MENU OPTION: Work in progress returns

When batches are completed it is necessary to return the final details using this option. Select a work in progress item to return, suspend or cancel.

Suspending a batch returns it to schedule and returns the raw materials.

Cancelling a batch removes it from work in progress and returns the raw materials to stock.




If for some reason it becomes necessary to reprint a batch card (for instance if the paper jams during printing) go to work in progress returns select the batch then click on suspend batch.

This will return the batch to work in progress, reversing the stock transactions, and allow you to reissue the batch.

RETURN BATCH

Pressing the <RETURN BATCH> button opens the following screen in which all details of adjustments to the issued formulation and how the batch was filled are recorded.

SCREEN FIELDS:

Completion date: The date of completion of the batch

Actual SG: Defaults to calculated SG of batch. You may overwrite with measured value

Formulation adjust: Record any changes to the issued formulation

Rework: Record any quantity of the batch to be reworked

Intermediate: Record quantity of batch to be used as an intermediate in another formulation

Finished goods fillings: Enter container codes and quantities filled. Press enter to look up container codes if unknown.


SCREEN BUTTONS:

OK: Save captured data

Cancel: Cancel captured data

Delete: Delete selected finished goods item

Completion date: The completion date must be within the range of the current period. This is because any raw material or container adjustments to the batch will be draw from the current stock period. The raw materials and containers which were specified on the original batch card have already been drawn from stock in the period in which the batch was issued.(See returning batch cards out of period)


RECORDING CHANGES TO THE ISSUED FORMULATION

All changes to the original issued formulation must be recorded by clicking the <formulation adjust> button.


TYPE OF CHANGES TO ORIGINAL FORMULATION

1. Used mass is different to issued mass

-record the correct used mass

2. Cost a time of usage differs from issued cost

-record the correct cost

3. A material that was not in the original formulation is to be added (e.g. adding part of an old batch)

-click <insert> to add the material. If the material is found on the raw material master file the cost will be inserted automatically. If not you will be prompted to enter the cost.

4. A different material from the issued material is used (raw material substitution)

-change the mass of the issued material to zero.

-click <insert> to add the new material and record the mass

RECORDING HOW THE BATCH WAS FILLED

The total quantity of the batch which was manufactured must be recorded under one of the three following categories.

1. Rework. The quantity recorded here is placed in a holding file for immediate use in another batch. There is no stock auditing on this holding file.

2. Intermediate. The quantity recorded here is placed in the raw material stock file. If a raw material stock code does not exist for this intermediate, one will be created automatically using the formulation code. This is the best way to record the filling of part batches which will subsequently be used in other batches with some modification (e.g. tints or resin letdowns). There is full stock auditing on this intermediate transaction in the raw material stock movement report.

3. Finished goods sales item. The number of sales items are recorded. These sales items must be defined for the particular formulation which you are currently working with. It is possible to create new sales items on the fly by clicking the <insert> button on the lookup window which appears when you press <enter> on a blank finished goods code field (see Enter Finished Goods)

SPECIAL COLOURS AND ONE-OFF BATCHES

To deal with the case of formulations which are made on a one-off basis, it is suggested that a dummy formulation be created containing a single dummy raw material.

When the batch card is returned the dummy formulation can be edited using the 'FORMULATION ADJUST' button on the 'RETURNING BATCH CARDS' SCREEN.

Any raw material, formulation or subsidiary material may be entered in this batch card.

If a subsidiary material is used you will have to manually enter the unit cost of that material in order to correctly cost the batch.


It is quite normal to issue batch cards in one stock period and return them in another.As soon as a batch card is printed the raw material and container stock is downdated in that period. When the batch card is returned any changes to the original scheduled formulation are stock adjusted in the current period. This is a normal situation and no special action is needed to deal with it.

However, if for some reason you have allowed a backlog of batch cards to accumulated from the previous stock period and you now want to return them after you have started a new period and you do NOT want any raw material adjustments to be accounted for in the current period, it is necessary to temporarily changed to back to the old stock period to which these cards belong.

Go to menu option: 'Files/ setup/calendar period' and change the current period to the previous period number. It will be necessary to exit the program then re-enter it in order for the program to register the previous period. Do not forget to return to the current period after entering the backlog.

FINISHED GOODS STOCK AND RAW MATERIALS STOCK.

There is no relationship between the finished goods stock period and the raw material stock period. When you return a batch the finished goods stock is always updated in the current finished goods stock period. The raw materials which have adjusted in the batch will be updated in the current raw material stock period. Any adjustments to the containers which were used in filling the batch will also be adjusted in the current raw material stock period.

Finished goods stock will always be posted to the current finished goods stock period and recorded on the date of the batch return. There is no manual override for this date.

In the case where finished goods stocks have been allowed to go negative these negative values will automatically be corrected when you return the finished goods in the same period.

Care should be taken when you are returning finished goods on the closing date of your finished goods stock period. You may have to enter some manual corrections to finished goods stock where stocks had been allowed to go negative in the old period and you are now returning finished goods stock in the new finished goods stock period.