Report Scrap

Explanation

Use this activity to report operation scrap for a shop order. I.e., scrap of the shop order main product.

To report scrap from:

• Shop Order Operations Reporting: Select the operation on which the scrap occurred and click Scrap.
• Shop Floor Workbench: Select the operation on which the scrap occurred, click Scrap and then Main Product.
• Operation Guide: Click Scrap and then Main Product.

         In Report Scrap dialog:

• Enter the Qty to Scrap.
  • If a serial number is entered, the value is always 1.
  • If the part has an input UoM group defined, you can enter the quantity to be scrapped in the input unit other than the inventory unit of measure by selecting an input UoM and entering an input qty to calculate the quantity to be scrapped. If the input UoM is using a formula, click Input UoM to use the assistant. Note that the input UoM and the input quantity are only used to calculate the inventory quantity, they will not be recorded on the material transaction.
• If the part is serial tracked and serial numbers have been reserved, enter the serial number in the Serial No field.
• If the part is lot/batch tracked and lot/batch numbers have been reserved, enter the lot/batch number in Lot/Batch No. If the part is both lot/batch and serial tracked and the serial number is connected to a lot/batch number, the corresponding lot/batch number must be selected.
• Enter a reason for the scrapping in the Scrap Reason field.
• If multiple resources are available in the work center, select the resource that produced the scrapped quantity in the Resource field. If a machine clocking is ongoing, the scrap is automatically registered to the clocked resource.
• If you want the operation to be closed, enable the Close Operation option.
• Click OK to report and close the dialog, or Apply to report and keep the dialog open to report more scrap.
• Time Clock client (Note: Depending on the Time Clock configuration, some of these fields may be automatically filled with default data and thereby the fields may be disabled or unavailable for editing.):
  • Click Report Scrap.
  • Enter the Employee or Team that reports the scrap.
  • Enter the Operation on which the scrap should be reported.
  • Enter the Quantity Scrapped select the Scrap Reason.
  • If the part is serial tracked and serial numbers have been reserved, enter the serial number in the Serial No field.
  • If the part is lot/batch tracked and lot/batch numbers have been reserved, enter the lot/batch number in Lot/Batch No. If the part is both lot/batch and serial tracked and the serial number is connected to a lot/batch number, the corresponding lot/batch number must be selected.
  • If you want to close the operation, select Yes in Close Operation.
• Shop Floor Workbench/Reports and Shop Floor Reports pages:
  • Click New Result and then New Operation Result.
  • Enter the Operation ID on which the scrap should be reported.
  • Enter the Qty to Scrap and select the Scrap Reason.
  • If the part is serial tracked and serial numbers have been reserved, enter the serial number in the Scrapped Serial No field.
  • If the part is lot/batch tracked and lot/batch numbers have been reserved, enter the lot/batch number in Scrapped Lot/Batch No. If the part is both lot/batch and serial tracked and the serial number is connected to a lot/batch number, the corresponding lot/batch number must be selected.
• Enter the date and time when the scrapped quantity was produced in the Time of Production field.

If the operation is connected to a component line and that component line is not issued prior to reporting the operations, it will be issued using the backflush feature. If any components issued by the backflush feature are catch unit enabled, the full quantity in the inventory part location must be issued to complete this activity. The operation must be connected to the material line.

If only a part of the quantity in an inventory location is issued, you will have to manually issue the components before reporting scrap.

Prerequisites

• The shop order operation status cannot be Planned, Parked or Closed.
• The shop order type must not be Disassembly.
• The shop order must not originate from MRO or CRO processes.
• If the Manual Operation Qty option is enabled for the operation, the sum of the reported quantity complete and scrap must either be equal to or less than the planned operation quantity.
• If the Over Reporting drop-down is set to Not Allowed on the Inventory Part/Manufacturing tab, the sum of the reported quantity complete and scrap must either be equal to or less than the planned operation quantity plus the defined over report tolerance.
• If WIP product(s) are linked as the To Operation, those must either be already issued, or enough quantity must be reserved at the inbound location(s) defined for the resource or work center.
• If you want to use multiple units of measure when entering the quantities of parts to be scrapped, an input UoM group must be connected to the part and the Manufacturing Usage Allowed option must be enabled for at least one input UoM (belonging to that input UoM group).
• To report scrap for a serial number or lot/batch number, sufficient component quantity must be included in the tracked structure of the scrapped serial number or lot/batch number. Only components connected to operations up to and including the operation on which scrap is reported are considered. Components connected to parallel operations, succeeding operations, no operation, or operations where Reserve/Issue Method is set to Manual are excluded. Components connected to an operation with Manual Operation Quantity enabled are considered only when scrap is reported on that operation.
• If the scrap is reported for a serial number and the part is connected to a serial lifecycle group, the serial number to scrap must not already exist for another part in the same group, except if the Operational Status of the existing part serial is Renamed, or automatic serial rename has been defined on the Serial Lifecycle Group page. The below conditions must be fulfilled in order for automatic serial rename to occur:
  • The shop order type is Remanufacturing.
  • An automatic serial rename record must exist where the From Part is the part for which the serial number currently exists, the To Part is the part to scrap and the Process is set to Remanufacturing Shop Order.
• The Operational Status of the existing part serial is not Renamed.
• The Current Position of the existing part serial must be either:
  • Returned to Supplier.
  • Contained and the Current Position Top Part must be Returned to Supplier, Issued (to a customer order, project deliverables or without order connection) or Unlocated (and the top parent Operational Status must not be Scrapped).
  • Issued (to the same shop order, a closed shop order, a customer order, project deliverables or without order connection).
  • Unlocated and the Operational Status is Disassembled.
• The serial number must not be defined as a VIM, Equipment, Tool Equipment or a Plant Design object.

System Effects

• The system reports scrap for an operation. The remaining quantity of the following operation decreases by the scrapped quantity. If the operation on which the scrap was reported has the Increased Lot Size on Scrap option enabled, the following operation will not decrease the remaining quantity by the scrapped quantity.
• If Auto Close Operations is enabled from work center level, status of the operation will be changed to either Partially Reported or Closed depending on what you scrap.  
• If Auto Close Operations is disabled from work center level, status of the operation will remain as Partially Reported even if the full quantity is scrapped.
• If the operation has ongoing clockings, the status remains Setup Started or In Process unless Close Operation is enabled. In that case, the status is set to Closed, and all ongoing clockings are stopped.
• An operation history OPFEED-SCP transaction is created.
• Preferred resource of the operation is updated.
• An inventory transaction history OPFEED-SCP transaction is created.
• If a serial number is selected, a part serial record is created, or the existing part serial record is updated and the serial number is unreserved from the shop order.
• If a lot/batch number is selected, the scrapping is recorded on the part lot/batch and its remaining quantity is reduced.
• If scrap is reported for a serial number or lot/batch number for a multilevel-tracked part, components in the tracked structure that can be determined to be included in the scrapped parent part are moved from the parent tracked structure to the tracked structure of the scrap transaction. This includes components connected to operations up to and including the operation on which scrap is reported. Components connected to parallel operations, succeeding operations, or no operation are excluded. For components with Reserve/Issue Method set to Manual, and for components connected to operations where Manual Operation Qty is enabled, only the quantity that would otherwise result in an excess quantity in the remaining tracked structure is included. However, when scrap is reported on the operation to which a component with Manual Operation Qty is connected, the full component quantity is included. The tracked structure of the parent serial number or lot/batch number is then rebuilt to reflect the remaining quantity and component structure.
• If scrap is reported for a serial number and the scrapped part is connected to a serial lifecycle group, and the same serial number already exists for a part with automatic serial rename defined, the existing part serial is renamed to the scrapped part, as follows:
  • The Current Position of the serial number for the existing part on the Part Serial page is set to Unlocated and the Current Position to Renamed.
  • The rename is logged on the Part Serial Rename History page with the Rename Reason set to Serial Lifecycle Rename.
  • Document and technical class characteristics attached to the part serial of the renamed part are moved to the part serial of the scrapped part.
• WIP products linked as the To Operation that have not yet been issued will be automatically issued primarily from reservations at the inbound location(s) defined for the resource. If insufficient quantity is available at those locations, the system issues from the inbound location(s) defined for the work center. An inventory transaction (SOWIPISS) is created.
• Reporting scrap will, in some cases, affect manual peggings. When reporting scrap on a shop order operation where the parent part has a manual supply pegging to a demand, a check is performed to see if the quantity to be received is less than the quantity pegged to the demand. If the quantity to be received after scrap is less than the quantity pegged, you will be notified to manually adjust the peggings before the scrap can be performed.
• If Buffered Operations Reporting is enabled and the Adjust Schedule Due To Shop Floor Reporting option on the Scheduling Basic Data/Shop Order Scheduling/Scheduling Server tab has been enabled, at the next execution of buffered operation reporting the scheduling server will adjust the operation time due to remaining quantity and:
  • if Prioritize Reported Operation is chosen - the reported operation will be given priority and scheduled as close as possible to now time.   
  • if Keep Scheduled Operation Sequence is chosen - the schedule will be updated without altering the previous schedule sequence. Subsequent operations in the same order structure will move closer to the reported operation in order to fill any capacity gaps which occur immediately after the reported operation.

• When tool demands exist for the operation for a tool group that is set for Auto Record Tool Usage, tool usage history is automatically created on Tool Usage History page linked to the scrap transaction.

Pages

Shop Floor Reports
Shop Floor Workbench
Shop Order Operations Reporting
Time Clock

Activity Diagrams

Report Operations from Shop Floor Workbench
Report Operations from Time Clock
Maintain Shop Order
Process Material Review Board Case
Report Operations