I’ve been playing around with the Rework functionality in Kinetic, but have been unable to determine a few things nor find anything here on the forum to address them.
Wondering how to tackle these and/or how any of you handle them:
Scenario 1:
User (in MES) Starts Rework on an operation that is not marked rework and then they enter the full quantity needed for that op on End Activity the “Complete” box gets checked, but when they click OK it doesn’t record any completed quantity on the operation, the op is not completed, and the only place I see to view the Rework Quantity is on the labor details for that op.
Q: I’m assuming that’s all as designed and there’s nothing else I’m missing in this process, with the expectation is that users will then Start/End Production on that op for the quantity to complete it. What is best way to manage this so it’s not as manual and isn’t so difficult to know that rework is completed and op is ready to be completed through normal clocking process that does complete it?
Scenario 2:
User Starts Rework on an operation marked Rework and then they enter the full quantity needed for that op on End Activity the “Complete” box gets checked, but when they click OK it doesn’t record any completed quantity on the operation, the op is not completed, and the only place I see to view the Rework Quantity is on the labor details for that op.
Additionally, because it is a marked Rework operation they cannot then start normal production to be able to End Activity and report a “real” quantity to close the Op, because the Rework flag requires a Reason Code be entered to start and the op will always act like described above and not like a regular op. Complicating matters is that we don’t allow proceeding ops to be started until the preceding are first completed. If we can’t complete the Rework op, then we can’t start the next op when it exists.
Q: I’m assuming that’s all as designed and there’s nothing else I’m missing in this process, so how is the op supposed to get completed?
Additional wrinkle: above scenarios assume rework of full quantity on op in a single activity; system doesn’t aggregate rework quantities like it does with production quantities to determine if the “Op Complete” box gets checked in End Activity.
Rework Activity is for when an employee is reworking parts on the original operation that they were produced on. For example, say Op 20 is a lathe turning operation. Alice makes 5 parts (Production Activity) but then finds that they are too large and need to be turned down more. Alice then logs into Rework activity for Op 20 and clocks the time it takes to do the additional turning for these 5 parts. She’s able to report the 5 parts “complete” for tracking purposes, but the system doesn’t consider these complete for the operation since it’s just reworking previously reported parts. The benefit of using Rework Activity is that you see the additional hours/cost and can assign reason codes for that additional time spent reworking the parts before they move forward.
A Rework Operation is for when you need to do something new to a part to rework it. In the diameter example above, imagine you wanted to send the parts to a separate grinding station to grind them down instead of re-turning them. Since it’s on a new machine and you might want to have a new production standard/hourly costs, you create a Rework operation 25 scheduled to that grinding station. Your employees can then clock time against the rework operation to track the costs/time for grinding down the 5 bad parts separately from any actual production quantities for the job. All of that time has to be clocked as Rework Activity.
Our company actually created an operation code called “Rework” and treat all “rework” operations as regular production. Employees log into Production Activity when they’re using this op code exactly for the reasons you described. We tried using Rework Activity and Rework flag on operations but most of our rework is either taken care of as part of the original labor entry and is captured as a lower labor efficiency or is assigned from DMR after the job or operation’s original run was already complete.
Ok, that was my understanding of those situations, too, given what other documentation I found and testing I did about it. Thanks for confirming my findings!
This is what we do, too. Was hoping to use the Epicor Rework items so they have an easier, more consistent way to analyze those costs and the reason for the rework. Guess I could recreate my own Flag and set of “Reasons” through UD Codes.
We aren’t doing anything ‘official’ for Rework, but should. I have a few questions if you are willing…
With ReWork Activity, are you able to issue additional material to the Job?
when you say you ‘treat all rework operations as regular production’ does that mean you are creating Jobs for Rework and the Op is your ‘rework’ Op? or are you creating Jobs for the Part with the Rework OP as the only Op?