Hey all. Trying to get a feel how everyone else keeps track of their WIP in bins from physical to virtual land. I would like to present a scenario to outline the workflow problem I’m trying to solve.
Say we need to produce 50 cases of product each with 10lbs of paper (qty/parent). Add our 10% scrap factor and the job says we need 550lbs. Cool.
We find a roll of paper and closest we have is 700lbs. We issue that to the job.
We have a ton of setup issues, trouble running the print lots and lots of broke, and we end up consuming all but 30lbs of the roll (at which point we throw it in the scrap bin we can run it anymore) and we have nothing of that roll left.
We reported a final qty of 50 cases so at this point only 550lbs of the parent roll has been relieved from WIP leaving us with 150lbs in WIP of a roll that doesn’t exist.
Enter the problem. An auditor comes along and sees that 150 lbs in WIP can’t find the physical roll because we used it. No biggie they recognize that it was consumed and move on.
We make direct but not everything will ship right away. Say that job sits a few days open and the intellectual property that knew that roll was consumed is not in today or has since forgotten and another super marks it as lost and moves the 150 to our lost bin. Now we are starting to create a mess.
How do others manage that WIP in such a way it doesn’t become a shit show of no idea where it went because it’s there till the job is closed, which could be days or weeks for our make direct.