You can complete an assembly quantity into inventory that is greater than the Discrete job or Repetitive schedule start quantity, whether or not the assemblies have a routing. This is referred to as an over-completion, and it is useful when your production process yields more assemblies than planned. You also can move a quantity that is greater than the quantity at an interoperation step, whether or not the assemblies have a routing, and this is referred to as an "over-move."
You can over-complete and over-move assembly quantities on the Completion Transactions and Move Transaction windows. You also can over-complete assemblies using the Inventory Transaction Interface and the Open Move Transaction Interface, however, you must explicitly specify the over-completion transaction quantity, as it will not be derived by Work in Process. The over-completion quantity is the transaction quantity minus the available quantity.
To be able to over-complete assembly quantities on jobs or schedules, you must:
First, set up a tolerance level to restrict the number of assemblies that can be over-completed.
Then, enable the over-completion feature when completing assemblies by checking the Overcompletion check box on the Completion Transaction or Move Transaction windows.
All resources for over-completed assemblies are automatically charged and any backflush components are backflushed.
If you will be over-completing assembly quantities in your manufacturing process, you must set up a tolerance level for the quantity of assemblies that can be over-completed on a job or schedule. The tolerance level, which is either a number or a percent, is used to validate the quantity being over-completed. If the quantity is greater than the tolerance allows, the transaction will fail.
You can set up tolerances at these levels:
Organization Level
You can set up tolerances item by item, or you can set a parameter at the organization level that sets the default over-completion tolerance percent for all items. When you set the tolerance at the organization level, you also are setting the default that will be used to validate over-completion assembly quantities when no tolerance level has been set at either the item or job and schedule levels.
If you do not set a tolerance level, the default over-completion tolerance percent will be Null, which in effect is equal to zero percent or no tolerance. If you then try to over-complete assemblies, you will receive a message telling you that you cannot over-complete the assemblies because there is no tolerance.
You set the Default Overcompletion Tolerance Percent parameter on the Other tab of the WIP Parameters window. See: WIP Parameters
Item Level
You also can set up over-completion tolerances at the item level in Oracle Inventory. The tolerance that you set up at the item level overrides the tolerance that you set up at the organization level. To set the over-completion tolerance at the item level, you define the following two item attributes on the WIP tab of Inventory's Item Definition window. Their values are defaulted to the Discrete or Repetitive item when it is defined:
Overcompletion Tolerance Type: the values for this attribute are: Percent or Amount. If you do not select an over-completion Tolerance Type, the tolerance defaults to the tolerance that you set at the organization level. (If you did not set a tolerance at the organization level, the default is Null, which signifies that no over-completions are allowed.)
Overcompletion Tolerance Value: the value for this attribute is the number value for the Overcompletion Tolerance Type that you selected. It determines the acceptable percent or quantity of assemblies that you will allow to be over-completed. For example, if you choose Percent as the Overcompletion Tolerance Type, and enter 100 as the Overcompletion Tolerance Value, you allow over-completions up to 100 percent of the original job or schedule quantity. If you did not select an Overcompletion Tolerance Type, you will not be able to enter a value in this field.
If you set tolerances at the item level, the item attributes default into the Overcompletion Tolerance Type and Overcompletion Tolerance Value fields on the Discrete Jobs and Repetitive Line/Assembly Associations windows, where you can manually modify them. Any modification to the tolerance is validated when the assemblies are completed to ensure that the value is not less than the already over-completed quantity.
Job or Schedule Level
You can set the over-completion tolerance at the job or schedule level when you define a Discrete job or Repetitive schedule. The tolerance then only applies to that particular job or schedule, and overrides any tolerance that you established at the organization or item levels. When you set a tolerance limit for a Repetitive item, it applies to all Repetitive schedules in which the item is used.
You set the tolerance by selecting the tolerance type and entering its value. For Discrete jobs, you set it on the More tab of the Discrete Jobs window. For Repetitive schedules, you set it on the Over-Completion block of the Repetitive Line/Assembly Associations window. See: Defining Discrete Jobs Manually and Associating Lines and Assemblies
Note: On Repetitive schedules, all over-completed quantities are allocated to the last open schedule, thus over-completion is subject to the tolerance limit of the last open schedule.
To perform over-completions from the Move Transactions window, you select the transaction type (Move or Completion), which enables the Overcompletion check box. You must select the check box before you enter the over-completion quantity. Once you select the check box, you enter the transaction quantity, which must be greater than the quantity at the "From" operation or the available quantity and within tolerance levels. The Overcompletion check box is disabled if you are performing a Return transaction or a reverse Move transaction, or if the From operation step is the Scrap or Reject step.
To over-complete assembly quantities from the Completion Transactions window, you select the Overcompletion check box in the Transaction region. If the transaction type is a WIP Assembly Return transaction, however, the Overcompletion check box will be disabled.
Selecting the Overcompletion check box enables you to complete more assemblies than the quantity in the To Move step of the last operation. If the total completion quantity specified in the Completion Transactions window exceeds the available quantity to complete, then the excess assemblies are moved from the Queue step of the first operation to the To Move step of the last operation, and all completion transactions are performed. The total transaction quantity (which is the sum of the transaction quantities for all completion transactions entered and must exceed the available quantity) is validated against the tolerance levels defined.
The system administrator must set up user access privileges that identify who has permission to perform over-completion transactions. If a user does not have permission, the Overcompletion check box will not be accessible on the Assembly Completion, Move Transaction, and Pending Move Transaction forms.
You can reserve over-completion quantities from jobs linked to sales orders when using the Completion Transactions and Move Transactions windows. The sales order number is entered for each completion line. This reserves the surplus amount, otherwise the over-completion is unreserved excess inventory. See: Linking Sales Orders and Discrete Jobs.