Transfer disposition code from Bulk product to finished goods

Peter Kure Bek-Thorngreen Updated by Peter Kure Bek-Thorngreen

Transfer disposition code from Bulk product to finished goods manual.

Overview

This manual provides a streamlined approach to transferring disposition codes (DC) from bulk production to finished goods (FG) batches and license plates (LPs). Utilizing advanced quality order (AQO) outcomes and parameter settings in the production formula, it ensures accurate DC application for both future and existing FG productions. Covering key scenarios, the manual offers practical guidance for maintaining product quality and operational efficiency.

Purpose

We developed this solution to address the requirement for transferring disposition codes (DC) from bulk production to finished goods (FG) batches and license plates (LPs). This enhancement ensures that FG productions accurately reflect the quality status of the bulk products they consume, regardless of whether quality work has been completed on the FG itself. By implementing a parameter-driven approach, we enable seamless DC changes based on advanced quality order (AQO) outcomes, improving product quality management and operational efficiency. This system accommodates various scenarios, including multiple AQOs affecting FG productions and complex setups involving multiple bulk products consumed by FG. 

Open orders - settings in Advanced quality control paramters

An important setting to take into account is the "Transfer batch disposition if all AQO's closed" found under advanced quality control parameters.

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This setting will by default be toggled to "no".

(The meaning of "connected advanced quality orders" below is all advanced quality order in connection with a production batch.)

The system will not trigger the code, if there are open Advanced quality orders, which means that all connected advanced quality orders have to be completed.

Toggled to no, the code will be triggered, when all connected Advanced quality orders change Advanced quality order phase to completed in spec / completed out of spec.

This can be a problem if there are connected Advanced quality orders with no priority 1 tests, since the phase will never change to completed in spec / completed out of spec and thus be interpreted as an order still open.

Example 1:

Two AQO's are created on the bulk batch. One with priority 1 and 2 tests and one with only priority 1 tests.

If the parameter is set to no, the code will be triggered based on the priority 1 tests on both AQO's. The priority 2 tests will have no effect.

If the parameter is set to yes, the code will not be triggered before the priority 2 tests have been completed and the AQO status is set to pass/fail.

Example 2:

Two AQO's are created on the bulk batch. One with priority 1 and 2 tests and one with only priority 2 tests.

If the parameter is set to no, the code which should be triggered based on the priority 1 tests will not be triggered, because the AQO with priority 2 tests will have the Advanced quality order phase as "created" and be treated as an "open" order.

The priority 2 tests will have no effect.

Only if the AQO with the priority 2 test has the Advanced quality order phase changed manually to completed in spec / out of spec before the AQO with priority 1 tests is completed, the code will be triggered.

If the parameter is set to yes, the code will not be triggered before the priority 2 tests have been completed and the AQO status is set to pass/fail.

Setup for Transfer disposition code from Bulk product to finished goods

To ensure the change of disposition code and more importantly that the system does not change disposition codes on products which are failed, the setup in the batch disposition master is crucial.

How disposition codes change is controlled partly on the BOM / Formula and partly on the Test Group / Advanced Quality order.

The code is triggered by the Report as Finished operation on the production order and by the following settings on the Test Group, which is copied to the Advanced quality order.

The "Update batch disposition" and the two settings under Automatic Validation have been a part of the module a long time, and their functionalities are described elsewhere.

It is possible to validate both priority 1 tests and the Advanced quality order manually by pressing validate buttons. This is also covered in other articles.
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The new button on Test Group / Advanced quality order "Transfer batch disposition to finished goods" is the new parameter which ensures that the code is run for transferring disposition code to finished goods.

It is important to note, that if the disposition code update is not triggered there will of course not be transferred anything to the finished goods. It is in other words vital that settings are correct.
The "auto validate priority 1 lines" setting is only used for orders with at least one Priority 1 test.
If any Advanced quality order with ONLY priority 2 - 4 test are included in the process of updating disposition codes, it is VERY important to make sure that the orders are validated using "Auto validate advanced quality order".
Toggling "Autovalidate priority 1 tests" to yes on an order without any Priority 1 might break the operation of code!
If an open order with only priority 2 - 4 exists, and the setting "Update batch disposition" is toggled to yes, the transfer of disposition will not happen until the last order change status to pass/fail. This behavior is a fact no matter what the setting under Advanced quality order parameters is!

Batch Disposition Master

The system explained below treat a failed disposition code as a signal to stop further changes.

A failed advanced quality order will immediately change the disposition code to the failed code, and if that code has this parameter toggled to yes, then no more changes will happen no matter what the outcome of other advanced quality orders are.

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INITIAL BATCH DISPOSITION CODE CAN BE COPIED TO THE FINISHED GOODS LICENSE PLATES WITH CERTAIN SETTINGS!
Make sure that the initial batch disposition code is not open for sales reservation, picking or shipping or maybe not available for consumption to production.
If the setting under Advanced quality control parameters "Transfer batch disposition if all AQO's closed" is set to no, it means that disposition code transfer can happen even with open Advanced quality orders.
If the initial batch disposition code is allowing for reservation, consumption and /or shipping the result might be that license plates receives a disposition code which makes them available even if there are open Advanced quality orders.

Bom / Formula

The settings below are transferred to the production order under setup

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And under the formula lines

On the formula header a couple of settings are needed.

The logic below ensures that the bulk batch disposition code is transferred to the finished goods batch / License plate at the time of Report as Finished.

It does not transfer at the time the advanced quality order is completed, unless the setting on the test group / advanced quality order is correct. See section below.

On the formula header the “transfer batch disposition to finished goods” must be toggled to yes to trigger the transfer of disposition code in the scenarios described later.

The “Transfer batch disposition to finished goods” can be set to four different settings.

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No: (default)

The disposition code is not transferred.

Batch:
The disposition code on the bulk batch is transferred to the finished goods batch number.

License plate:

The disposition code on the bulk batch is transferred to the finished goods license plates.

Batch and license plate:

The disposition code on the bulk batch is transferred to the finished goods batch and license plates

Under Consumption the “Trace BOM Consumption” must be toggled to “yes” to allow for the register of consumption to be active. The system needs to have the information as to which bulk batches has been consumed into the finished goods.

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Formula line:

One setting on the formula line has to be checked.

Checking the “Transfer batch disposition to finished goods” for a formula line ensures that the product marked can transfer the disposition code to the finished goods.

This means that for a formula with many different ingredients (formula lines) it is possible to toggle one or more lines to allow them to affect the finished goods disposition code.

Further down in this document it is explained how multiple lines can interact.

Prerequisite for flushing principle

IMPORTANT: For the picking list and consumption to follow the correct procedure and link the consumption to the correct bulk batches, the flushing principle must be set to “finish”.

Consumption/picking list

When the production runs, the picking list journal will include a new consumption table.

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The BOM Consumption link contains information about which batch it originates from and what finished goods it has become – including the license plate – which is essential to ensure, that the right license plates change to the correct disposition code.

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Settings on the test group

On test group it is possible to set “Transfer batch disposition to finished goods” to yes.

By doing so the transfer, which is happening at the time of Report as Finished, will also happen when the advanced quality order phase change to completed in spec / Completed out of spec.

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Please note that it is not possible to change the target for the disposition code change on the Advanced quality order. The decision if the disposition code change should be on batch, license plate or both batch and license plate is done only on the formula.

The setting on the test group is inherited to the advanced quality order, where it is also possible to change it:

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Scenarios

Scenario 1: Future Productions - Batch

Description: When a bulk product passes quality checks and its Disposition Code changes to OK, future Finished Goods productions consuming that bulk batch reflect the same Disposition Code.

Solution: When the settings on the formula and formula line is set to allow transfer of disposition code to batch, and the BOM consumption settings are correct, the picking journal will include a record of which bulk production, the finished goods batch has picked from.

Since all priority 1 tests on Advanced quality orders are completed, the transfer of disposition code can take place, which will happen at the moment there is a Report as Finished.

Scenario 2: Existing Productions

Description: If production has started and Advanced Quality Order results later change the bulk batch Disposition Code to OK, the Finished Goods Disposition Code updates immediately.

Solution: The setting on the Advanced quality order taken from the Test group “Transfer batch disposition code to finished goods” will trigger the code to update already existing productions. Remember that the setting on the formula itself decides if the transfer is done to batch, license plates or both. If these settings are wrong, the transfer will not take place.

Any future productions will also change Disposition Code (see above)

Scenario 3: Multiple Bulk Consumptions

Description: Finished Goods production consuming multiple bulk products should reflect Disposition Code changes from each bulk product.

Solution: Since the setting on the formula line can decide, which lines should have the possibility to affect the Disposition Code change, the change will be based on the sequence and the consumption table.

The system will run through each formula line and see the setting that Disposition Code transfer is allowed. The consumption journal is then checked to see from which bulk batch the finished goods has consumed. The Disposition Code will change to that of the bulk product batch. Please note the logic in the code explained above concerning open or failed Advanced quality orders.

After the first line is checked, the system then checks the next and repeats the process.

Scenario 4: Shared Bulk Productions

Description: If two Finished Goods productions use the same bulk product, the bulk product Disposition Code affects both Finished Goods batches.

Solution: On the Report as finished the Disposition Code will be transferred to the batch number.

If an Advanced quality order is still open, no transfer will take place until the Advanced quality order has been completed as mentioned above. At the time of completion the consumption journal will hold the information of which FG batches have consumed from that specific bulk and the Disposition Code transfer will take place.

Scenario 5: Advanced Setup with Multiple Bulk Products

Description: Disposition Code changes from any consumed bulk product affect Finished Goods Disposition Code. Changes occur at RAF if any Advanced Quality Orders fail, or upon Advanced Quality Order completion if all orders are approved.

Solution:

Same explanation as on Scenario 4 above. Failed batches (with a Disposition code which is set to block automatic reset will always block the activation of code)

Open Advanced Quality Orders will also prevent the change of Disposition code (see settings about open Advanced Quality Orders above)

Scenario 6: License plates and Future Productions

Description: Future Finished Goods license plates inherit Disposition Code changes from bulk batches.

Solution: Disposition code will be transferred at RAF unless there are open Advanced Quality Orders (see settings about open Advanced Quality Orders above). The Disposition code will be decided based on the batches, which the license plate has consumed from. Relation is the consumption table explained above.

Failed disposition code:

If any batch has a failed Disposition code, the license plates will immediately be changed to the failed Disposition code.

Scenario 2: License plates and Existing Productions

Description: Existing Finished Goods license plates update Disposition Code when bulk batch Disposition Code changes.

Solution: Disposition code will be transferred at the completion of the Advanced Quality Order unless there are open Advanced Quality Orders (see settings about open Advanced Quality Orders above). The Disposition code will be decided based on the batches, which the license plate has consumed from. Relation is the consumption table explained above.

Failed disposition code:

If any Advanced Quality Order fails, the license plates will immediately be changed to the failed Disposition code.

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