Performing a forward trace using Process Manufacturing Lot Recall: recommended actions

This topic describes recommended actions to take as part of a forward lot trace.

Perform the initial steps to recall lots or inventory, selecting Forward Trace.
See Preparing to recall lots or inventory.
In the Process Manufacturing Lot Recall form, select an item/lot in the tree and review the On Hand Stock tab.
If there is inventory on hand, go to the production floor and isolate all identified on-hand inventory. (For forward traces, this inventory consists of any raw material or parent components into which the recalled item/lot was issued.) Move the inventory physically and systemically into a quality hold location.
Review the information in the Manufacturing tab for the item/lot.
Identify job orders with a Released status.
On the production floor, move all WIP into a Quality Hold location. Change the job status to Stopped for all related job orders.
For each suspect item/lot number, validate item/lot consumption by comparing purchase receipt quantity to issued quantity in two areas:
- In the tree in the left pane of the Process Manufacturing Recall form, select the material and lot requiring consumption validation. Use the information in the Manufacturing tab to sum the quantity of material issued for the given lot. Compare this issued quantity to the remaining on-hand balance and the PO line receipt quantity. Verify that the quantity issued equals (PO receipt qty – Qty on-hand) for the selected material/lot number.
- Open the Material Transactions form and filter on these values:
  - Transaction Type: Set to Issue/WIP Change.
  - Lot: Specify the lot number associated with the recall.
  - Item: Specify the item associated with the recall.
  Export the returned collection of records into Excel. Verify that the sum of the material issued in the Quantity column equals (PO receipt qty – Qty on-hand) for the selected material/lot number.
The Process Manufacturing Recall form shows the material item lots issued into a parent job or customer orders. It does not show cycle counts or miscellaneous transactions. Use the Material Transactions form to verify all material consumption and considerations for cycle counting and miscellaneous transactions.

Note: If materials from unassociated lots are withdrawn incorrectly, or if incorrect materials/lots are issued into jobs, the Process Manufacturing Recall data cannot be totally accurate. You must identify the transactions made in error and back them out in order to obtain accurate data.
From the previous step, identify all dates when the suspect item/lot was issued to parent job orders.
Use the Material Transactions form to identify all job orders for the item/lot that were issued on those dates.
Export this collection into Excel. Cut and paste the completed suspect items/lots into a separate worksheet and eliminate duplicate records.
Use the Item/Lot Locations form to identify any on-hand inventory for suspect items produced on the dates in step 7.
For each of the suspect item/lots, sum the on-hand balance with the quantity issued into job orders. Validate that this quantity equals the total amount completed and issued on the Lots form for the suspect item/lots.
Isolate all on-hand inventory for the suspect items identified in step 7 into a quarantined location, both physically and systematically.
Enter each suspect item/lot into a new recall in the Process Manufacturing Recall form. Using Forward Trace, generate a new recall.
Review information in the Customer Orders tab of the Process Manufacturing Recall form. Identify all shipped customer order lines that are linked to the respective suspect item/lots generated in the recall.
Contact all customers identified in the previous step and recall any associated products they have on hand
Use RMAs to process the recalled products that are returned by customers.
When the returned products are received as RMA line items, quarantine the inventory upon receipt.
Scrap all recalled products.