Auto Merge - Relaxed Router

[Former Member]

Hi Folks,

We are using relaxed routers and a single SFC with a qty, we have set up a non conformance code for when operators accidentally complete an operation and this non conformance code has a disposition group of 'return to any previous'  .

We have set up the auto split and auto merge but we have an issue where after the non conformance is dispositioned the SFC gets slip into two SFC's and doesn't get auto merged back again (since we didn't complete anything)

We are using a work center POD and this shop order now appears as two lines on the POD work list which is not ideal. The correct qty is moved to the previous operation as required its just the multiple SFC's that are an issue.

Is there any other settings I'm missing that will auto_merge them back together again after dispositioning?

Thanks

Kev

[sergiy_katerinich · Accepted solution]

Hi Kev!

It should work as described here.

In List Maintenance, there is Status field which has a list of allowed values. There is no Invalid status - so if the SFC of zero qty after auto-merge has Invalid status, then it should not be shown in POD Work List.

BTW what do you mean by "we didn't complete anything"? Completing a child SFC (that you get after auto-split) and returning it from NC routing to the original production routing should trigger auto-merge. If you "didn't complete anything", then it could be the root cause why the child SFC remains available.

Regards,

Sergiy

[Former Member · Accepted solution]

Hi Sergiy,

I read the non serialized order processing how to guide from cover to cover and I don't think this scenario will work.

The issue is that sometimes operators will make a mistake and complete the wrong qty against a SFC. This qty needs to moved back to the proper operation. Whilst this can be achieved using SFC Step Status its not typically a good idea to give operators access to this activity and I normally restrict access to super users and supervisors who might not be available at the time to correct this issue.

So, what I attempted to do was create a Non conformance code that automatically dis-positioned the NC to a "return to any step". Because this is automatic the operator only has to select the operation that the Qty should be returned to and the auto split moves it back to the prior operation. The problem with the non serialized order processing is that the auto merge functionality is tied to the complete activity and since the complete activity was never triggered in this scenario it never gets auto-merged into the original SFC. (I would assume that if I started it on the new split SFC and then completed the operation it would merge back).

Thanks for taking the time to answer.

Kev

[sergiy_katerinich · Accepted solution]

Kev,

I would agree with you that such scenario is not covered by the design. The original idea was that completing a child SFC at NC routing when Return to original production routing gets executed will trigger auto-merge. Your case looks like a local rework that hardly was considered for implementation.

Anyway, why don't you use some dummy 1-step NC routings for this case? This does not need an access to SFC Step Status as you require, but of course they will have to complete one more step at this NC routing, as anticipated by the design.

Regards,

Sergiy

[Former Member · Accepted solution]

Hi Sergiy,

Agreed, I already suggested to the client using a dummy step and demonstrated it working but they don't want that extra step, so they are going to use SFC Step Status (carried out by a supervisor).

I would be a nice additional feature for future releases if this scenario was added

Thanks for you help.

Kev