Re: [WebERP-developers] Completed Work Order deletes unused serial inventory

[Andrew G. <aga...@re...>]

Robert,
Just a few comments.
I assume when you said " Work Order Issue -7 New quantity 2" you meant ' Work Order Issue -5 New quantity 2" since previously you said "Issue 5"

Returning Unused items to inventory should be a manual step I believe (Reverse the issue).  You cannot assume the items are going back into inventory.  They may have been scrapped/damaged etc.  We have the possibility of loss (not 100% yield).
You should see this anomaly in the W/O Costing screen as a usage variance.  Used more than expected

It sounds like what you are looking for would be a new 'module' or method of consumption,  Require each raw material that is serialized or batched to be input for each Serial or Batch produced.  So the issue would actually be done during receipt instead of as 2 steps.  Or you could still do 2 separate steps and then 'allocate' the raws to the finished good (like you allocate cash to multiple invoices in A/R).  You would need a method to allow for loss (Product issued or damaged during manufacturing).  Theses issues would remain unallocated but be noted as not used (to force everything put in to be noted).  

As for your "Demand" 0 instead of 3 you might try to replace the code in SelectProduct.php that looks like this (might be slightly different based on version)
$sql = "SELECT SUM(qtypu*(woitems.qtyreqd - woitems.qtyrecd)) AS woqtydemo
		FROM woitems INNER JOIN worequirements
		ON woitems.stockid=worequirements.parentstockid
		INNER JOIN workorders
		ON woitems.wo=workorders.wo
		AND woitems.wo=worequirements.wo
		INNER JOIN locationusers ON locationusers.loccode=workorders.loccode AND locationusers.userid='" .  $_SESSION['UserID'] . "' AND locationusers.canview=1
		WHERE  worequirements.stockid='" . $StockID . "'
		AND workorders.closed=0";
$ErrMsg = _('The workorder component demand for this product cannot be retrieved because');
$DemandResult = DB_query($sql, $db, $ErrMsg);
if (DB_num_rows($DemandResult) == 1) {
	$DemandRow = DB_fetch_row($DemandResult);
	$Demand+= $DemandRow[0];
}

With something like this. (Not tested)
$sql="SELECT SUM(qtypu * (woitems.qtyreqd - woitems.qtyrecd)) as reqqty,
			SUM( - qty ) as issqty
		FROM worequirements INNER JOIN woitems
		ON woitems.wo=worequirements.wo
		AND woitems.stockid = worequirements.parentstockid
		INNER JOIN workorders on workorders.wo=woitems.wo
		LEFT OUTER JOIN stockmoves ON stockmoves.type =28
		AND reference=woitems.wo
		AND stockmoves.stockid='" . $StockID."'
		WHERE workorders.closed=0
		AND worequirements.stockid='" . $StockID."'";

$ErrMsg = _('The order details for this product cannot be retrieved because');
$RequirmentsResult = DB_query($sql,$db,$ErrMsg);
$WoResult = DB_query($sql,$db,$ErrMsg);
$WoRow = DB_fetch_row($WoResult);
if ($WoRow[0]!=null){
	$ReqQty =  floatval($WoRow[0]);
} else {
	$ReqQty = 0;
}
if ($WoRow[1]!=null){
	$IssQty =  floatval($WoRow[1]);
} else {
	$IssQty = 0;
}
$Demand+= ($ReqQty - $IssQty); 


Best Regards,
Andrew Galuski


-----Original Message-----
From: rfthomas [mailto:rf...@as...] 
Sent: Thursday, March 10, 2016 11:30 AM
To: web...@li...
Subject: Re: [WebERP-developers] Completed Work Order deletes unused serial inventory

To provide further detail:

Work Orders do not properly deal with serialized inventory

To demonstrate the problem create the following two inventory items:

TEST_SERIAL – purchased/controlled/serial number TEST_SERIAL_M – manufactured/controlled/serial number

Create a BOM for TEST_SERIAL_M with one entity:

TEST_SERIAL QTY 1, Not Auto Issued

Add 7 of TEST_SERIAL to inventory, S/N 1, 2, …, 7

Create a Work Order to manufacture 5 of TEST_SERIAL_M.

Issue 5 of TEST_SERIAL to the newly created work order, using serial nos. 1, 2, 3, 4, and 5

Receive 2 of TEST_SERIAL_M where the received items have serial nos. 1 and 2

When one looks at inventory for TEST_SERIAL: quantity on hand = 2, quantity demand 3, available -1.  This is the first error in inventory: The demand is
0 since 5 parts have already been issued to the work order to manufacture TEST_SERIAL_M and there are 2 parts available.  When one examines serial numbers there are serial numbers 6 and 7.

Inventory movements show:
Stock Adjustment +7 New quantity 7
Work Order Issue -7 New quantity 2

The receive function does not force entry of the serial numbers of TEST_SERIAL when receiving TEST_SERIAL_M.  This is incorrect since the reason serial numbers as well as batch/lot numbers is to provide component traceability.  The receive function must properly allocated the material and make a proper move notification.  Such never occurs.

After the work order is closed, not having consumed all of the issued items, unused items are never returned to inventory.  Three unused serial number items are deleted from the system with no trace.

There should be 5 of TEST_SERIAL in inventory and 2 in TEST_SERIAL_M parts in inventory.  If the 2 TEST_SERIAL parts in TEST_SERIAL_M parts need to be tracked back, reports could be written to generate the migration of the part.

In the US, there are regulations that require traceability of components. 
The FAA (Federal Aviation Administration), DOD (Department of Defense), FDA (Food and Drug Administration), among others require such.  An example are components going into a jet aircraft engine:  Each piece of raw material is tracked by Foundry/lot, then serialized when cut into blanks, and traced throughout manufacture to the completed rotor and engine.  One would expect that such is also required by other countries.
Any thoughts/suggestions on what can be done to meet these requirements and correct the inventory errors?




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