Scenario: Job 123456 is initially released with a job qty of 100 to meet a sales order demand of 100. On some operation on job 123456 a scrap qty of 20 is reported meaning that it is only possible for a maximum of 80 good parts, out of the original 100, to ever get put into inventory. Demand will no longer be met without manual intervention.
Right now our team’s only known way of responding to this is to manually review scrap reports, or other system reports/dashboards, or look at job tracker for example job 123456 to see that they need to cut a new additional job with a job qty of 20 to replace the 20 that were scrapped to still fulfill the original demand of 100.
Our current MRP setup doesn’t catch or fix this until job 123456 would be marked as completed. At that point MRP should see that we have a demand of 20 and create a corresponding unfirm job to resolve this.
However, relying on MRP to resolve this or trusting our team to always catch every single scrapped part and then cut a new job to make up the lost qty seems to be a losing strategy as we continue to grow and diversify our business. Also, regardless of if MRP fixes it or manual human intervention fixes it we are generally going to catch it too late to still meet the original due date for the customer.
So a hypothetical fix has been suggested in which we’d have some custom logic in place that would automatically update the job qty of any job when parts were scrapped. So, in my initial example job 123456 would be immediately and automatically updated with a job qty of 80 at time of the 20 parts being scrapped. In this way we’d then have the best chance of fixing this demand shortage because it would be caught ASAP and a new job could be created.
Now that I’m thinking of this, maybe the custom logic could even be taken one step further and the “catup up job” could be automatically created by the custom logic as well so we wouldn’t have to wait for MRP to run overnight.
Anyway, I’m looking for any pitfalls with this hypothetical strategy or any better ideas to resolve this. Maybe there is even a built in base system way of handling this that we’re unaware of.
recalculate production yield could work for this and mrp running frequently would make the makeup job. You could also make the job by hand and there is code here for that process.
Production Yield
The Production Yield functionality is useful on jobs that have sequential operations. This feature adjusts quantities on a job based the actual production quantity reported on each operation.
Production Yield Recalculation Process
Use the Production Yield Recalculation Process program to run and schedule production yield recalculation for jobs
Hey Greg, I think this is exactly what we are looking for. One point of confusion though:
From Kinetic Help:
Operation Maintenance-Detail Fields
Recalculate Yield Under %
After selecting the Recalculate Expected Yield check box, enter the threshold for under-production in the form of a percentage. If the application finds a variance between the actual and estimated production quantities of the operation, and that variance is greater than the percentage you enter in this field, the application will recalculate the expected production yield quantity of any job that uses this operation and has been flagged to use the automatic recalculation feature, and it will adjust the job production quantity.
Tip: If you enter a zero value in this field, yield will never be recalculated automatically. If you want to trigger automatic recalculation, enter a higher percentage or do not select Recalculate Expected Yield check box. For example, enter 3 to maximize yield recalculation.
I understand the help explanation up until the 2nd to last sentence. What in the world does it mean to leave the checkbox unchecked as a valid way to still trigger automatic recalculation?! Is this just bad help language or am I missing something?
I have not used in in over ten years, so I am not sure. This is from the job entry field help with a lot of conditions to be met to make it happen. I would set one operation and one job in test and run the recalc to understand the process.
Production Yield
When selected, this check box instructs the Epicor application to perform production yield recalculation for this job in the event that its operations result in over-production or under-production. You also need to select one or more of the three system actions available on the Operation master for every operation used in this job to enable production yield recalculation to result in some action. If a system action is not selected on the Operation masters for operations for this job, the Epicor application performs production yield recalculation, but cannot undertake further action such as sending a warnings or alerts, or adjusting the job quantity automatically.
In addition, you also need to select the Production Yield Default option on the Plant master of each plant that stocks the parts used in this job (and its operations), along with one or both Production Yield system actions available on the Plant master. If this job does not have any operations, the recalculation process is not executed even if the Production Yield check box is selected for the job.
This check box is automatically selected if this job uses a part stocked in a plant that has the Production Yield Default check box selected on the Plant master.
Important: The actual production quantity of the operation is the quantity reported in Labor Entry or in Office Data Collection. Once the operation is marked as Complete on the Labor Entry - Labor Detail sheet, the Epicor application can start production yield recalculation. The estimated production quantity of the operation is the required quantity plus the estimated scrap.
Tip: The recalculation process does not start automatically after labor entry. You need to schedule or run the automated recalculation by scheduling the Production Yield Recalculation Process. This is a batch process.
Note: If you select the Recalculate Expected Yield checkbox and the job holds an operation in its method that includes the Recalculate Yield Under % value of zero, as defined in Operation Maintenance, and the last operation on the job is completed short, but marked as Completed, the job production quantity will be recalculated after you run the Production Yield Recalculation process.
