Creating a Rework Order

To repair an item that you have received through a return material authorization (RMA), you create a rework job order (or estimate job order). The rework order's bill of material includes the item as the end item and as a component. This recursive BOM structure is allowed only on a bill of material for a rework order.

After receiving a returned, defective item (through an RMA return transaction), follow these steps to create a rework order and repair the item:

  1. Open the Job Orders (or Estimate Job Orders) form and create a new order. We recommend you decide on a special prefix to use in the job numbers for rework orders. Using a special prefix will allow you to filter your job reports to include only rework orders, if necessary.
  2. In the Item field, select the returned item that you want to repair.
  3. Select the Rework field. Selecting this field will allow this job's bill of material to be recursive.
  4. Enter or select the appropriate values for the job in the remaining fields as desired.
  5. Enter the job operations (click the Operations button to open the Job Operations form).
  6. Define the job bill of material (click the Materials button to open the Job Materials form). Enter the item to be repaired as a component, along with any other materials necessary for the repair.
  7. On the Job Material Transactions form, issue the item to be repaired (from its non-nettable location where you originally received the RMA order) to the rework order.
  8. Issue any other needed materials to the rework order.
  9. Enter job operation transactions to record setup, labor or machine time, and overhead, and to move the completed, reworked item to inventory.
Note: 
  • Only job orders and estimate job orders can be rework orders. You can also create a rework job order on the Engineering Workbench form (if you copy an estimate job to a job and the estimate job is a rework order).
  • When defining the bill of material for the rework order, the rework item can be recursive only two levels down in the BOM. For example, if end-item A is made from material B, A and B can be the same item. However, if A is made from B and B is made from C, C cannot be the same item as A.
  • Once you add a recursive BOM to the rework order, you cannot clear the Rework field on that job or estimate job (that is, you cannot change the rework order back into a normal job or estimate job).
  • When issuing the returned material to the rework order, you must enter the job material transaction on the Job Material Transactions form. You cannot use backflushing and you cannot use the Post Material Issues option on the Job Pick List report.
  • For MRP and APS planning, the end item of the rework order is considered as a planned supply/receipt. The same (recursive) item in the bill of material is not considered as a demand/requirement. If the rework order has no routing/BOM, MRP and APS ignore the rework order completely.
  • If you use Standard costing for a rework item, you may encounter large routing and/or material usage variances, because the routing and materials used to repair the item may vary greatly from those used to build the original item.
  • If a job is marked as Rework:
    • The Preassign Serials and Preassign Lots fields on the Job Orders form are disabled.
    • The Lots and Serials preassignment tabs on the Job Orders form are disabled until the rework material is issued to the job.

    When the material is issued for the rework job:

    • If Preassign Serials is selected on the material's Items record, then Preassign Serials is also selected on the Job Orders form, and the Serials tab is enabled and displays the item's serial number.
    • If Preassign Lots is selected on the material's Items record, then Preassign Lots is also selected on the Job Orders form, and the Lots tab is enabled and displays the item's lot number.
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