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WO issues do not equal receipts (Read 658 times)
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WO issues do not equal receipts
08/10/05 at 06:28:12
 
We came up with a couple of negatives on our exceptions report today on parts entered thru WO-P.  When I ran a transaction report, the issues from one part do not agree with the receipts in the next stage, therefore it creates a negative in that part. I.E. Showing six parts issued to next stage, but only showing up as five received within that stage. This happened within three stages of parts and leaves negatives in two parts.
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Re: WO issues do not equal receipts
Reply #1 - 08/10/05 at 07:52:51
 
Jsapp,
Is that enter batch labor?  (my WO-P is different).  If it is batch labor, could it be fractions that are creating problems or outside services?  Our outside services are usually in pounds and the quantity on the work order is in pieces.  When the conversion happens, sometimes it can be a piece or two off.  
 
If it is a major issue, for items on the labor end, you could always go into WO-F (enter labor) and correct the quantity.  As a rule, we correct labor at the end of the run and adjust all quantities to the actual so pieces/hour reports come out accurate.  Instead of trying to distribute it to this or that person, we just use a dummy employee number, no hours, and adjust quantity up or down.
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Karen Mason, Vice President
Bula Forge & Machine, Inc.
1-60# forgings, machining, & assembly
Cleveland, OH
Tel:216-252-7600 Fax:216-252-7601 www.bulaforge.com
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Re: WO issues do not equal receipts
Reply #2 - 08/10/05 at 09:56:24
 
We enter production thru Batch Finished Production (WO-P) and we're running the latest update.  The units of measure are identical so there's no conversion needed.  It just appears that the computer allowed an unbalanced entry, twice.
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Re: WO issues do not equal receipts
Reply #3 - 08/10/05 at 14:14:46
 
Assuming you are referring to backflushing of components, you need to look at the next level to rule out human error (which is what I suspect).  For the sake of simplicity, let's assume all BOM Quantity per are 1 so to make 1 assembly it takes 1 component.  If you ended up with a negative on hand of subassembly A then for Work order that makes the subassembly, you entered fewer into stock than were consumed by the work order for the next higher level assembly.  Those are 2 completely separate transactions so the user may well have entered different quantities.  To identify a program problem, go to WO-A for the higher level assembly and look at the Quantity complete on the first screen (number of end assemblies made) with the quantity issued on the Component screen you can see when pressing the Materials Button.  If those do not match, then there is a program problem.
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Re: WO issues do not equal receipts
Reply #4 - 08/11/05 at 04:58:40
 
Ok, I'm not making myself clear. The transaction reports for Stage 1 and Stage 2 do not agree.
 
Stage 2 shows a correct RECEIPT of 10 items from Stage 1 (operator entry done correctly). Stage 1 should show an identical ISSUE of 10 to Stage 2, but shows an ISSUE of 25 instead, leaving a negative quantity of -15 in Stage 1.  
 
As you suggested, I checked the completed quantities within the WO-A and the completed amts of each stage are correct. The transactions for stage 1 do not agree with the completed amt.
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Re: WO issues do not equal receipts
Reply #5 - 08/11/05 at 07:20:41
 
What is the Stage 2 quantity of Completed parts?  That is what controls the issuing of Stage 1 parts as components to Stage 2.
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Re: WO issues do not equal receipts
Reply #6 - 08/11/05 at 08:41:49
 
There are 10 items in Stage 2 at the point of receipt. Of course, they are then sent to Stage 3, so my ending balance won't match what was received to begin with.  
 
My whole point is that what is entered as work done on the w/o is not agreeing with what was issued, even though within the w/o the materials agree with the completed amt.  The Issues of stage 1 should equal the Receipts of Stage 2. undecided
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