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Free preview · Implementing Manufacturing and Materials Management: From Empty Plant to Costed Work Order

What breaks

"The work order will not complete." Check in this order. One. Is there stock for every backflush component — in the work center supply subinventory? That qualifier is the whole first check: organization on-hand is not the question. Two. Have all prior count point operations been reported? Three. Is the inventory period open? Four. Is the completion subinventory valid, and does locator control permit it? Five. Is the work order released? Six. Does your security include this plant?

Then eight cases. One. "It will not complete — backflush shortage." The number one cause, every time. Check the work center supply subinventory specifically, not just organization on-hand — the material is often in the building and in the wrong place, which is why the operator can see it and the system cannot use it. Two. "It completed but there are no finished goods in stock." Completion subinventory wrong, or completion at an operation rather than at the work order. Three. "On-hand went negative." Backflush consuming stock that was never received; trace via transaction history. Four. "The work order is scheduled for six weeks." Resource basis, or capacity. Five. "The operator cannot see their work." Plant security context, or the dispatch list filtered to the wrong work center. Six. "Scrap was reported at the end of the month in one batch." Cost is wrong for every unit, because scrap value depends on where in the route it happened. A process problem — fix it by training, not by configuration, and catch it early, because every unit built while it goes on is mis-costed. Seven. "Two hundred work orders open from last year." No closure discipline: WIP value is meaningless and the controller cannot close. Eight. "Quick complete did something unexpected." It does everything at once. If the work definition is wrong, quick complete propagates the error faster.

Most of these trace back to master data from the previous phase rather than to anything configured in this module — supply subinventory, supply type, resource basis, item assignment. The symptom is on the shop floor. The cause is in the master data. That is the shape of manufacturing support, and it is why a supervisor reporting a stopped work order is very rarely reporting a work execution problem.

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