Unplanned Output/Consumption

Introduction

The Unplanned Consumption function makes it possible to set up one or more items that can, for example, replace or serve as an alternative for a component item when a material is not available.

This is done so that a shop floor employee is able to add component items without changing the selected production BOM in the production order.

Unplanned Consumption

If unplanned consumption must be added during the production process, for example, because a specific item has run out of stock, it is necessary to narrow down the items that can be added as unplanned consumption. In this way, the production process can be continued by using other consumption than the planned item from the Production BOM.

Setup Unplanned Consumption

A setup table is needed to assign item numbers/ variant codes that are allowed to use for the function Add Unplanned Consumption.

• Select the Search icon , enter Unplanned Consumption Setup and then choose the related link. The Unplanned Consumption Setup page opens.

With this setup, it’s specified which (unplanned) component item is allowed to replace the (planned) consumption item in the production order components.

An unplanned item can be set up based on the item number or set up with a specific item attribute.

It’s also possible to specify that the unplanned consumption item can only be used in a specific production BOM instead of any production BOM.

Unplanned Consumption in production order components

If during the execution of a production order unplanned consumption arises, for example because the item is out of stock, an extra production order component line should be created for this unexpected consumption.

Via the Add Unplanned Consumption function, this extra production component line can be created. Via this function, it is only allowed to add new lines for item/variant combinations that are set up as Unplanned Consumption Item and Variant in the Unplanned Consumption Setup.

1. Select the Search icon , enter Released Production Orders and then choose the related link.
   The Released Production Orders list page opens.
2. Select the required No.
   The Released Production Order page opens.
3. On the Lines FastTab, navigate to the desired line.
4. On the action bar, select Line > Components.
5. Select the production consumption with Item No. 0029 Four Pepper Blend.
6. On the action bar, select Add Unplanned Consumption.
   The Add Unplanned Prod. Order Component page opens.
7. In the Unplanned Item No. field, click the AssistEdit button to select the item that can be added as unplanned consumption for Item No. 0029 Four Pepper Blend.
8. Select OK.
9. Enter Quantity.
10. Select OK.

The unplanned consumption item is now shown below Item No. 0029 Four Pepper Blend. The entered quantity of 15 is shown in the Expected Quantity field.

The Unplanned Consumption Derived From Line No. field specifies the Prod. Order Components Line No. from where the unplanned consumption derives, which is line number 30000 in this case. When clicking on the 30000, it is shown which component item has an unplanned consumption item.

You can post consumption on substitute items when there’s a shortage of the original component to fulfill a production order due to partial consumption. During the production order posting, if there’s an insufficient quantity of the original component but a substitute item is available, users can seamlessly perform unplanned consumption. This allows the completion of the production order even when consumption entries exist for the original component.

By utilizing this capability, the Production Order Status transitions to Finished with backward flushing, ensuring seamless order completion. For successful execution, the finished item should have both BOM, and the component to be substituted must be configured with the option for unplanned consumption. This feature streamlines the production processes by enabling you to manage shortages efficiently, ensuring production orders are completed despite insufficient original component quantities.

Unplanned Output

If, during the execution of a production order, an unplanned output arises, an extra production order line needs to be created for this unexpected output. Via the function Add Unplanned Output, this extra production order line can be created. Via this function, it is only allowed to add new lines for item/variant combinations that are set up as Unplanned Item and Variant in the table Unplanned Output and Consumption Setup.

It’s possible to add unplanned output items to a production order. The setup is different from the unplanned consumption, but you have to assign the allowed unplanned items in the same manner.

Setup Unplanned Output

A setup table is needed to assign item numbers/ variant codes that are allowed to use for the function Add Unplanned Output.

Select the Search icon , enter Unplanned Output Setup and then choose the related link.

The Unplanned Output Setup page opens.

With this setup, it’s specified which (unplanned) output items are allowed to add as an extra production order line.

An unplanned item can be set up based on the item number or set up with a specific item attribute.

Unplanned Output in the production process

If during the execution of a production order unplanned output arises an extra production order line should be created for this unexpected output. Via the Add Unplanned Output function, this extra production order line can be created. Via this function, it is only allowed to add new lines for the item/variant combinations that are set up as Unplanned Item and Variant in the table Unplanned Output and Consumption Setup. In this way, a co-product can be added to the production order on the fly.

1. Select the Search icon , enter Released Production Orders and then choose the related link.
   The Released Production Orders list page opens.

2. Select the required No.
   The Released Production Order page opens.

3. On the Lines FastTab, select the production order line for which extra unplanned output must be added.

4. On the action bar, select Line > Add Unplanned Output.
   This function can be used in the Shop Floor Production extension as well.
   The Add Unplanned Output page opens.

5. In the Unplanned Item No. field, click the AssistEdit button to select the required item no.

6. Select OK.

7. Enter Quantity.

8. Select OK.
   Before creating the extra production order line for unplanned output item 0018, the system checks if the production BOM assigned to this unplanned output item contains one or more production BOM lines with the setting Re-allocate Consumption from Main Item= Yes. Each combination of the Item number, Variant code, and Unit of Measure must be present in the production component lines of the production order line of the Main Item.
   If this check succeeds, a second production order line is created for the unplanned output item 0018. The production order line contains the same starting and ending timestamps as the first production order line. The Production Type field has been filled in with Unplanned Output because the production order line is created due to unplanned output. The first production order line is then changed to Main Item. No Production Component lines are created for the Production BOM lines with the Reallocate consumption from Main Item setting enabled.

   

9. On the Lines FastTab, select production order line with Main Item as Production Type.

10. On the action bar, select Line > Consumption Reallocation Item.
    The Consumption Reallocation Item page opens.
    For each Item No./Variant code that was marked as Re-allocate consumption from Main item= Yes in the used Production BOM in the production order line for the Unplanned Output item, a line is created in the Consumption Reallocation item, together with an extra line for the same Item No./Variant code linked to the Main Item

11. On action bar, select Change Status.
    If the status of a released production order is changed to Finished, the actual posted consumption of the Reallocation item needs to be proportionally allocated to the Main item and the Unplanned Output item. This correction needs to be executed via posting of extra consumption journal lines. Because the posting of these extra consumption journal lines can run in unexpected errors, it must be possible to skip the posting of these extra journal lines when changing the status of a released production order to Finished. The toggle Skip Reallocation Consumption Correction specifies if the production order must be finished without creating and posting extra consumption journal lines for the reallocation item.

12. Turn off the Skip Reallocation Consumption Correction toggle.

13. Click Yes.

After finishing the production order, extra consumption journal lines are automatically created for the reallocation item. For more information about the calculation and posting of these extra consumption journal lines, see Co-Products.