Define unit quantity on WIP start
When operators are working with a full tracking operation in a non-serialized production process, there may be scenarios where batches need to be split, for example:
Scenario 1
Some manufacturers need to split non-serialized job batches if a subset of a batch requires additional rework operations or requires a Just In Time (JIT) reroute to avoid holding up the remaining quantity from being produced.
Scenario 2
A batch might need to be split into several different paths and again into ever more paths from the first split. All WIP, defects, symptoms, measurements, and activities associated to the units in each path must be associated to the batch no matter what path each quantity follows. In such cases, both the Trace window in Production and the Analytics client application need to be able to show the full picture of the batch’s history.
To accommodate both of these scenarios when working with a full tracking operation in a non-serialized production process, there is a new global option in NPI (NPI > System Configuration > Settings): Allow entering of the quantity of Non-serialized batches on the Start (also referred to as quantity on WIP start). The option allows shop-floor operators to identify the number of units they will work on when they start a WIP transaction.
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When the Allow entering of the quantity of Non-serialized batches on the Start option is set to True, operators have four methods to record their work in Production, as described in the following table.
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Method | How operators record production work | Options and results |
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Method 1 | Select the WIP Start drop-down to start a quantity of 1. | The operator has the option to convert any or all of the units in the WIP transaction to serialized units. When the WIP transaction is started, the started item is shown in the drop-down list in the WIP gadget. |
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 Note The started item can be a quantity of units, a serialized carrier containing a quantity of units, or a single serialized unit. Only one item may start a WIP transaction when using a non-serialized process. | ||
Method 2 | Select the WIP Start drop-down, then enter a quantity of units about to be worked on. | The operator has the option to convert any or all of the units in the WIP transaction to serialized units. When the WIP transaction is started, the started item is shown in the drop-down list in the WIP gadget. |
Note |
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The started item can be a quantity of units, a serialized carrier containing a quantity of units, or a single serialized unit. Only one item may start a WIP transaction when using a non-serialized process. | ||
Method 3 | Select the WIP Start drop-down, then enter the serial number of a serialized carrier containing a quantity of units about to be worked on. | One serialized carrier/unit is started per WIP transaction. |
Method 4 | Select the WIP Start drop-down, then enter the serial number of a unit about to be worked on. | One serialized carrier/unit is started per WIP transaction. |
When the started item identifies a quantity of units (the operator started a quantity of units using Method 1 or Method 2) the WIP gadget allows the operator to press a button to do one of the following:
Generate a new UID
Print a product label for this new UID
Add the new UID to the list of items in the WIP transaction (as an added item)
Replicate all data collection activity state and collected values to the newly serialized unit.
Reduce the quantity identified by the started item by 1.
The operator can repeat this action as long as the quantity identified by the started item is 1 or more. If the quantity identified by the started item is 1, the system reduces the quantity identified by the started item to 0 (zero). In this situation, the operator can continue to record data (measurements, symptoms and/or defects) against the started item since these values are recorded against the batch. Each generated UID (also referred to as added item) is added to the list of items in the WIP gadget drop-down.
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Important |
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When you set the Allow entering of the quantity of Non-serialized batches on the Start global option to False, the started quantity defaults to 1. However, when the system is determining whether a UID may be generated and added to the WIP transaction, the calculation is based on the quantity of WIP recorded at the current location (including the number of units in the current WIP transaction) and the quantity of WIP recorded at the previous location. Recorded data collection measurements, symptoms, and defects are the same as when Quantity on WIP start is set to True. When finishing items, all added items are finished before the started item is finished. For the started item, operators are prompted to enter the quantity of units they are finishing. This quantity must be an integer value of zero or higher where the maximum is determined using the quantity of WIP recorded at the current location (including the number of units in the current WIP transaction) and the quantity of WIP recorded at the previous location. As with Quantity on start mode, if the started item is recorded as finished with a quantity of 0 (zero), the WIP transaction is recorded as Completed and the required steps and activities are ignored. In this situation, all data is collected against the batch and will persist as recorded against the batch. |
UIDs for non-serialized units in a WIP transaction
When the operator assigns a serial number to one of the anonymous (non-serialized) units in a WIP transaction, the system generates the UID for this unit using the barcode template defined in the Batch Properties to produce a new UID. If this batch property isn't defined—or it is defined but not in a way that allows generating a new, unique UID—the system generates a GUID and assigns it as the new UID.
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Important information about serial number generation
FactoryLogix limits the number of unit serial numbers (UIDs) for a batch to the batch quantity and demand may exceed this limit. Customers should recognize this batch quantity limitation and plan accordingly. If the number of generated UIDs is close to the batch quantity, operators should use the assigned UIDs to WIP units through to the end of the process (that is, instead of trying to WIP quantities after the UID has returned to the main route).
Example
Consider the following non-serialized process example:
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The batch quantity is 10.
All 10 units are transacted through Operation 1 as a quantity of 10.
At Operation 2, issues are found on every unit and all 10 are serialized. These units go to an out-of-route operation where issues are resolved, then come back into the route at Operation 3. All 10 units are transacted though Operation 3 as a quantity of 10.
At Operation 4, all 10 units are started but issues are found on one unit. The operator needs to serialize the unit but there are already 10 units associated to the batch—the limit for that batch.
In this situation, a new UID cannot be generated since it would exceed the batch limit. The UIDs already associated to the batch cannot be used since they are inbound to Operation 3 which was flagged as completed for the required batch quantity.
Print product labels
When printing the label for a newly-serialized unit, the system uses the printed label template defined in the Unit Printed Label value in the Edit Batch dialog in the Production client application.
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If the Unit Printed Label value isn't defined, the system uses the default Product Label Template defined in the Printed Label Templates area of the NPI client application:
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Determine the label printer
The printer used to print product labels for non-serialized units serialized within a WIP transaction is determined the same way as for the Print Label Activity. When the operator requests one or more units to be serialized, the system checks the Ability to Override Label Template Printer global setting in the Production Portal - Activities category (NPI > System Configuration > Settings):
If set to False, labels will be printed on the printer defined in the label template.
If set to True, labels will be printed on the printer last used to print labels at the operator’s workstation. This selected printer is already saved to the local machine by FactoryLogix. If no labels have been printed from the workstation (determined by not finding the printer identified in the settings saved to the workstation by FactoryLogix) the operator is prompted to select a printer.
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Replicate data collection activities states and values
During a WIP transaction, the system tracks completed data collection activities and collected values. This information is used when the WIP transaction is closed to validate that all required data collection activities were completed.
When a unit is serialized, the following information recorded against the non-serialized quantity of units in the current WIP transaction is replicated to the newly-serialized UID:
The Activity Complete status for each activity in the current WIP transaction
The data collection values collected against activities marked as Completed in the current WIP transaction
Values collected against activities not marked as Completed in the current WIP transaction are not replicated to the new UID. For non-data collection activities, only the Completed state is is replicated.
Create defects
Before an operator creates a defect, they need to select the items against which the defect will be recorded from the drop-down list in the WIP gadget.
When creating a defect, the operator can assign it to one or more of the items in the drop-down. The system replicates the defect after the first assignment so that each item identified has its own copy, with its own defect life cycle.
Create symptoms
When an operator creates a symptom manually in Production, the system replicates the symptom after the first assignment so that each item identified has its own copy.
Create measurements
When an operator executes a data collection activity in Production, the new measurement is recorded against each item identified in the WIP gadget drop-down. The system replicates the measurement after the first assignment so that each item identified has its own copy.
Finish the WIP transaction
When an item in the WIP gadget drop-down is finished, the touch time recorded is the current date and time minus the date and time when the WIP transaction was first started. For added items, the start time for the touch time is the same as the start time for the started item—not the time the added entity was added to the WIP transaction.
The started entity isn't allowed to finish until every added item in the WIP transaction finishes. If the quantity of units associated to the started item is 0 (zero), the WIP transaction for the started item is recorded as Completed when the last added item for the WIP transaction finishes. All data recorded against this started item is recorded against the batch, not against the started item itself. If the quantity of units associated to the started item is 0 (zero), the processing will not validate all required steps and activities were completed with respect to the started item.
When finishing an added item, the system behaves as if the operator started the WIP transaction using Method 3 or Method 4 (see the previous table).
When finishing the started item, the system behaves as if the operator started the WIP transaction using Method 1 or Method 2 (see the previous table).
When every item in a WIP transaction is finished, the touch time clock (started when the WIP transaction began) stops.
The replication of data collection values collected against the non-serialized quantity in WIP to the newly-created UID is controlled by a new global setting to allow the system behavior to vary by installation. The system shall work in one of the following two modes:
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No values are copied (default).
Values collected against activities marked as Completed in the current WIP transaction are copied to the new UID.
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Note
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Any replicated data values are collected using these data collection activities: Collect a Date/Time Activity, Collect a Date/Time Range Activity, Collect a Number Activity, Collect a Number Range Activity, Collect Text Activity, Collect true False Activity, Collect List Activity.