Scrap
Scrap is the unusable material from a manufacturing operation that will be discarded.
It can be subdivided into these categories while used as a general definition for all rejected material.
- Raw material
- Scrap that is rejected in raw material form. This might be due to spoilage or off-spec characteristics. This material has had no additional processing or partial processing added to it.
- Semi-finished goods
- Scrap that has been partially processed, typically due to failure at a step in the process, meaning the goods must be rejected. This is more expensive than scrapping raw material as the partially finished part has had some value-added labor.
- Finished goods
- Finished goods must be scrapped due to failure to meet specifications. Some can be reworked by adding labor to adjust the part or turn it into something else. Others might require complete scrapping if no rework can be performed.
The Infor MES scrap functionality can work either automatically, through a connection to the equipment using a PLC, or manually, enabling operators to manually record scrap in real-time, or at the end of a job or shift.
- Automatically
- In automatic mode, operators are alerted in real-time when there is scrap recorded
on the operator dashboard.
If the PLC knows the reason code for the scrap, then it is captured automatically. However, if the reason code is unknown, then the operator must explain the scrap reason on the dashboard.
Note: Scrap can also be recorded periodically in automatic mode. For example, if the scrap bin is full, and the weight of the scrap is recorded through a set of scales.
- Manually
- In manual mode, the operator can either record scrap in real-time. Or the scrap can
be entered retrospectively at the end of the production run or shift, or when the
scrap is weighed.
The scrap counts are then used to calculate the Quality Rate, which feeds into the OEE calculation.
Scrap and rework incur costs and reduce production capacity, labor and energy resources. ERP systems can typically report scrap at a high level only, as input versus output. However, to reduce waste and rework it is important to know about scrap in finer detail, to analyze losses and improve processes.