Executing Repetitive Transactions

Repetitive transactions provide feedback for repetitive operations. Like those in the Shop Floor Control module, they require use of an employee code. However, Repetitive Labor Transaction differs significantly from shop floor control transactions because it triggers inventory transactions to backflush components and receive completed units.

See Shop Floor Control.

The reporting of setup hours, labor hours, downtime, reject quantities, rework quantities, and scrap quantities works much the same in Repetitive as in the Shop Floor Control module but with the following differences:

• Operation scrap can be reported in Repetitive but not in Shop Floor Control. Like the reporting of reject and rework quantities, scrap quantities have no impact on the general ledger and do not affect costing.

When a routing has many operations, there may be a few that are used to report completions, called milestone operations.

In Routing Maintenance (14.13.1), you can define any operation—including standard operations—to be a milestone. At a milestone operation, that operation and all previous non-milestone operations are backflushed when repetitive labor is reported. The last operation is always treated as a milestone.

The following rules govern reporting:

• You can report setup, downtime, reject, and scrap against a non-milestone operation. However, this reporting does not affect WIP.

If you do not report setup at non-milestone operations and report labor at milestone operations, the standard setup will be backflushed. If you report setup at the milestone operation, then no setup will be backflushed.

Completed units are received into inventory when quantities are reported as complete for the last operation for an item, using Repetitive Labor Transaction (18.14). Components can be backflushed when completed units are received if the components are linked to the last operation.

Note: For each change in the quantity complete at a milestone operation, the quantity complete at all of the previous non-milestone operations is changed to reflect the fact that the later operation was completed.

If completions are recorded on nonscheduled dates, the reporting of quantities on these dates causes entries to be automatically added to the repetitive schedule.

If you are using shipping groups and inventory movement codes, you can enter shipment information and generate shippers when items are backflushed The system looks for a shipping group with matching addresses for the issuing and work order sites and with inventory movement codes that include ISS-WO.

See the Shipping chapter in User Guide: QAD Sales for details.

If you report completions for today’s date using Repetitive Labor Transaction, the report has the following effects:

• Inventory is incremented by the completion amount. A backflush occurs. Component inventory is shown as issued to the repetitive order. The requirements for components at all previous non-milestone operations are decremented. Floor stock items are accounted for.

• If there is a scheduled amount for today, the quantity completed is incremented and the quantity open decremented until the scheduled quantity is reached. These quantities can be reviewed in Operation Schedule Report (18.2.5).

• If there are previous non-milestone operations, the quantity completed at each previous operation is also incremented, up to the amount required to make the scheduled amount of the finished item.

• If the quantity open at the last operation is still nonzero, indicating the quantity completed is less than the quantity scheduled, the quantity open is treated as supply by MRP, and shown as the current amount of the planned order in MRP Detail Inquiry (23.16). See Material Requirements Planning.

The Consume Forward, Consume Back, and Start of Week settings in Repetitive Control (18.24) determine how the system handles item completions that exceed the quantity scheduled on a given day. For example, you may complete some items ahead of schedule or scrap fewer items than expected. When this occurs, the system follows these steps to record the excess completions against other exploded schedules:

1 The system searches for a scheduled order routing with a start and due date range that includes the effective date of the repetitive labor transaction. If the system finds scheduled order routings that meet this criterion, it applies the excess completions to their corresponding schedules, starting with the schedule that has a due date closest to the reporting transaction effective date.

2 If excess quantities still remain after the previous step has executed, the system subtracts the number of days specified in the Consume Back field from the reporting transaction effective date. It then searches for exploded schedules with due dates that are between this day and the effective date. Schedules with due dates that are before the day specified in the Start of Week field are not considered.

See Defining Control Program Settings.

Starting with the schedule that has the earliest due date, the system consumes open scheduled quantities until all available quantities are consumed or all excess completions have been recorded against a schedule.

Note: When Start of Week is set to Today, the system does not consider the Consume Back value when searching for open schedule quantities to consume. Only the Consume Forward setting is used.

3 If excess quantities still remain after the system has consumed open quantities on past schedules, the system adds the number of days in the Consume Forward field to the reporting transaction effective date. It then searches for exploded schedules with due dates that are between this day and the effective date.

Starting with the schedule that has a due date closest to the transaction effective date, the system consumes open scheduled quantities until all available quantities are consumed or all excess completions have been recorded against a schedule.

When Consume Back and Consume Forward are both 0 (zero), the system simply transfers excess completed quantities to inventory and does not report them against a repetitive schedule. This also occurs when the system runs out of open schedule quantities to consume.

Completed planned orders are not considered by MRP.

An item scrapped in the first operation may have a lower cost than one scrapped on receipt. It will not have the accumulated labor, burden, and additional material costs that accrue during subsequent operations.

Repetitive Scrap Transaction (18.18) reports scrap at the item’s accumulated cost through the operation where it is scrapped. The system uses the standard cost created by the most recent use of Operation Cost Calculation (14.13.17). However, if no operation costs exist for the item/ routing/cost set, Repetitive Scrap Transaction automatically rolls up and totals the material, labor, burden, and subcontract costs by operation. It also does this for scrap reported for alternate BOMs/routings not included in Operation Cost Calculation.

The item cost by operation can be reviewed using the Operation Cost Browse, (14.13.18) or the Operation Cost Report (14.13.19). After the scrap transaction is recorded, the scrap cost can be verified using the Repetitive Operations Accounting Report (18.4.10). Repetitive Scrap Transaction debits scrap and credits WIP for the operation cost multiplied by the quantity scrapped.