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Order Requirements To Scrap

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The Order Requirements to Scrap function, is used to scrap requirement parts issued to an order. An External Organisation deemed to be responsible for the scrapping can be entered on the movement. This function is used when the user wants to scrap material and needs new material to be issued in order to still manufacture the original order quantity. Scrapping of material will inflate the required quantity with the material scrapped.

If the user selects  Part Number, any data that was selected in the Routing part combo will be cleared and vice versa. Only one of the two methods can be used. When a part number is selected the Requirement data of the selected part number will be populated and only the selected part can be scrapped.

It is also possible to perform the scrapping of associated labour via the same transaction. This is performed by selecting the Routing part, which may be either the Order Line part or any Phantom in the structure of the order line part which has operations. When such a part is selected , the user must also select the operation on which the scrap transaction is to be performed. The system will then insert order operations with a operation type of scrap for the selected operation as well as all the preceding operations as well as a actual for the quantity to be scrapped. This value is then journalized to the  Scrap Labour, Overheads and Fixed Overhead accounts of the Order Division.

When a quantity of a Routing part is selected to be scrapped, the grid below will be populated with all the requirements associated with the selected routing Part where the user have to select which parts are also scrapped. The system will default a scrap quantity based on the quantity of the Routing part to be scrapped as well multiplied by the quantity per of the requirement as suggested scrap quantity but this can be changed by the user.

It is also possible for the user to select only labour and no material in a case where all the material has been recovered and only certain labour costs has to be scrapped and no material is needed in addition to the issued material.

 

 

 

Security Profile

The user must have a security profile linked to the function Order Requirements to Scrap with an access Change rights to perform the function..

 

On this tab the following fields or controls can be accessed:

 

hmtoggle_plus1Apply

The user must have a security profile linked to the function Order Requirements to Scrap with an access allowed of Change.

 

The "Apply" button is enabled when a line is selected in the Order Line Requirements for Part Number grid.  When the "Apply" button is clicked, the following updates are performed:

 

1.  The system validates that a serial number is entered (if Serialised is "Yes") and that a valid stock status and account are selected. It ensures that the scrap quantity is greater than zero and that only one serialised part can be scrapped at a time.

 

2.  The system determines if the selected order is still valid.

 

If a Movement Routing part is specified, the stored procedure Movement OrderReq Scrap Labour is executed.  If you are not using the front end to perform updates, the following parameters can be passed to the stored procedure:

 

FIELD

 TYPE

 COMMENTS

Movement_From

 char(3)

 "ORQ"

Movement_To

 char(3)

 "SCP"

RoutingPart_Number

 varchar(30)

 Movement Routing Part

RoutingPartScpQty

 Decimal(16,5)

 Movement quantity

Order_Number

 varchar(30)

 Movement Order Number

Order_Type

 char(4)

 Movement Order Type

Line_Number

 smallint

 Movement Order Line Number

Line_Type

 char(4)

 Movement Line Type

Completion_Date

 smalldatetime

 Movmement Line Completion Date

Operation

 Varchar(10)

 Movement Scrap Up To Operation

OperationSeq

 integer

 Up to operation sequence

ReturnLabourDateTimeComplete

 datetime

 spaces

 

 

3.1.Labour Backflushing

Any Labour to be backflushed will be backflushed from the order operation table. For each movement, a record will be inserted per operation in the table Order Operation Actuals. The quantity complete will be updated with the Scrap quantity for all operations where the operation part number is equal to the order line part number. If the operation part number is not equal to the order line part number, i.e. for Phantoms with order operations in the structure of the order line part, The operation quantity complete will be inserted as the Scrap quantity multiplied by the composite quantity per.

Labour can also be reported back from the Order Operation front-end, in which case the labour credits will be given to the applicable cost centers recovery accounts, and the Debits will be Debited to the WIP Labour, Overheads, and Fixed Overhead accounts of the Order's Division. If labour was reported via the Order Operation function, the backflushing of labour via the movement will in turn credit the WIP Labour, Variable- and Fixed overhead accounts in stead of the cost center's Labour and overhead recovery accounts.

The Labour of all order types will be backflushed in the same manner.

 

3.2.  The Order Requirements to Scrap Labour Journal for standard or average costing is created.

 

4. The stored procedure, Movement Order Req Scrap is executed.  If you are not using the front end to perform updates, the following parameters can be passed to the stored procedure:

 

FIELD

 TYPE

 COMMENTS

Movement_From

 char(3)

 "ORQ"

Movement_To

 char(3)

 "SCP"

Part_Number

 varchar(30)

 Movement Scrap Part

Serial_Number

 varchar(30)

 If serialised, Part serial number, else spaces

Employee

 Employee_ID

 ID of signed on user

Order_Number

 varchar(30)

 Movement Order Number

Order_Type

 char(4)

 Movement Order type

Line_Number

 smallint

 Movement Order Line Number

Line_Type

 char(4)

 Order Line Type

Completion_Date

 smalldatetime

 Order Line Completion Date

Quantity

 Dec 16,6

 Movement quantity

Reason_Code

 varchar(10)

 Movement Reason Code

Operation

 Varchar(10)

 Movement Scrap Up To Operation

Division_Code

 varchar(4)

 Order Division

Stock_Status

 char(1)

 Apply Stock Status value on Requirements table

Account

 varchar(10)

 Movement Account (default is Prod_Scrap_ Mat_Cost_Account on Division table)

Deliver_To_Operation

 varchar(10)

 Manufacturing Deliver to Operation

Revision

 varchar(5)

 Movement Revision

Responsible_Organisation

 varchar(20)

 Movement Responsible Organisation

Required_Date

 smalldatetime

 Value on Requirements table

Original_Date

 Varchar (30)

 spaces

Delivery_Note

 Varcher(15)

 spaces

Quantity_Returned

 Dec 16,5

 (zero)

 

 

4.1.The Ratio Checker Routine stored procedure is executed.

The stored procedure determines if the movement is allowed.  (If the completed quantity on the order is 90%, it will be impossible to scrap 30% of the requirements depending on the sensitivity of the ratio checker.)

 

4.2.MOVEMENT UNIT COST

 

4.2.1 Standard cost.

If the Stock Valuation Method is Standard Cost "S", the part source is Interplant "I", the movement's division code is equal to the part's controlling division, the part's unit cost is calculated as the (Material Price + Labour Price + Subcontract Price + Overhead Price + fixed Overhead Price) from the Part financial Year Data table.

 

ELSE

 

The unit cost is calculated as (Material Price + Labour Price + Subcontract Price + Overhead Price + Fixed Overhead Price + Transfer Price) from the Part Financial Year Data table.

 

4.2.2 Average Cost

If the Stock Valuation Method on System Configuration is equal to average cost, and the part source code is not equal to I(interplant) the movement unit cost is calculated as the Sum of the Order Operation Actual Cost for the Order line for a quantity of one, plus the Sum of the required material's multiplied by the requirement's average unit cost for a single order line part.

 

ELSE

 

If the Part source code is equal to Interplant and the order Division = the part's controlling Division, the movement unit cost is calculated as the Sum of the Order's Labour as on Order Operation Actual plus the sum of the issued material as on requirements at the requirements Average unit cost.

 

If the part source is I (Interplant) and the order Division is not equal to the part's controlling Division, the movement unit cost is calculated as described above plus the selected order line's Unit cost.

 

4.3.The movement is created.

 

4.4.The Requirements table is updated. The Scrapped Quantity is set equal to the Scrapped Quantity + the Movement Quantity.  The Required Quantity is set equal to the Required Quantity + the Movement Quantity.

 

4.5.The Order Requirements to Scrap Journal for standard or average cost is created.

5. Journals inserted

The following Journals will be inserted as a result of the movement:-

 

Condition

Account

Debit

Credit

Notes

Standard Cost:

Part Scrapped Fixed Account yes

Order Line has No Account or Node

Selected Scrap Account

Sum of Part Financial Year data * movement Quantity




Work in Progress account for the Order Division


Sum of Part Financial Year data * movement Quantity * -1


Order Line has a node or Account




No Journal, Scrap value Stays on account or Node

Average Cost:

Part Scrapped Fixed Account yes

Order Line has No Account or Node

Selected Scrap Account

Requirement Average Cost * Movement Quantity




Work in Progress account for the Order Division


Sum of Part Financial Year data * movement Quantity * -1


Order Line has a node or Account




No Journal, Scrap value Stays on account or Node

hmtoggle_plus1Order Line

It is populated with all released order lines for the selected order number i.e. the line number, completion date, part number, and line type from the Order Line table where the order line status is Released "R".

 

hmtoggle_plus1Order Line Requirements For Part Number

It displays all the order line requirements for the selected part and order line key from the Requirements, Order Line and Part Master tables where the scrapped quantity is greater than zero.

 

PART NUMBER (Routing Part Only)

 

 

PART DESCRIPTION

It is a read only field that displays the part description from the Part Master table for the selected part scrap number selected and order line key.

 

REQUIRED DATE

It is a read only field that displays the required date from the Requirements table for the selected part scrap number and order line key.

 

REQUIRED QUANTITY

It is a read only field that displays the required quantity from the Requirements table for the selected part scrap number and order line key. (For Decimal Quantities)

 

QUANTITY ISSUED

It is a read only field that displays the issued quantity from the Requirements table for the selected part scrap number and order line key. (For Decimal Quantities)

 

QUANTITY SCRAP

This field is used to specify the quantity to be scrapped.  It displays the scrapped quantity from the Requirements table for the selected part scrap number and order line key.

 

The scrap quantity can be between 1 and the line's requirement quantity.  The scrap quantity can only be 1 for serialised parts.  Cannot scrap zero quantity. (For Decimal Quantities)

 

SERIAL NUMBER

It is populated with the serial number from the Movement table for the selected scrap part number, order number, order type, order line and completion date where:

 

The sum of the movements (Stores to Order Requirements - Order Requirements to Stores-Order Requirements to Scrap) is greater than zero.

 

 

REASON CODE

This code describes the reason for the scrap movement.  It is populated with all order requirements scrap reason codes and descriptions from the Movement Reason Codes table.

 

 

DOCUMENT REFERENCE (Routing Part only)

 

 

STOCK STATUS

It is populated with the stock status from the Movement table for the selected scrap part number, order number, order type, line number and completion date.

 

 

DELIVER TO OP

It is a read only field that displays the deliver to operation from the Requirements table for the selected part scrap number and order line key.

 

ACCOUNT

The default is the division's scrap production material account. It is populated with all the divisional, income statement accounts I.E. the account, cost centre and division code, and the account description from the Account and Account Codes tables where:

 

The account status is active "A",

The account is a divisional, income statement account,

The Account Code application "Order Requirements to Scrap" is selected, and

The status change date is less than or equal to today's date.

 

The user may override the default scrap account by selecting another account which conforms to the above criteria.

 

REVISION

It is populated with the revision number from the Movement table for the selected part number, order number, order line type, order line and completion date where the (quantity - quantity returned) is greater than zero.

 

 

RESPONSIBLE ORGANISATION

This field indicates the external organisation seen to be responsible for the scrap quantity.  

 

It is populated with the name, and organisation code from the External Organisation table where trading status creditors or debtors is Active "A".

 

 

USE ORGANISATION

If checked, each stock status of existing movements for the order with the order's external organisation will be populated in the status field.

 

STOCK STATUS QUANTITY

It is a read only field that displays the stock status quantity.

hmtoggle_plus1Order Number

It is populated with the order number, order type, notes, organisation code, and the division code from the Order Master and Order Line tables where:

 

         The line is not a Non Stock or Stock line, and

         The status is Released "R".

 

hmtoggle_plus1Project Serial Number From/Project Serial Number To

When the routing part is selected and subranges for projects is applicable, those subranges will be displayed for selection.  See also Product Structure Help.

hmtoggle_plus1Quantity To Be Scrapped

The user can enter a quantity greater than or equal to the (Order Quantity - Quantity Complete - Quantity Scrapped) from the Order line.

 

If Decimal Movements are Allowed on the Part Master table, the user will be allowed to enter a value resulting in a decimal. For Non-Stock lines Decimal Movements must be allowed if the Unit Of Measure allows it.

 

ALTERNATE UOM QUANTITY

This field on the Movement table will be the same as the Movement Quantity on the Movement table.

hmtoggle_plus1Routing Part

It is populated with Routing Parts from the Order Operations and Part Master tables where the part source is "N" (Phantom) or the part number is equal to the order line part number.

 

The Part Number, Description and Source the selected part are displayed.

hmtoggle_plus1Scrap By Routing Part

hmtoggle_plus1Scrap To Operation

It is populated with Operations from the Order Operations table where the selected part number in the Routing Part field is equal to the Routing Part on the Order Operation.

 

Displays operations in sequence of the sequence from order operations. The operation number, sequence number, operation description and work center are displayed.

hmtoggle_plus1Scrap Part Number

It is populated with the part number, part description, required date, required quantity, issued quantity, serialised, allocated quantity, fixed account, source, and the controlling division from the Requirements and the Part Master tables, for the selected order number, order type, and line number where the issued quantity is greater than zero.