Rework Job Enhancement

Permits the user to issue an item to a job to make or re-finish the same item.

Problem... If you need to rework parts because they are out of spec or need refurbishing then you've already discovered that SyteLine does not permit a part to be issued to a job to make the same part. Doing so creates the potential of a 'recursive' bill of material. The MRP process gets caught in an infinite loop as it processes the BOM structure and repeatedly returns to the same part.

The workarounds are horrendous. For example: Take the item to be re-worked and do a miscellaneous issue from inventory, posting the item's value to a clearing account. Then do a miscellaneous receipt into a dummy inventory item, crediting the clearing account with the same value. Then issue that dummy inventory item to the job to rework the first item. This gives the user proper costs, but destroys any audit trail for the item, especially bad if the item was serialized or lot controlled. It is also prone to operator error, as the operator must be sure to credit and debit the correct accounts, the correct parts and complete all transactions to avoid leaving value out-of-balance.

Or perhaps you've tried this: Create a different item number for re-worked items. So one would issue the item to be reworked to a job for the re-work item number, EG: Issue an FA-10000 to a job to make an FA-10000-R. The result however is now the manufacturer has two different part numbers on hand for something that is functionally identical, a situation that is not visible to material planning or order entry. The effect of this will be over-planning of goods because the material system does not show the re-worked part on the bill. Customer order entry will not have visibility of the re-worked item on the shelf and so may quote lead times based on having to manufacture a replacement part rather than shipping from stock.

Solution... You can have true rework jobs on the floor, permitting costs to accumulate to the refurbished parts as they are repaired and put back to inventory. We've enhanced SyteLine to create a special circumstance permitting the user to issue a part to a job to make the same part on the condition that the job number starts with the letter 'R' for rework. We've then told the MRP and bill of material logic to ignore all jobs that start with the letter 'R'.

Price: $2,250 / Annual Maintenance:  $450

Available for SyteLine Versions 4, 5, 6 & 7