Entering Production Jobs Using the Custom Adds Feature
The Custom Adds or Custom BOM feature is used in situations where tweaks or modifications to an item's bill of materials is necessary on a job by job basis. Using custom adds is not related to the use of Part Substitutions. Substitutions represent a one to one relationship in which one item is replaced by another similar item on the job's bill of material and does not require any adjustment to the BOM ratio/formula. Custom adds, on the other hand, represent a situation in which the ratio of the BOM will be changed and certain parts may be removed completely, new parts added and existing parts have their quantity modified. Once the Custom BOM form and Job have been saved, the system will automatically update the issuing requirements in the system to reflect the new quantities required. Issuing is handled normally as in the main application.
In addition, the Custom Adds feature is used for the Rework process. Reworking is the process of rectifying mistakes made during manufacture so that a product meets requirements. Rework involves using previously processed sub-components or portions.
Configuration
The same configuration steps covered on the Entering Production Jobs page are necessary prior to using the Custom Adds feature. The fields and security settings in the list below are specifically related to custom adds in Deacom:
Configuration Settings
-
Custom Add Unit - located in Production > Options this field allows companies to determine how quantities on custom add forms will be displayed. Options are Issue Unit/Stock Unit (default), or BOM Unit/Stock Unit.
Security Settings
- "Sales orders -- edit/view custom BOM"
- "Jobs -- edit/view custom adds"
- "Inventory -- issue failed QC lots" may be needed in situations where lots that have previously failed QC may be re-worked in order to meet QC requirements.
Process
Using the Custom Adds feature
- Navigate to the Production > Job Reporting.
- Select the appropriate criteria on the pre-filter and click "View" to display the Job Summary report.
- Select a job and click the "Modify" button to display the Edit Job form.
- Click the "Custom Adds" button to display the Custom BOM form. The system will display the BOM used on the job.
- At this point, users may double click on a BOM Line to display the Edit Custom BOM Line form. See the Custom BOM help section for information on the fields available to this form.
- Make changes as required. Once all changes have been entered, click the "Save" and "Exit" buttons to close the Edit Custom BOM Line form.
- Repeat steps 5 and 6 for any additional lines that will be modified.
- Once finished making adjustments, click the "Save" and "Exit" buttons to commit changes and close the Custom BOM form.
- Click the "Save" and "Exit" buttons on the Edit Job form to complete the process.
Batch Ticket Notes: As far as batch tickets and the Custom Adds feature, the batch ticket will print both the original items and their quantities and any new items and their quantities. Quantities that have been modified will also be reflected accordingly. This is done so that users will have a record of the changes and modifications that have been made to the bill of materials for this job. Note that new items and quantities that have been added on the Custom BOM form will print at the at the end of the original bill of materials list on the batch ticket.
Example
The following example better illustrates the use of Custom Adds in the DEACOM application. A production job to make cake batter calls for 5 pounds of flour, 1 pound of sugar and 1 gallon of water. Prior to the actual start of the process it is discovered there is not enough sugar to produce the batter. There is no sweetener material available that could be substituted at 1 pound that would satisfy the BOM formula/requirements. At this point the custom adds feature could be used to formulate a BOM for this job. Corn syrup is available in sufficient quantity and represents a good sweetener alternative to the sugar. Corn syrup is a liquid so a reduction in the amount of water will be necessary to maintain the consistency of the batter. The custom BOM form will therefore be modified as follows:
|
Part Number |
Description |
Unit |
Original Qty |
New Qty |
Source |
|---|---|---|---|---|---|
| 2000 | Flour | Pound | 5.0000 | 5.0000 | Original BOM. |
| 4000 | Sugar | Pound | 1.0000 | 0.0000 | Unavailable for Job. |
| 1000 | Water | Gallon | 1.0000 | 0.7500 | Modified original BOM qty for custom Job. |
| 4500 | Corn Syrup | Gallon | 0.0000 | 1.2500 | Added to replace sugar. |
Using the Rework feature
The Custom Adds feature is used for the Rework process. Reworking is the process of rectifying mistakes made during manufacture (Lots that have failed QC testing) so that a product meets requirements. Rework involves using previously processed sub-components or portions. It is important to note that batch tickets for Jobs with reworked material will print the original BOM requirements first and list the rework Part Numbers last, which may cause issues if the materials must be consumed in a specific order. To combat this, users may add Job header notes specifying something like "Workaround" or "Custom BOM" and configure the notes to print very visibly at the top of the batch ticket (or somewhere where the reader would easily notice them). This way, production employees will see that this Job will be manufactured in an atypical manner.
- Obtain a list of all Lots that failed QC testing.
- Navigate to Inventory > Inventory Reporting.
- Select a "Report Type" of "On Hand" and a "QC Status" of "Failed QC" then click "View".
- Take note of the desired Lots or keep this report open for reference.
- Open the Job that will be used to rework the failed Lots.
- Navigate to the Production > Job Reporting.
- Select the appropriate criteria on the pre-filter and click "View" to display the Job Summary report.
- Select a job and click the "Modify" button to display the Edit Job form.
- Click the "Custom Adds" button to display the Custom BOM form. The system will display the BOM used on the job.
- Click the "Add New" button to display the Edit Custom BOM Line form. See the Custom BOM help section for information on the fields available to this form.
- Select the Part Number of the failed Lots and specify the rework portion to be used in the "New Quantity" field.
- If the Part being added is already on the Job, the requirements (BOM) will automatically adjust down to account for the custom add. If the Part is new to the Job, the requirements will need to be manually adjusted.
- Once all changes have been entered, save and exit the Custom BOM.
Note: It may be useful to use the "Source" field on the modified BOM line to specify a note of "Manual" and provide a short explanation as to why the BOM was modified. This information could be used in the future by other production employees if they run into the same issue.
Utilizing Scrap and Over issue factors
The "Scrap %" and "Overissue %" fields are available when modifying a custom BOM line. In a custom add scenario, these fields are handled just as they are on a normal BOM and are available for modification/entry if necessary. The Facilities tab on the Item Master record contains item "Scrap %", "Scrap cost %", and "Over issue %" fields. If these fields are populated and the "Use Scrap and Over Issue" flag is checked, the system will use these values when issuing inventory on jobs for this part in the specified facility, both in terms of costs and inventory issued. Additional information on not just this feature, but on the overall scrap and over issue process, is available via Utilizing Scrap Factors.
FAQ and Diagnostic Tips
Tip: The b2_source field can be added to Batch Tickets in DEACOM to determine if the lines on the Batch Tickets came form a Custom Add rather than the Bill of Materials.
Tip: Items added in the Custom BOM on production jobs can be marked as sequential, ensuring that they are to be issued and staged to Jobs in the order they are sequenced on the Custom BOM.
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