Hello, New user, mid-implementation. My consultant and I are not 100% sure how the scrap feature works in epicor. My company makes machined components with roughly 1-20 operations in the manufacturing process. In our current MES, we assign a global scrap rate in %. This dictates how many pcs of overrun we will plan for. Example, an order for 100 pcs, but we expect 30% fallout, then we will start the order for 130 pcs. This is not done at the op level, simply a global % based on the part itself. Ideally we could switch to per op scrap rates(data we have) and use that to drive the total overrun quantity. Seemingly the scrap rate as it sits in kinetic just serves to tell us to make more for each op but that does not feedback in any way to the first op or the material requirements. We can trick the system by setting the first op to have the 30% scrap which does give us the overrun we need, but ultimately we would have to set all other opâs scrap rate to 0%. This is not how we want to use the system. Ideally the system would combine the individual scrap rates and give us the correct quantity to start with to make the order. Example, 3 operation part with 5% scrap at each op would net a starting quantity of 1.05 x 1.05 x 1.05=115.8%. Seemingly I just donât understand the purpose of the native scrap rate. Before building a customization, I wanted to reach out and see if anyone could point me in the right direction. Thanks.
The scrap rates for the material is on the material, not the operation. See the screen shots below for a sample job of 20, with a material at 1 per with a scrap rate of 10% give a required material of 22.
Scrap rates on the operations have to with how much labor is required. So if you add a scrap rate on your operation, it adds it to the labor time (not the material)
These are separated to give to the appropriate control that you need as different industries have different definition of what that scrap would be. For example, if assembly has a scrap rate of 2%, they can probably just take it apart and put it back together again, so there is no wasted material. While a machining operation probably ruins the material. But Epicor canât know that, so they put you in charge of figuring out the material scrap rate, and the labor time scrap rate separately.
If you want to relate the operation scrap rates to the material scrap rates, a BPM can be make to recalculate the material scrap rate to equal the total of the operation scrap rates if you so desire.
That will go on this method.
Remember whenever trying to figure out what Epicor (or any software for that matter) is doing, keep the perspective that Epicor has to be a jack of all trades and try to fit as many industries as possible. That makes it a master of none, and the trade off to that is it usually doesnât make 100% for every process in your business because each business has itâs own way of doing things.
Thank you for your input. I just wanted to make sure I wasnât overlooking something obvious. We will write a BPM to figure this out.
@Banderson , @josecgomez , @bderuvo , @jgiese.wci , or any other admins.
Can you mark Brandonâs response as the answer? This is a very well explained response that needs to be highlighted as correct for anyone else searching the forum.
Heâs already abused his own power and done so #Dictator! 
At least I waited until someone asked.
You have to give him credit for that.
Hi - bit of a thread bump.
Whats the best way in Epicor to plan for scrap if the scrap could occur at anyone one of the multiple operations required to produce the part?
Say we have an order for part A, qty 50, and the production method has 10 unique ops each with a material requirementâŚ
We know from past production that every time we make this part, regardless of starting qty, we scrap 2, but the operation causing the scrap is different each time.
Is there a way to get Epicor to add 2 onto the required qty, ie raise a job for 52, so that we yield the required 50
Thanks
Sorry for the double bump but reading through this thread has taught me I was making an incorrect assumption.
I wanted to start having Epicor do the thing @paul_luvaglia is referring to here.
I have a part that has 5 operations, and I can expect a certain amount of predictable loss between each op.
If I want 100 pieces to come out of the final op, how do I tell the first op to make 110 so my final op person has enough material to work with to satisfy all 100?
@hackaphreaka and @paul_luvaglia
We do this but we had to execute this 100% with custom code. Essentially we assign a scrap rate to each op, then back that up to the first op and multiply to arrive at an âoverrunâ number. All custom code. Found nothing native in Epicor to handle this.
What about scrap generated during the setup process? I just canât find where to put it or how to deal with it. Thanks.
With this discuss open again - I would like to chime in that if you are experience a yield issue at various operations.
Putting Scrap on the operations (Yield)
You may want to put in the scrap factor at each operation as it will do a couple things for you.
- calculate the estimated hours for the operation
- Print on the traveler the quantity that you want to start on the given operation
Calculate Production Yield
The other aspect you would want to consider is the yield of the job. If you are experiencing yield issues an you havenât setup your configuration to calculate the yield from the jobs currently running, you are blind to the actual quantity of job being completed.
Using production yield will actually change the production quantity based on the operations that you have flagged to calculate yield. The yield will also drive demand on following operations because the job production quantity is changed.
Note that material did not increase based on the estimated operation quantities.
Entering the lower yield and scrap during time entry will change the production qty on the job. Giving a heads up to planners they may need to run additional quantities.
@JACadeena You can enter in Scrap on Production or Setup in these fields.
.
Thanks for your reply, Bruce.
I was talking about the setup process. I want to tell the system that everytime we do the setup for operation âXâ there will be âNâ amount of scrap and, therefore, the warehouse should provide these pieces (it is usually steel sheets for us).
If we declared it after the fact then we will be asking warehouse guys for the same part many times.
Are you talking about setup pieces or percent of sheet?
You can add an Additional Setup Qty on the operation in Engineering Workbench.
Thanks a lot, John. It was literally in front of me.
Additional setup qty is used when you need to do some re-setup during the run.
Replace Cutting tools after running 100 pieces you replace the carbide inserts.
You enter 100 additional Setup Qty
1/2 hour for additional setup time.
Jose,
You will need to add an additional material line with a fixed qty for extra material required for startup.
In printing or Aluminum extrusion - you add some material to start the machine up.
@LarsonSolutions , I thought it also added the quantity to the overall required quantity? That is, it is not just for additional setups. Let me know if I am incorrect.
No, I did some testing - today on this topic.
The additional quantities on the operation shows up on the printed traveler, but does not drive the material requirements.
There could be a calculation with a BPM to update the material to add a scrap factor to drive the material correctly, or adding an additional material sequence to drive the additional materials.
The additional quantity for the setup really could be call a trigger qty for the timing that additional setups that are required for tooling updates and adjustments.