Rework orders can be created only for Items that are Lot/Serial tracked when it has failed its "Quality Order". The concept of using a Rework Order is to allow the user to rectify the item that has failed by processing it via either a "Production Order" or "Assembly Order". The type of Rework Order created is defined by the Replenishment Method on the Item Card. If the replenishment method is set to 'Purchase' then the type of Rework Order that will be created will be taken from "Quality Setup".
Ensuring you have an Active "Test Automation" for the output choice (i..e ,'Production Output' or 'Assembly Output'), a new "Quality Order" will automatically be created once the output has been posted, ensuring new results can be entered (and ideally Passed) before posting. The previous "Quality Order" that had failed can be posted with the failed results for audit purposes.
Business Central will use the fields on the Rework FastTab of the "Quality Setup" page to determine what to create. Rework Type will define whether a "Production Order" or "Assembly order" is to be used. If Production, the Rework Production Order Status can be used to determine which status of order is required. The Rework Production/Assembly Components field will outline exactly what is to be reworked, whether it's just the item or inclusive of components. Finally, you can confirm if a specific routing is to be used for reworking items by changing the toggle for Use Setup Routing for Rework Prod Orders from 'No' to 'Yes' and choosing the Routing No from the dropdown in the Rework Prod Order Routing field. If the toggle is left as 'No', the routings from the original orders will be used.
Open up the "Quality Order" that has a Calculated Result as 'Fail'. Ensure a Lot/Serial No is stated. In the Failure Responses button in the ribbon, select either Create Rework (Failed Quantity), or Create Rework (Full Quantity), depending on which you want to rework. Doing this will do 2 things. Firstly, the Qty reworked field in the Test Quantities Fasttab of the "Quality Order" will update with the qty you were about to rework.
Secondly, a "Production Order" or "Assembly Order" (depending on which you selected in "Quality Setup") will open for you to process the rework.
This effectively makes the existing "Quality Order" now void, as you have recorded the result of 'fail' and moved goods to rework them. As all of this is recorded on the "Quality Order", you can Post this as when you post your Output from the Production/Assembly Order, providing you have a "Quality Automation Rule" set up for the appropriate Transaction Type for Production/Assembly outputs, that will create a new "Quality Order" for you to record your new results in, based on the reworked Lot/serial number.
Using Production Orders
Once the "Production Order" opens, go to the Production Journal from the Lines FastTab. This will display your Consumption lines as per your "Quality Setup", i.e. where "Quality Setup" is 'Components and Rework Item', the lines to consume in the Production Journal will also be the 'Consumption and Rework Item' lines. Ensure the Lot/Serial Numbers are assigned for the Consumption lines. The Output line works a little different and will need a new Lot/Serial No assigned via Item Tracking Lines as this Item has now changed and should be recorded with a new reference.
Post the journal.
This will then create a new "Quality order" against the Production Output Transaction Type (if Active in "Quality Automation Rules"), linking the new Lot/Serial No used for the Output line.
You can now enter your test results for this "Quality Order" which would ideally then result in an Overall Result of 'Pass' but can still 'fail' if it doesn't meet your Target Result. Post the "Quality Order".
Using Assembly Orders
Once the "Assembly Order" opens, it will display whatever you confirmed in the Rework Assembly Components field in the "Quality Setup" page. For example, selecting 'Components & rework Item' will display your Assembly order like the image below, showing both the Rework item and all Components. Clicking onto the Rework Item and choosing Item Tracking Lines should display the previous Lot No used for the Item. In the ribbon, you must assign a new Lot Number as your outputted Item requires this. Clicking into 'order' and then Item Tracking Lines will open up the page. Assign a new Lot Number and Post the "Assembly Order". This will close the order and return you back to the original "Quality Order" which failed. Enter the Confirmed Result and Post the "Quality Order". You will see that the Quantity Reworked field has been populated with the failed reworked quantity.
Finally, open up the old "Quality Order", the one that originally failed. This will now be stamped with a quantity in the Quantity Reworked field so to close this "quality order", populate the Confirmed Result field. If the Quantity Reworked is for the full quantity on the order, Post the order. If there is a difference in qty, enter the difference in the Quantity Failed field (so that the Quantity Failed and Quantity Reworked = the full Qty) and Post the order.
If you have 'Assembly Output' as Active in the "Test Automation" page, a new "Quality Order" will be raised for the New Lot Number you created for the reworked goods which ideally would now pass its quality check. If this is not required, ensure the Active option for 'Assembly Output' is switched off.
Note - Rework is not possible where Replenishment Type on Item is NOT Purchase and where the Transaction Type is Purchase.