Stock is issued to jobs using the Job Issues screen.
Job issues must be performed in real time
DBA is designed for real time inventory updating, which means that job issues must be performed concurrent with actual material issues out on the shop floor. This is the only way to achieve accurate location stock quantities, which are needed for job issuing, order picking, and stock counts.
DBA is not designed for “backflushing” at time of job finish
DBA is not designed for “backflushing” where job components are deducted in batch fashion at time of job finish. Backflushing is commonly used by light manufacturing systems that do not have time-phased jobs, location control, or lot and serial control.
Do not attempt to simulate backflushing
Do not attempt to simulate backflushing by delaying job issues until the end of the job. This is a destructive and inefficient practice that converts your inventory into a set of tentative, unreliable location quantities that take no account of materials in WIP. Without reliable location quantities, it is not possible to perform stock counts or to accurately dispatch job issues or order picking. Users will be aware that quantities on the screen cannot be trusted and will be less committed to proper procedures, which compounds the unreliability of your inventory.
Backflushing is error-prone and time-consuming
It is a mistaken notion that backflushing saves time, when in fact it consumes a great deal of extra time. Job issue transactions are exactly the same whether they are done when issues are made or at job end, so there is no time saved by delaying what has to be done anyway. A real time transaction is always more accurate than one performed hours or days later, often by a different person than the one who actually issued the material. A backflushing environment consumes a great deal of extra time tracking down and correcting inventory errors.
Job release assures material availability
Jobs are only released to production in the Job Control Panel when material is fully allocated to all job components and therefore the job release process assures that material will be available when needed for specific job sequences.
Initiate job issues through the Work Center Schedule
The Work Center Schedule screen is designed to manage work in process within each work center. Use the screen to determine when materials are needed and to initiate job issue transactions.
Issue material on a “just in time” basis
Because material is fully allocated on job release, there is no need to hoard material in advance, which clogs aisles and staging areas. Instead, material can be issued on a “just in time” basis prior to job sequences being started.
The Material icon indicates when material is needed
Within the work center queue in the Work Center Schedule screen, a red Material icon indicates when material is needed and has not yet been issued to a job sequence.
Any components assigned to the sequence are to be issued prior to sequence start. Additionally, if the First Seq checkbox is selected, this is the job’s first sequence, in which case all components that are not assigned to specific sequences are to be issued as well.
Click the icon to issue the material
To issue the material, click the icon in the Material field to launch the Job Issues screen, which is filtered to include just the components that are to be issued to this sequence.
Do not use the job traveler as an issue list
Do not use the job traveler as an issue list because it is not designed for that purpose and does not include location or lot and serial information. Components and quantity per amounts are listed on the traveler for manufacturing specification purposes.
Use the issue list or dispatch list
You can issue the material using the issue list or dispatch list method.
Issue List Method
The issue list is printed by clicking the Issue List button above the grid in the Job Issues screen. The issue list includes stock quantities by location and by lot and serial number and is limited to the components needed for this sequence. You print the pick list, gather the material, and then you return to the Job Issues screen to make your entries.
Dispatch List Method
The dispatch list method works in the opposite manner. You issue the material on the screen first, then you go to the Batch History tab and click the Dispatch button to print the dispatch list. The dispatch list provides a listing of the components, locations, and lot and serial values that were issued.
The dispatch list is highly useful if you rely on warehouse personnel to gather the material for you. You submit the dispatch list to the warehouse and it provides all the instructions needed for gathering and delivering the material to the work center.
Using the Pre-Fill button
The Pre-Fill button can be clicked to pre-fill the remaining quantities with available stock against all components where stock is stored in a single location and a single lot or serial number.
Issuing items with lot or serial numbers
When multiple lot numbers exist, an issue quantity must be manually entered against each applicable lot number. When multiple serial numbers exist, serial numbers must be selected, one-by-one.
Failure to issue affects downstream work centers
If material does not get issued against an associated job sequence, the material icon will continue displaying in red against all downstream job sequences until the material gets issued.
Return unused material and correct the BOM if needed
When a sequence is completed, any unused material should be returned to stock. This is done by clicking the Return button on the Transactions sub-tab within the Job Issues screen, which enables you to return a portion of the original issue amount back to stock.
If the unused material was due to an error in the bill of materials, it is vitally important that the BOM gets corrected immediately so that the error does not get perpetuated in future jobs.
