How to transfer test results from bulk batch to Finished Goods batch

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

Test results from bulk batch to Finished Goods batch.

 

Purpose

The primary goal of this manual is to streamline the transfer of quality test results from bulk products to finished goods, ensuring that production processes are efficient, traceable, and adhere to quality standards. By leveraging Bill of Materials (BOM) and Formula methodologies, along with batch attributes, this manual provides a detailed framework for maintaining consistency and accuracy in test result transfers, regardless of the presence of direct quality work on finished goods.

 

Overview

Finished goods production is a complex process that involves the consumption of one or more bulk products. Each production cycle may include various item numbers and batch numbers, but all are derived from the same bulk productions. The ability to accurately transfer test results from bulk product batches to finished goods batches is crucial for maintaining product integrity and ensuring compliance with quality standards.

In this manual, we will explain each setup item and then explore different scenarios where the outlined functionality should be possible. Each scenario is designed to address specific challenges and provide solutions for transferring test results under various conditions, such as differing bulk product batches, open advanced quality orders across production, and advanced setups involving multiple bulk productions.

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.

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!

Open orders - settings in Advanced quality control paramters

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

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 test results from bulk batch to Finished Goods batch.

The base for the functionality is the attribute setup on the released products. The same attributes must be setup on both bulk and finished goods product.

Common for both bulk and finished goods products is that the attributes must be active under product specific and customer specific found under "manage inventory" in the batch attributes section.

Et billede, der indeholder tekst, skærmbillede, linje/række, Font/skrifttype AI-genereret indhold kan være ukorrekt.

As explained in  Microsoft Learn the product specific setup lets you choose the different product specific attributes and then connect attributes and set tolerances for customers.

Without this setup, no attributes will be transferred.

Et billede, der indeholder linje/række, skærmbillede AI-genereret indhold kan være ukorrekt.

Batch attribute selection

For the finished goods there is a BOM / formula defining, which products are used to create this finished goods product.

Under batch attribute selection on the finished goods product, a choice of which attributes should be transferred as well as from which bulk products must be made.

In the example below there are two different bulk product going into one finished goods product. Test 1 and 2 are unique for bulk product PBT0528-1.

Test 4 is unique to bulk product PBT BP 02, but test 3 is present on both bulk products.

In this case a choice must be made as to which bulk product should provide test results to the finished goods product. In the screenshot below it is to use the results on test 3 for PBT0528-1.

Bom / Formula

The settings below are transferred to the production order under setup

Et billede, der indeholder skærmbillede, tekst, nummer/tal, linje/række AI-genereret indhold kan være ukorrekt.

And under the formula lines

On the formula header a couple of settings are needed.

The logic below ensures that test results on the bulk batch attributes are transferred to the finished goods batch attributes 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 attributes to finished goods” must be toggled to yes to trigger the automatic transfer of attributes in all scenarios described later.

The “Batch attribute transfer type” can be set to four different settings.

Et billede, der indeholder tekst, skærmbillede, Font/skrifttype, linje/række AI-genereret indhold kan være ukorrekt.

Min:

The lowest value will be transferred to the finished goods batch attribute. The functionality will evaluate each result towards the existing and overwrite if a new value is lower than the value already on the batch attribute.

Max:

The highest value will be transferred to the finished goods batch attribute. The functionality will evaluate each result towards the existing and overwrite if a new value is higher than the value already on the batch attribute.

First:

The first value transferred will be added to the batch attributes. Any subsequent values will be ignored.

Last:

The values will be overwritten whenever a new value is transferred in batch attributes

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.

Et billede, der indeholder tekst, skærmbillede, nummer/tal AI-genereret indhold kan være ukorrekt.
Formula line:

Two settings on the formula line has to be checked.

The inherit batch attributes to end item has been a setting in the system for a long time ensuring that the transfer will happen at the Report as Finished.

Transfer attributes to finished goods is the added functionality where the calculation of min/max/first/last is added as well as the possibility to transfer when an advanced quality order on the bulk product has the transfer possibility enabled as well.

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.

Et billede, der indeholder tekst, software, skærmbillede, Font/skrifttype AI-genereret indhold kan være ukorrekt.
Et billede, der indeholder tekst, skærmbillede, software, nummer/tal AI-genereret indhold kan være ukorrekt.

The BOM Consumption link contains information about which batch it originates from and what finished goods it has become – including the license plate.

Et billede, der indeholder tekst, skærmbillede, linje/række, Font/skrifttype AI-genereret indhold kan være ukorrekt.

Settings on the test group

On test group it is possible to set “transfer attributes 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.

Et billede, der indeholder tekst, skærmbillede, software, nummer/tal AI-genereret indhold kan være ukorrekt.

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

Et billede, der indeholder tekst, nummer/tal, skærmbillede, Font/skrifttype AI-genereret indhold kan være ukorrekt.

Scenarios

Scenario 1:

Transfer of test results from completed bulk product AQO to finished goods batch attributes.

User Story: As a production manager, I want the test results from the completed Advanced Quality Order on bulk product A0001 to transfer to Finished Goods batch number 0408-06, when FG item 21015103 is produced. The batch attributes on the finished goods should include the last result.

Settings:
  1. On the bulk product A0001 the product specific and customer specific attributes are setup.
  2. On the finished goods item 21015103 the similar attributes are setup.
  3. On the batch attributes selection, the correct attributes from A0001 are set to active.
  4. On the formula header the settings are these:
  5. On the formula lines only the line for bulk product A0001 should have a checkmark in “transfer attributes to finished goods”.

Scenario 2:

All advanced quality work is not done, when the finished goods are produced, but the transfer of test results needs to happen as soon as the advanced quality orders are done.

This must happen towards multiple finished goods productions, which have all consumed from this bulk product.

Settings:

Same settings as above, but with this addition:

  1. On the test group header for the test group used in connection with the bulk production, the “Transfer attributes to finished goods” must be toggled to yes.
  2. The other settings about transfer of batch attributes described in another article here will also affect which results are transferred.

The “Trace BOM Consumption” and the flushing principle set to “finish” ensures that the consumption is linked from bulk to finished goods productions.

 

How did we do?

Printing of quality order report

Item sampling

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