 with IST 7/21/04 version. Since loading this version in August, we have continued to see the same level of work order issue errors. The fix that relates to a temporary file for locked records only turns up a very few of the issue errors.
I therefore think that there is something going on that is beyond record locking. In many cases our BOM's are very long and I wonder if the length of the BOM may increase the likelihood of error.
Currrent example. Work has been completed. All units show as closed in inventory transactions as Work Order receipts. Nonetheless the BOM material shows as only issue to 2.38 % up to 21.43%. When I look at inventory transactions on a component on the BOM the work order issues all show correctly. The errors in Work Order material issues, wreaks havoc on the allocated quantities for the BOM items.
This problem may well be caused by something we are doing but we have not been able to isolate any operator error. On the other hand, the significance of the problem would seem to have raised a much higher level of complaints from the field if others saw this problem as often as we do.
Help

Title: Re: Work Order Issues -Deja Vu
Post by Lynn Pantic on 11/02/04 at 16:09:20

What is your default setting in SD-B for Backflush at Enter Finished Production?

Title: Re: Work Order Issues -Deja Vu
Post by mtopich on 11/03/04 at 07:29:48

The backflush default is set to "A"

Title: Re: Work Order Issues -Deja Vu
Post by mtopich on 11/03/04 at 14:50:02

Lynn,
We have been watching closely for the work order issue problems since we are trying to get to the bottom of the problem and put a fix in place. On a work order finished goods close from 11/1/02, we find that the material issues all appear in the INVTXN table but are no where to be found in the WOMAT table. In this case the entire set of BOM backflush transactions are missing from WOMAT.
I thought this info might be heipful in thinking about the problem.

Title: Re: Work Order Issues -Deja Vu
Post by mtopich on 11/03/04 at 14:51:18

Lynn, In my previous message I incorrectly said the date of transaction was 11/2/02. I meant yesterday 11/2/04.

Title: Re: Work Order Issues -Deja Vu
Post by Lynn Pantic on 11/03/04 at 18:50:00

Did the person doing WO-I have any errors? I have tested and have not seen a problem with the WOMAT records being generated.

Title: Re: Work Order Issues -Deja Vu
Post by mtopich on 11/05/04 at 04:47:43

I am not sure what you mean by errors. No error message came up at the time of the finished goods unit closes.

On the specific incident I mentioned in the previous message, I am told that the material issue screen which is at WO-A originallly reflected that all but one BOM item was correctly issued at 100%. Iin an attempt to correct the one item a work order rebuild was run. After rebuild all BOM items were in error by the components associated with 12 units of finished goods. When we compared WOMAT to INVTXN we can see that a 12 unit close did not hit WOMAT.
This type of problem has been a long standing and very recurrent problem for us. But I get the sense that the rest of the user community isn't seeing this problem. So I wonder if our software could be contaminated or something peculiar to our use.

Title: Re: Work Order Issues -Deja Vu
Post by mtopich on 11/06/04 at 07:12:31

Lynn,
In looking into this further I find that a particular work order that had no WOMAT transaction for any of about 12 different date finished good closes has a BOM that has the same component part number on the BOM more than once. That is the item is on the BOM twice. This is fairly common in our BOM's because certain components are placed at two different points in our process.
Could the double entry on the BOM lead to the problem ?

Title: Re: Work Order Issues -Deja Vu
Post by Lynn Pantic on 11/06/04 at 17:57:11

No, that might cause WOBOM allocations to be incorrect but it would not cause the WOMAT records to not exist at all.

Title: Re: Work Order Issues -Deja Vu
Post by mtopich on 11/09/04 at 08:17:19

We continue to see the failure to post data to the WOMAT file. Your thoughts on cause and fix ?

Title: Re: Work Order Issues -Deja Vu
Post by cathyh on 12/06/04 at 11:56:47

We have a issue today similar to what is being discussed in this thread. An issue was made to a work order with 100 % of this component already issued. All the fiels contain the4 data, I have looked in WOMAT, INVTXN, the transactions print out in the job cost JC-E and show up in all the inventory reports, but they do not show in WO-A screen for materials. WE actually use that screen a lot to check to the issue status quickly. The transaction was done in Evo. I don't know if the same would have happened in Classic. Of course my people are blaming Evo.
I don't know where the WO-A screen gets the data for the materials screen or I would fix it. Is that possible?

Title: Re: Work Order Issues -Deja Vu
Post by Tim Keating on 12/06/04 at 12:51:46

This sounds like a legitimate bug. Anyway it can be traced to a particular update so that we can be careful not to apply it?

I don't see why it would be and Evo/Classic issue as my understanding is the underlying code hasn't changed.

Title: Re: Work Order Issues -Deja Vu
Post by Lynn Pantic on 12/06/04 at 13:11:59

What program generated the issue? WO-G, WO-I or backflush by sequence using WO-F or DC-H? Was there any scrap processing involved?

Title: Re: Work Order Issues -Deja Vu
Post by cathyh on 12/07/04 at 08:58:36

Lynn, she was in WO-G and it was a straight-forward issue of 5 additional of a part already issued to 100%, and no scrap issue was involved.
We are on version 2004.1, 10/08/04 update. By the way, my "about" button in Evo Help doesn't do anything!

Title: Re: Work Order Issues -Deja Vu
Post by Lynn Pantic on 12/07/04 at 16:23:49

So what exactly is the problem (or perceived problem)? WO-G will certainly allow issues over 100% - that in and of itself is not a bug but the % issued in WO-A should reflect the overissue.

Title: Re: Work Order Issues -Deja Vu
Post by cathyh on 12/08/04 at 08:24:12

The problem is the WO-A Materials screen does not reflect the issue total of ten(200%) it only shows the first issue, 5(100%). The two issues were done on different dates and we can see them everywhere but here. As I said previously, we use this screen quite a bit to check materials issued to a particular work order instead of going to JC-E Material Issues. But if it is not accurate.....

Title: Re: Work Order Issues -Deja Vu
Post by Lynn Pantic on 12/08/04 at 10:49:17

WO-K-H (or UT-A, program BKREBWO) should rebuild it but I am not sure why it didn't update properly in the first place.

Title: Re: Work Order Issues -Deja Vu
Post by cathyh on 12/15/04 at 10:42:11

Rebuilding the work order did nothing, and now I have another one-- This time as before, all the transaction reports are correct, and are properly reflected in the GL, but the work order WO-A Materials screen is wrong, and this time the work order job cost report JC-A in detail is wrong also.

User defined Inv trans- IN-O:
1400065 10/19/04 I WO ISSUE 8.00 4474- 2 17.6700 KVICHAK MARINE INDUSTRIES 01:59:31 p10/19/04
1400065 11/02/04 I WO ISSUE -8.00 4474- 2 17.6700 KVICHAK MARINE INDUSTRIES PMOREY 10:44:53 A11/02/04
1400065 11/30/04 I WO ISSUE 8.00 4474- 2 17.6700 KVICHAK MARINE INDUSTRIES SHERRY 01:08:06 P11/30/04

JC-E material issues:
Date Work Order S Parent Part Part Number Description Qty Issued Scrapped SC Cost
-----------------------------------------------------------------------------------------------------------------------------------
10/19/04 4474- 2 C 9300042 1400065 VALVE,PRV,MRD,2.3-2.5 8.0000 0.00 141.36
11/02/04 4474- 2 C 9300042 1400065 VALVE,PRV,MRD,2.3-2.5 -8.0000 0.00 -141.36
11/30/04 4474- 2 C 9300042 1400065 VALVE,PRV,MRD,2.3-2.5 8.0000 0.00 141.36

Job cost report JC-A for this line item:
1400065 0 0.000000 141.360000 0.00 -141.36 0.00
VALVE,PRV,MRD,2.3-2.5

WO-A Materials screen: reflects the same data as job cost with -8 issued.
I have tried changing status from closed to Released to recalculate also, but nothing changes. There is faulty data somewhere, but where, and why?

Title: Re: Work Order Issues -Deja Vu
Post by Juan on 12/15/04 at 12:09:48

The only problem we have encounter that is similar to what you guys are talking about is with two items that are B type and they both used the same component. Here we find that the system over issue one line and under issue the other, but at the end is a wash, because the total issued is equal to what was needed. When we issued manually thru WO-G we don’t have this problem. The problem is only with backflush.
Juan

Title: Re: Work Order Issues -Deja Vu
Post by cathyh on 12/15/04 at 12:42:24

Not the case here, this is an R type issued using WO-G to a F type.

Title: Re: Work Order Issues -Deja Vu
Post by cathyh on 12/23/04 at 12:08:11

I would really like to know if there is any way to correct a work order actual materials cost when WO-K-H rebuild costs does not fix the problem. Anyone have any ideas on this?
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