Manufacturing Execution System (MES)

Dynamic Routing

User Guide

Version 6.0
June, 2018
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 MES D ynamic Routing User Guide

Contents
Chapter 1 Fundamental Dynamic Routing Elements ....................................................... 5
Dynamic Routing Concepts ....................................................................................................... 5
Dynamic Routing Process.......................................................................................................... 7
Dynamic Routing Code.............................................................................................................. 8

Chapter 2 Configuring Dynamic Routing Usage ............................................................. 11

Introduction to Configuring Dynamic Routing Usage .................................................................. 11
Creating a Dynamic Routing Usage Entry ................................................................................. 12
Specifying the Dynamic Routing Process.................................................................................. 12
Selecting the Reason Code ..................................................................................................... 13
Selecting the Originating Routing Code .................................................................................... 13
Specifying an Item and Originating Process As Conditions (Optional) ......................................... 13
A vailable Items and Processes Tied to Selections ............................................................... 14
Specifying the Maximum Number of Times a Unit May Be Reworked (Optional) .......................... 15
Specifying a Re-Entry Routing Code (Optional)......................................................................... 16
How a Dynamic Routing Process Is Chosen from Multiple Possible Choices ............................... 16

Chapter 3 Dynamic Routing Parameters ......................................................................... 19

Introduction to Dynamic Routing Parameters ............................................................................ 19
Dynamic Routing is a separate WO from original ....................................................................... 20
Label for work orders created by a dynamic route ..................................................................... 20
Redo job originating dynamic routing at end of dynamic process ................................................ 21
Copy remaining jobs to end of WO created for dynamic routing.................................................. 21
Use label in dynamic routing work order or operation IDs ........................................................... 22
Combine dynamic routing from the same operations of different work orders .............................. 23
Modify lot numbers of dynamic routes ...................................................................................... 24
Differentiate Parameters .......................................................................................................... 24

Chapter 4 Dynamic Routing During Runtime .................................................................. 27

Introduction to Dynamic Routing During Runtime ...................................................................... 27
Dynamic Routing Flow Example............................................................................................... 28
Determining Whether New Work Orders Are Needed for Additional Rework ................................ 30
Completing the Rework ........................................................................................................... 30
Serialized Items ...................................................................................................................... 30
Reporting Production for Dynamic Routing Jobs ....................................................................... 30

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Chapter 5 Examples of Dynamic Routings ...................................................................... 33

Introduction to Dynamic Routing Examples ............................................................................... 33
Assumptions Made for the Examples........................................................................................ 33
Dynamic Routing is a separate WO from original Parameter Is Set to No .................................... 34
Scenario 1 ........................................................................................................................ 34
Scenario 2 ........................................................................................................................ 35
Scenario 3 ........................................................................................................................ 35
Scenario 4 ........................................................................................................................ 35
Scenario 5 ........................................................................................................................ 36
Dynamic Routing is a separate WO from original Parameter Is Set to Yes .................................. 36
Scenario 1 ........................................................................................................................ 36
Scenario 2 ........................................................................................................................ 37
Scenario 3 ........................................................................................................................ 37

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C HAPTER 1
Fundamental Dynamic Routing Elements
In This Chapter
Dynamic Routing Concepts ............................................................................................................. 5
Dynamic Routing Process ............................................................................................................... 7
Dynamic Routing Code ................................................................................................................... 8

Dynamic Routing Concepts

To understand dynamic routing, let's first start by discussing routings in general. In Manufacturing
Execution System (MES), a routing refers to the preferred or actual sequence of actions needed to
manufacture somet hing. To the extent these actions take plac e on different physical entities within a
plant, a routing mimics the movement of material that occurs as a product is being made. In MES, a
process is the set of planned actions required to manufacture somet hing (or possibly more than one
thing, if the products differ only in the ingredients or components that comprise them or in the details of
how these actions are done, and not in the overall flow of how they are made).
A process consists of a set of major actions called operations, and possibly also of a set of steps for each
operation, which c an be considered to be sub -operations. Each operation accomplishes a trans formation
of the material being worked on. The normal assumption is that all steps for an operation will actually be
done on a single entity. However, for planning purposes, multiple entities can be identified as candidates
for a single operation. The association of one or more entities with each operation is also part of the
routing of the process.
Unlike a process, which is purely a plan or template that is intended to be used many times, a work order
represents the intention to manufacture a cert ain amount of a certain product. It will only be executed
once. Like a process, a work order also has a routing. However, instead of consisting of a s et of
operations and their candidate entities, it consists of a set of jobs, which are instances of operations
identified for specific entities. Like operations, jobs can also have steps. A work order is often creat ed by
instantiating a process and its routing, but it can also be constructed from scratch without first starting out
as a process. The work order's jobs (and job steps if defined) are the things that are actually executed in
the manufacturing facility. As the product is being made, the work orde r is transformed from a statement
of intention to a record of what actually took place.
A dynamic routing is one that is designed to allow for change from its original form to accommodate
events that happen during the actual manufacturing process. These events are usually deviations from
plan because something did not occur as expected. If material is irretrievably spoiled, altering the routing
cannot change that. But if the problem is correctable, it can typically be addressed through rework. In
general, rework is extra processing that is performed on a specific amount of work -in-process material to
recover from a problem experienced in a manufacturing job that caused some or all of the output of that
operation to be unsuitable for continuing with its normal processing.
If production is reported to the system with a reason that does not indicate normal operation but also
does not indicate an irrecoverable outcome for which the production must be scrapped, then MES adds
extra processing by creating rework jobs. Some examples of problems that might be correctable through
rework, and the sort of rework involved, are provided in the following table.

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Problem Rework

Too much metal removed from a mold during Weld in replacement metal and re-mac hine that
machining section
Poor paint adherenc e Strip existing paint, clean, prepare surface, repaint
Incorrect final packaging Remove product and repack

The term dy namic is used because while the work order is being done, new jobs can be creat ed
dynamically in response to the recording of production (either manual or automated) with a reason that
indicates a recoverable problem. Some or all of these additional jobs are not represented by operations
and entities in the original routing.
There is another situation for which the flow of material through a routing can be altered in response to
events that occur during its actual manufacture, but for which the occurrence is a normal variation in the
process and does not indicate a problem. This is referred to as conditional routing. With conditional
routing, the routing—in the sens e of which job is done next for some amount of production (and thus
where the material from the current job flows or is moved) —depends on conditions encountered during
the manufacturing process. The main differenc e between this and dynamic routing is that variation in
these conditions can be anticipated to occur even during normal operat ion, and thus the potential set of
operations and entities involved are defined as part of the normal manufacturing process. That is,
additional jobs do not appear automatically, but the way material flows from one job to another is altered.
The set of c onditions that can cause these changes in routing is typically more inclusive than just an item
reason entered for production. For example, a range of a particular dimension, even if within
specifications and thus reported as normal, good production, might c ause a change in which job
(typically which operation) is done next.
Dynamic routing can be used to address some of the same effects of manufacturing variation as
conditional routing, but the variation has to be reflected in the item reas on, and the orient ation towards it
being a non-normal outcome impos es certain limitations while also opening up certain possibilities not
allowed within conditional routing. The point is that dynamic routing is oriented towards handling rework,
and its suitability for use in other situations must be evaluated carefully on a case -by-case basis.

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Dynamic Routing Process

A dynamic routing process determines the set of jobs that will be instantiated when needed that are not
part of the original work order. (Instantiate means to create a specific instance of something from a
pattern.) The main difference between a dynamic ro uting process and a normal manufacturing process
(i.e., other than dynamic routing) is their usage—a dynamic routing process cannot be used to create a
normal work order, and a normal manufacturing process cannot be used to instantiate dynamic routing
jobs. To identify a process that is to be used for dynamic routings, the Dynamic Routing check box must
be selected on the Propertie s pane of the MES Client Proce sse s module. If the Dynamic Routing
check box (highlighted in the following figure) is not selected, the process is a normal manufacturing
process.

The dynamic routing proc ess will contain all the additional operations that need to done to accomplish a
specific sort of rework. Not e that there is no special relationship bet ween the dynamic routing process
and the proc ess (if any) that was used to create the work order in the first place.
The only other differenc e between dynamic routing processes and normal processes is that dynamic
routing processes may have only one first operation, and only one entity for that operation. This
restriction is needed so that the operator, when reporting production that will trigger rework, does not
need to tell MES to which particular job the material to be reworked needs to go, as this is information he
probably does not have. All the material to be reworked will go to the first dynamic routing job, which will
be instantiated from the first operation of the dynamic routing process, and for the single entity to which it
is scheduled.
The filter pane for processes contains a Dynamic Routing list (shown in the figure below) that can be
used to filter processes by whether or not they are for dynamic routing. The Dynamic Routing list
includes the following choices:
 All (the default), which will show both sorts of processes
 True, which will show only dynamic routing processes
 False, which will show only normal processes

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For example, if a new dynamic routing process is being created and the Dynamic Routing filter is set to
False, the new process will disappear once it is saved.

Dynamic Routing Code

A dynamic routing code is an arbitrary string of up to 40 characters that links the operation of the
manufacturing process that requires rework with the dynamic routing process from which the jobs to
accomplish the rework will be instantiated. Each operation of a process, and each job of a work order,
can be assigned a dynamic routing code. When a job is created by instantiati ng a work order from a
process, the operations' dynamic routing codes are used to set the dynamic routing codes of the jobs that
are created from those operations, though the codes can subsequently be modified. If a job is to be
capable of initiating rework, a dynamic routing code must be assigned to it, as the code is used to identify
which dynamic routing process to use. This identification is needed because it is possible to require
rework at multiple operations in a manufacturing process, and the proces s for the rework—the dynamic
routing process—that is required at different operations might be different, because the nature of the
product changes at each operation.
It is reasonable to ask why the operation ID is not used directly to identify the particular dynamic routing
process used to handle rework, since it obviously has to include something that varies with the operation.
While that would be possible, it can be easier to set up and maint ain the correct linkages by referring to
the operation indirectly via the dynamic routing code. There are two reas ons for this:
 In addition to the appropriate dynamic routing process depending on the operation from which the
rework is initiated, it also depends on the reason for the rework —that is, the particular problem the
rework is to resolve, as expressed in the reason code given for production. These t wo factors —the
operation from which the rework is initiated and the reason for the rework —are the minimum amount
of information required by the system to choose which dynamic routing process to use. The choice
can further be based on the item being made and the identification of the process from which the
work order was instantiated.

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 It is often the case that the same dynamic routing process would be used from multiple operations of
a manufacturing process, given the same reason code, manufactured item, and manufacturing
process. In this case, it is useful to have the indirect dynamic routing code by which to reference the
operation. Instead of having to define dy namic routing processes for each combination of these four
elements, the same rework code can be used for multiple operations, thus greatly reducing the
number of combinations to be defined. It also allows for different manufacturing processes that use
different naming conventions for operations to use the same dynamic routing process for rework
without having to define the usage for each naming convention.
The following example shows how a single dynamic routing code Deburring can be used to identify
operations from multiple operations of multiple jobs, and to link to multiple dynamic routing processes
through the use of different production reas ons X and Y:

The dynamic routing code has a second function, whic h is to define the point in the manufacturing
process to which reworked material is to be returned if it is not being returned to the very next operation
after the one that originated the rework. Since an operation is defined as that which accomplishes a
physical transformation in the product being manufactured, if the dynamic routing jobs involved in
correcting a problem also accomplish an equivalent transformation, it might be desirable to skip one or
more operations in the manufacturing process if the reworked material is returned to the work order from
which it came, and the same dynamic routing code is used to identify the target operati on wherein normal
processing of the reworked mat erial will be resumed. Since the reason we allow for a dynamic routing
code in the first place is because the same rework may be initiated from multiple operations, there could
be multiple points to which it ought to return. The rule is that the reworked material is brought back to the
next operation aft er the one from which the rework originated that has the correct re -ent ry routing code.

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For example, the following diagram shows how a dynamic routing process that is originated from routing
code A1 and uses routing code B1 as its re-entry routing code would look if initiated from two different
operations (20 and 50). In both cases, the reworked material is returned to an operation other than the
operation immediately following the one from where the rework originat ed. In the case of rework
originating from operation 20, it is returned to operation 40. In the case of rework originating from
operation 50, it is returned to operation 70. But the same dynamic routin g process (consisting of
operations A and B) is used in both cases.

If there is no downstream operation wit h a routing code that matches the re-entry code, the material is
returned to the operation immediately following the one that generated the rework. So in this example, if
the re-ent ry code were C1, the mat erial would flow back to operation 30 or operation 60, just as if no
re-entry code had been defined.

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C HAPTER 2
Configuring Dynamic Routing Usage
In This Chapter
Introduction to Configuring Dynamic Routing Usage ........................................................................ 11
Creating a Dynamic Routing Usage Entry ....................................................................................... 12
Specifying the Dynamic Routing Process ....................................................................................... 12
Selecting the Reason Code ........................................................................................................... 13
Selecting the Originating Routing Code .......................................................................................... 13
Specifying an Item and Originating Process As Conditions (Optional) ............................................... 13
Specifying the Maximum Number of Times a Unit May Be Reworked (Optional) ............................... 15
Specifying a Re-Entry Routing Code (Optional) .............................................................................. 16
How a Dynamic Routing Process Is Chosen from Multiple Possible Choices .................................... 16

Introduction to Configuring Dynamic Routing Usage

Dynamic routing processes are associated with the normal manufacturing processes that require their
use in the Dynamic Routing Usage tab of the Proc ess Definition group in MES Client. The applicability
of a dynamic routing process for particular situations is also defined in this tab. For additional information
about associating dynamic routing processes to normal processes, see the chapter on Dynamic Routing
Usage in the MES Client Guide or online help.
Associating a dynamic routing process with a normal process comprises the following steps in MES
Client. This procedure assumes that both the dynamic routing processes and the normal processes have
already been created.
1. Create a new dy namic routing usage entry.
2. Select the dynamic routing process that should be run for the rework.
3. Define the conditions that will c ause the dynamic routing process to run by selecting the reason c ode
and selecting or entering an originating routing code.
When production is reported using this reason from a job wit h this routing code, the specified
dynamic routing process will be us ed to instantiate rework jobs for that amount of productio n.
The following optional steps can also be performed:
 Include additional conditions that would be required to trigger the dynamic routing process:
o By a particular manufactured item
o If an item is specified as a condition, by also requiring that a particular process was used to
instantiate the originating job's work order
 Specify the maximum number of times a given unit of production may be reworked.
 Specify a re-entry routing code.
Refer to the following topics for a complete description of these general steps.

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Creating a Dynamic Routing Usage Entry

To create a dynamic routing usage entry
1. In MES Client, go to the Dynamic Routing Usage tab in the Process Definition group.
2. Right -click the grid and click New, or press the Ctrl+N keys.
An empty dynamic routing usage entry appears in the grid.

Specifying the Dynamic Routing Process

To specify the dynamic routing process for the dynamic routing usage entry
1. Click the ellipsis button in the entry’s Dynamic Routing Process I D column or next to the Dynamic
Routing Proce ss ID box in the Properties pane. The Select Process window appears. Only
processes that have been designated as dynamic routing processes are listed (notice that the check
boxes in the Dynamic Routing column for all processes are selected).

2. In the Select Item column, select the check box of the dy namic routing process to be used, and t hen
click OK. The selected dynamic routing process is added to the entry in the Dynamic Routing Usage
grid and to the Propertie s pane.

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Selecting the Reason Code

To specify the reason code that is required to start the dynamic routing process for this
dynamic routing usage entry
1. Click the ellipsis button in the entry’s Reason De scription column or next to the Reason
Description box in the Propertie s pane. The Reason Code dialog box appears.
Because descriptions can be the same for reasons in different groups, both the reason group and
reason description are provided to indicate unique reason codes.

2. In the Select Item column, select the check box of the reason code to be used, and then click OK.
The selected reason code is added to the entry in the Dynamic Routing Usage grid and to the
Properties pane.

Selecting the Originating Routing Code

There is no master list of routing codes as there is for production reasons or rework processes. Also,
there is no requirement that routing codes be assigned to particular operations or jobs before they are
used here.
To specify the routing code that is required to start the dynamic routing process for this
dynamic routing usage entry
 In the Originating Routing column or in the Originating Routing box in the Properties pane,
select an existing routing code or type a new routing code.

Specifying an Item and Originating Process As Conditions

(Optional)
In addition to the reason code and routing code, you can also use one or bot h of the following as
conditions required to trigger the dy namic routing process:
 The item currently being made at the job from which rework is being instantiated
 The process used to instantiate this job's work order

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To specify an item as a condition for the rework

1. Click the ellipsis button in the entry’s Item ID column or next to the Item ID box in the Properties
pane. The Select Item window appears.

2. In the Select Item column, select the check box of the item and then click OK.
To specify an originating process as a condition for the rework
1. Click the ellipsis button in the entry’s Orig. Proce ss ID column or next to the Orig. Process ID box in
the Properties pane. The Select Process window appears.

2. In the Select Item column, select the check box of the originating process to be used and then click
OK.

Available Items and Processes Tied to Selections

For MES Client versions 4.0 and lat er, if the dynamic routing process or originating process has already
been selected for this usage entry, only those items that have been identified as ones that the process is
capable of manufacturing will be listed in the Select Item window. Likewise, if an item is selected for the
usage entry before the dynamic routing or originating process, only those processes that can
manufacture that item will be listed in the Select Process window when selecting one of those process
types.

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For MES version 3. 5, the item and process lists in the equivalent dialog box —the Proce ss window of
MES Supervisor—are not dependent on the other’s selection. In that window, you may select processes
without regard for items, and vice versa. The sample Proce ss window for MES version 3. 5 below
illustrates this.

Specifying the Maximum Number of Times a Unit May Be

Reworked (Optional)
The Max Dynamic Routes entry in the Propertie s pane allows you to limit the number of times a given
unit of production may be reworked.
A dynamic routing process is similar to a normal manufacturing proc ess with the few exceptions noted
previously. Therefore, it is possible to assign routing codes to the operations of a dy namic routing
process, and define rework usages from them. This allows for reworking the rework. In practice,
reworking the rework is not uncommon—if a particular repair fails, the remedy is often to redo the entire
repair. For example, if the paint on a part is scratched, the solution could be to repaint it. If the new paint
gets scratched again, for example in the course of inspecting the repaint, it might need to be repainted
again. This can lead to a potentially very long cycle of rework, or to producing units that are not
acceptable (e.g., the unit cannot have more than three coats of paint, or it might no longer fit where
intended), unless there is a limit to the number of times dynamic routing jobs may be instantiated for a
certain amount of production. That limit can be set with the Max Dynamic Routes entry.
To specify a Max Dynamic Routes value
 Type the value in the Max Dynamic Route s box in the Propertie s pane.
Before instantiating any rework jobs, the applicable current rework count (if any) for this amount of
production will be compared to the Max Dy namic Routes value.
If the current rework count is equal to (or greater than) the Max Dynamic Routes value, the operator will
be notified that the production cannot be reworked. If the item reason is not a scrap reason, the
transaction to add production will be failed and rolled back, requiring the operator to select a different
reason.
If the current rework count is less than the Max Dynamic Routes value, the rework count is incremented
by 1 and the rework is allowed.

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Exactly what gets counted together versus what is counted separately is controlled by a set of five
general parameters that are discussed in Differentiate Parameters on page 24. If Max Dynamic Routes is
not set, meaning there is no limit to the number of times an amount of production may be reworked, these
general paramet ers have no effect.
If Max Dynamic Routes is not set, meaning there is no limit to the number of times an amount of
production can be reworked, the five general paramet ers discussed in Differentiat e Parameters on page
24 have no effect.

Specifying a Re-Entry Routing Code (Optional)

To specify a re-entry routing code for the dynamic routing usage entry
 In the Re-entry Route Code box in the Propertie s pane, select an existing routing code or type a
new routing code.
When the dynamic routing process completes, the reworked material will be returned to the
downstream operation in the originating process that has been assigned that re -ent ry code.
If no re-entry code is entered, or the entered re-entry code is not found assigned to a downstream
operation, the reworked material will be returned to the very nex t operation after the one from which the
dynamic rework process originated.

Note: To avoid arbitrary apportioning of rework quantities across multiple jobs for an operation, the
system requires that there be only one job for that operation at which rework is returned into the
originating routing.

How a Dynamic Routing Process Is Chosen from Multiple

Possible Choices
The effect of the dynamic routing usage entry settings is to have the system select the correct dynamic
routing process for a given situation. Only one dynamic routing process should be used to instantiate
jobs for rework in response to a single production transaction. However, it is possible for one situation to
fit as many as four dynamic routing processes, as shown in the following example dynamic routing usage
entries.

In this example, if production was reported from a job with a routing code of FG Production using a
reason code of Gouged, all four of these dynamic routing us age entries would be applicable. To choose
just one, two rules are applied:
 If multiple dynamic rout es apply in a given situation, the dynamic routing usage ent ry for which the
most conditions are specified is used.
 A dynamic usage entry that specifies a process but not an item is used instead of a dynamic usage
entry that specifies an item but not a process, if both apply in a given situation.
So, in this example, Gouge repair 4 would be used, because it was the most conditions
specified—four—of the possible choices.

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If process Gouge repair 4 did not exist, Gouge repair 3 would be used instead. This is because even
though both it and Gouge repair 2 had three conditions specified, the second rule says that the one
specifying a proc ess but not an item is used. In this case, that is the Gouge repair 3 entry.

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C HAPTER 3
Dynamic Routing Parameters
In This Chapter
Introduction to Dynamic Routing Parameters .................................................................................. 19
Dynamic Routing is a separate WO from original ............................................................................ 20
Label for work orders created by a dynamic route ........................................................................... 20
Redo job originating dynamic routing at end of dynamic process ...................................................... 21
Copy remaining jobs to end of WO created for dynamic routing ....................................................... 21
Use label in dynamic routing work order or operation IDs ................................................................ 22
Combine dynamic routing from the same operatio ns of different work orders .................................... 23
Modify lot numbers of dynamic routes ............................................................................................ 24
Differentiate Parameters ............................................................................................................... 24

Introduction to Dynamic Routing Parameters

There are 12 general parameters that control the way dynamic routing is used in a specific installation.
They are listed in the Dynamic Routing section in the General Parameters tab of MES Client.

All but two of the parameters have Yes/No choices. Some of the parameters depend on the choices
made for others, either in t erms of whether or not they are enabled, or in terms of their actual effect on the
system.
Each of the paramet ers is discussed briefly in the MES Client Guide and online help, but a more
complete explanation follows, in the order of their impact on the system and each other. The last five are
listed together because of their similar function.

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Dynamic Routing is a separate WO from original

Choices Are:
Yes/No
Default:
No
Enabled When:
Always
Meaning Depends on the Following Parameters:
None
Description:
The choice for this parameter is driven by whether the reworked quantity back should be merged into the
original flow of jobs or the reworked quantity will always be processed separately from the first rework
operation until it is finished.
 If this parameter set to Yes, dynamic routing jobs are associated with a new work order wit h an
automatically-generated ID. In this case, re-entry route codes do not apply, since the reworked
material never returns to its original routing. The re-entry route code will not appear in the Dynamic
Routing Usage module of MES Client.
 If t his parameter is set to No, dynamic routing jobs are added to the work order from which the rework
originated.
The choice of this paramet er’s value also affects how item reasons used to initiate rework should be
defined.
 If set to Yes, the dynamic routing reasons should be set up as reject reasons (i.e., the associated
item grade’s production type must be set to Rejects), so that these units are not expected to be
processed further in the original work order.
 If set to No, the dynamic routing reasons should be set up as good reasons, so that these items are
expected to be processed further in the original work order.

Label for work orders created by a dynamic route

Entry Is:
80-character string
Default:
The text string "Dynamic"
Enabled When:
Always
Meaning Depends on the Following Parameters:
 Dynamic Routing is a separate WO from original
 Use label in dynamic routing work order or operation IDs
Description:
This paramet er works with the Dynamic Routing is a separate WO from original and Use label in dynamic
routing work order or operation IDs parameters in the following ways:

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 If Dynamic Routing is a separate WO from original is set to Yes, this string is used for the description
of dynamic routing work orders. It differentiates work orders created for rework from ot her work
orders. It is similar to the Description for automatically-generated Kanban work orders parameter,
but for dynamic routing work orders. If Use label in dynamic routing work order or operation IDs is
also set to Yes, that parameter is also used to alter the work order’s ID.
 If Dynamic Routing is a separate WO from original is set to No but Use label in dynamic routing work
order or operation IDs is set to Yes, this parameter is us ed along wit h that value to alter the operation
IDs of dynamic routing jobs. See Use label in dynamic routing work order or operation IDs on page
22 for a more complete description.
 If both Dynamic Routing is a separate WO from original and Use label in dynamic routing work order
or operation IDs are set to No, this parameter is not used.
Note that while the value for this parameter can be up to 80 characters, this is only possible when used
strictly as a work order description. If combined with other values for use in a work order or operation ID,
the total lengt h of the combination may not exceed 40 characters.

Redo job originating dynamic routing at end of dynamic

process
Choices Are:
Yes/No
Default:
No
Enabled When:
Always
Meaning Depends on the Following Parameters:
None
Description:
If this parameter is set to Yes, a copy of the job at which the need for rework is determined is appended
to the end of the set of jobs created from the dynamic routing process. This is the case when the same
dynamic routing process might be appropriat e after different original jobs, and yet require the work done
in that original job to be done again aft er reworking, as in the case of an inspection job.
E ven when rework is done as part of the same work order as the original production (i.e., when Dynamic
Routing is a separate WO from original is set to No), to avoid double-counting the output of the
originating job, the output of the dynamic routing jobs may not be returned to that job. Instead, a copy of
the job is inserted. The copy of this job is identified as a dynamic routing job (i.e., the rework flag is set in
the job table), just as it is for jobs instantiated from the dynamic routing process, since it is being done
again due to the need for rework.
When Dynamic Routing is a separate WO from original is set to No, the output of this copied job is
returned to the operation identified by the re-entry route code (if defined).

Copy remaining jobs to end of WO created for dynamic

routing
Choices Are:
Yes/No

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Default:
No
Enabled When:
Dynamic Routing is a separate WO from original is set to Yes
Meaning Depends on the Following Parameters:
None
Description:
This parameter controls whether the rest of the jobs following the one in which the need for rework was
identified are copied to the end of the new work order. Unlike the jobs instantiated from the dynamic
routing process, and the copy of the job in which the need for rework was identified (if Redo job
originating dynamic routing at end of dynamic proc ess is set to Yes), these jobs are not identified as a
dynamic routing jobs. This is because they simply represent jobs yet to be done in the normal course of
production.
To avoid arbitrary apportioning of rework quantities across multiple jobs for an operation, the system
requires that there be only one job for that operation at which rework is returned into the originating
routing. Also, the first copied job can receive input from only the originating job, and none of the rest of
the copied jobs receives input from any jobs other than the ones that were copied.

Use label in dynamic routing work order or operation IDs

Choices Are:
Yes/No
Default:
No
Enabled When:
Always
Meaning Depends on the Following Parameters:
 Dynamic Routing is a separate WO from original
Description:
If the Dynamic Routing is a separate WO from original parameter is set to No, this general parameter will
specify whether the set of dynamic routing jobs added from a dynamic routing proc ess are to have their
operation ID (oper_id) values modified by appending the following:
 A dash
 The contents of the Label for work orders created by a dynamic route general system attribute
 An ordinal number that is one more than the last set of dynamic routing jobs (starting at 1 for the first
set) within the same work order
For example, a dynamic routing process that consists of operations A, B, and C would create jobs with
operation IDs of A-Dynamic1, B-Dynamic1, and C-Dynamic1 the first time it is added to a work order, and
A- Dynamic2, B- Dy namic2, and C- Dynamic2 the second time it is added. This assumes that the
dynamic routing parameter Label for work orders created by a dynamic route is set to its default value
Dynamic.

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Since the same dynamic routing process may be used to instantiate a set of dynamic routing jobs more
than once in a given work order, or even because multiple dynamic routing processes may re-use
operation IDs, there needs to be a way to maintain uniqueness of operation ID values for dynamic routing
jobs that are not truly part of the same operation, since they will all be made part of the same work order.
This is really only useful when rework is kept in the same work order (i.e., when the Dynamic Routing is
a separate WO f rom original parameter is set to No), so that operation ID values can be guarant eed t o be
unique within the same work order.
If the Dynamic Routing is a separate WO from original parameter is set to Yes, this general parameter
will det ermine whether a similar renaming is applied to the work order ID (wo_id) of dynamic routing work
orders. That is, if both the Dynamic Routing is a separat e WO from original and Use label in dynamic
routing work order or operation IDs parameters are set to Yes, when a work order for rework is created,
its ID should be set to the ID of the work order generating it appended with:
 A dash
 The contents of the Label for work orders created by a dynamic route general system attribute
 An ordinal number that is one greater than any work order that exists with a wo_id like that of the new
dynamic routing work order up to that ordinal number
For ex ample, if the original work order's ID is ABC, the first dynamic routing work order created from work
order ABC is assigned the work order ID ABC-Dynamic1. This assumes that the dynamic routing
parameter Label for work orders creat ed by a dynamic route is set to its default value Dynamic.
Note that because there are not a fixed number of places for the ordinal number, the ordinal number of
the ID is treated as being right-justified for sorting work order IDs. For example, this ensures that
ABC-Dynamic10 is considered a higher work order ID than ABC -Dy namic9, which is treated by the
system as "ABC-Dynamic09".

Combine dynamic routing from the same operations of

different work orders
Choices Are:
Yes/No
Default:
Yes
Enabled When:
Dynamic Routing is a separate WO from original is set to Yes
Meaning Depends on the Following Parameters:
None
Description:
This parameter controls whether rework that would differ only in the work order or operation from which
they originated is added into an existing dynamic routing work order, or a separate dynamic routing work
order is generated because of that difference. Additional quantity may only be added to an existing
dynamic routing work order if none of that work order’s jobs have been started. If any of that work order’s
jobs have been start ed, a separate dynamic routing work order is generated for additional rework
quantity.

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So, if this parameter is set to Yes and there already exist unstarted dynamic routing jobs corresponding
to all (and only, for a given rework work order) those that would be creat ed when a new amount of
production is added, their amounts will merely be incremented by the amount of the new production.
Otherwise, a whole new set is created. (When determining whether such jobs exist, all the unstarted jobs
would need to exist in the same work order, but that rework work order would not need to have originally
been generated by the work order from which this rework is originating; that is, the one for which
production was entered.) Note that all aspects of the existing dynamic routing jobs have to match those
that would be created, including their linkages, for them to be used instead of creating new ones.

Modify lot numbers of dynamic routes

Choices Are:
 Never
 Always
 If quantity reworked < total lot quantity
Default:
Never
Enabled When:
Always
Meaning Depends on the Following Parameters:
None
Description:
This parameter defines whether the lot numbers of the parts to be reworked are:
 Never changed
 Always changed to new automatically generated values
 Changed to new values only if the quantity being reworked is less than the total quantity for that lot
(as defined by invent ory)
This parameter applies only if the lot numbers are not the serial numbers, and is more a preference than
something needed to implement dynamic routing.
If lot numbers are being changed, item consumption records of type lot split (transaction_type 1) will be
created. Item consumption records provide traceability and allow for batching of rework that have the
same reason and originate from the same job. For example, say some portion of production is
determined to have an item reas on requiring a certain dynamic routing process, and lat er in the course of
that same job another portion of production was determined to have that same item reason. If none of the
original dynamic routing jobs has started, you would want to add the additional portion to them rather
than creating a whole new set of dynamic routing jobs just for the second portion. However, if lot numbers
are changing, the system needs to be able to identify from which original lots the lots already awaiting
rework have come. This allows the system to know whet her to create a new lot number or use one that
was creat ed previously, for the same original lot. This prevents the unnecessary generation of new lot
numbers when production is reported in small amounts (e.g., for serialized parts).

Differentiate Parameters
 Differentiate rework count by item reason
 Differentiate rework count by job sequence number
 Differentiate rework count by operation ID

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 Differentiate rework count by rework process

 Differentiate rework count by WO ID
Choices Are:
Yes/No
Default:
Yes
Enabled When:
Always
Meaning Depends on the Following Parameters:
None
Description:
These parameters define whether or not to aggregate counts of rework that have a different value for the
field named in the parameter.
Counts of the number of times something is reworked are kept in a table called rework_count. This table
has fields for the item ID, the lot number, and the sub-lot number, which are used to identify a specific
amount of production. Of these, only the item ID is guaranteed to exist, since it is not necessary in MES
to use lot numbers or sub-lot numbers (of course, without at least a lot number the system has no good
way to track a specific amount of production).
In addition to these fields, there are also fields for the work order ID, the operation ID, and the sequence
number of the job; the item reason; and the rework process .
These eight fields together are guarant eed to be unique; that is, each different combination of these field
values will have its own row in the rework_count table, and for each row, a rework count is maintained.
When rework is reported, only the fields that correspond to the differentiate parameters that are set to
Yes will be written to in the rework_count table.
As an example, let’s assume that a given lot of material may not be reworked for the same defect more
than three times. In this case, only the Differentiate rework count by item reason parameter would be set
to Yes. This means that for a given lot of a given material, different item reason codes (corresponding to
different defects) would be recorded separately, and rework for one defect would not count towards
rework for another type of defect. However, neither the job generating the rework nor the process used to
generate the rework jobs (i.e., the method used to remedy the defect) would be recorded. Therefore,
rework for a given defect found in one job would count against the number of times it could be reworked
for the same defect in other jobs, even if the different jobs used different dynamic routing processes.

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C HAPTER 4
Dynamic Routing During Runtime
In This Chapter
Introduction to Dynamic Routing During Runtime ............................................................................ 27
Dynamic Routing Flow Example .................................................................................................... 28
Determining Whether New Work Orders Are Needed for Additional Rework ..................................... 30
Completing the Rework ................................................................................................................. 30
Serialized Items ............................................................................................................................ 30
Reporting Production for Dynamic Routing Jobs ............................................................................. 30

Introduction to Dynamic Routing During Runtime

It is important to understand how dynamic routing works from the standpoint of manufacturing
operations—what happens, in res ponse to what actions, in what order, and (most importantly) why —that
is, its runtime behavior.
Dynamic routing is initiated by the reporting of production using a reason c ode t hat has been identified as
a dynamic routing reason.
If reasons that have been identified as being used to generate dynamic routing jobs apply to the current
job, then the Dynamic Routing Quantity option is included in the Enter Production dialog box.

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When a user selects the Dynamic Routing Quantity option, the Select Dynamic Routing Reason
dialog box appears. Only reasons that have been identified as being used to generate dynamic routing
jobs and that apply to the current job are listed.

When the user selects a reason, then enters a value in the Dynamic Routing Quanti ty box and clicks
Save, this production is entered into the database, just as it is for good or reject reasons. Other than this
dialog, there may be no other direct indication t o an operator that one or more rework jobs have just been
initiated.
As with reject reasons, the Select Dynamic Routing Reason dialog box can be opened again either by
reselecting the Dynamic Routing Quanti ty option or by clicking the button to the right of the title of the
field on the dialog that displays the currently-selected item reason.

Dynamic Routing Flow Example

For example, let’s say that the following figure shows the original routing.

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Further, let’s assume that the operator is running the second operation (machining) in the flow, and
reports one unit of production with a reason of Gouged. This unit requir es rework by welding filler
material into the gouge and then machining the filler down to match the rest of the piece.
If the dynamic routing paramet er Dynamic Routing is a separate WO from original is set to No, the
operator will be able to see the rework jobs appearing in the Route cont rol (the Route tab in Operator),
because they are part of the same work order as the job that he is now running. Not e in the following
figure sthat the flow from the job initiating the dynamic routing to the first job in the dynamic routing has
0%, because the transfer of the one unit of production took place outside normal good production.

If the dynamic routing paramet er Dynamic Routing is a separate WO from original is set to Yes, there is
no direct indication to the operator in the Route tab that rework has been initiated, because it is in a
newly created work order. The quantities for downstream jobs have been reduced by 1, as shown in the
following figure, just as if the unit of production had been scrapped.

To see the new work order, the operator would have to log in to its first job. (This assumes that he is
permitted access to the entity on which the job runs, and also whether it is far enough up in its queue to
be visible to him.) If the dynamic routing parameter Copy remaining jobs to end of WO created for
dynamic routing is set to Yes, the new work order for which the dynamic routing was created would have
the route control flow shown in the following figure.

The first two jobs in it are the dynamic routing jobs. The other three are the copies of the remaining jobs
of the original work order. Note that for all jobs in this dynamic routing work order, the quantity is 1,
because only one unit of production was reported as requiring rework.

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Determining Whether New Work Orders Are Needed for

Additional Rework
If the first (or any other) job of t he dynamic routing work order was started, and the operator report ed that
another unit of production out of the second job of the original work order needed to be reworked, a
second dy namic routing work order would be instantiated that would contain the same set of jobs with the
same quantities as the previous example, except that it would have a different work order ID. This would
be true even if the same reason, Gouged, was chosen.
If no jobs of the first dynamic routing work order had been started yet, then the quantities of the first
dynamic routing work order would have been incremented by one, and a second dynamic routing work
order would not have been created.
Note that because the rework in both cases is coming from the same work order, the setting of the
dynamic routing parameter Combine dynamic routing from the same operations of different work orders
does not matter, as it is relevant only for the case of rework coming from different work orders. That is,
rework from a single work order is always combined if possible.

Completing the Rework

From this point on, in a straight forward case such as this example, there are no furt her special actions
that dynamic routing causes to occur. If the dy namic routing parameter Dynamic Routing is a separate
WO from original is set to No, after the second rework job is completed all five units will be avail able for
the third normal operation. If this paramet er is set to Yes, the dynamic routing work order is processed on
its own with no more interaction with the original work order.

Serialized Items
When dealing with serialized items, the dialog box for reporting production looks different. However,
choosing a dynamic routing item reason for a unit’s production will have the same net effect. As noted in
Modify lot numbers of dynamic routes on page 24, the dynamic routing paramet er Modif y lot numbers of
dynamic routes does not affect serialized items, becaus e each possible unit of production already has its
own unique "lot" number, that being its serial number, and that will not change just because the unit is
being reworked. Moreover, production of serialized items only really happens with a quantity of 1; it is not
possible that half of a unit requires rework and the other half does not, because only one item reason can
be ent ered for each unit.

Reporting Production for Dynamic Routing Jobs

Since a dynamic routing job is similar to any other job, production for it is reported in the same way. So a
dynamic routing reason can be used to report production from a dynamic routing job. What this means is
that the rework itself requires rework. Other than any limitation impos ed by the parameter Max Dynamic
Rout es, there is no limit to the number of times rework can be initiat ed from ot her rework.
If the dynamic routing paramet er Dynamic Routing is a separate WO from original is set to Yes, each
rework of a rework will cause a new dynamic routing work order to be created (unless the dynamic
routing parameter Combine dynamic routing from the same operations of different work orders is set to
Yes and the new rework can be accommodated within an existing dynamic routing work order).
However, if the dynamic routing parameter Dynamic Routing is a separate WO from original is set to No,
and all rework is being done in the original work order, then the necessity for having the Use label in
dynamic routing work order or operation IDs paramet er set to Yes becomes apparent, if any of the
dynamic routing processes could be used more than once. Otherwise, because the operation IDs in the
dynamic routing process are predefined, they would instantiate dynamic routing jobs wit h the same
operation IDs every time, even though the operations are not really doing the same thing and need to be
kept separate from one another.

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There is one special case to be aware of when the dy namic routing parameter Dynamic Routing is a
separate WO from original is set to No. If a second dynamic route is initiated from the last job of a
dynamic rout e (e.g., because the original reworking of the mat erial caused other problems that require a
second type of rework), once t he second dynamic route is finished, material is returned to the same job in
the original work order as the first dynamic route would have ret urned it. This is because there are no
remaining jobs in the first dynamic route to which to return the material.

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C HAPTER 5
Examples of Dynamic Routings
In This Chapter
Introduction to Dynamic Routing Examples ..................................................................................... 33
Assumptions Made for the Examples ............................................................................................. 33
Dynamic Routing is a separate WO from original Parameter Is Set to No ......................................... 34
Dynamic Routing is a separate WO from original Parameter Is Set to Yes ........................................ 36

Introduction to Dynamic Routing Examples

Let’s examine the dynamic routing behavior that is controlled by the parameter Dynamic Routing is a
separate WO from original using two examples:
 With the parameter set to No, so that all dynamic routing jobs stay in the original work order.
 With the parameter set to Yes, so that a new work order is created for dynamic routing jobs.
The effect of several of the other general parameters are illustrated, along with an example in Dynamic
Routing is a separate WO from original Parameter Is Set to No on page 34 showing reworking the rework
and an example in Dynamic Routing is a separate WO from original Parameter Is Set to Yes on page 36
showing when rework will and will not be combined in the case for which the dynamic routing parameter
Combine dynamic routing from the same operations of different work orders is Yes.

Assumptions Made for the Examples

In all the examples, the following information is assumed to be defined.
Dynamic routing process D1:

Dynamic routing process D2:

Normal manufacturing processes P1 and P2:

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Dynamic routing usages:

Orig. Dynamic Max Re-Entry
Routing Orig. Routing Dynamic Routing
Item Reason Code Process Item Process Route s Code

R1 W (none) I1 D1 (none) (none)

R1 W (none) I2 D1 (none) Y
R1 A (none) I1 D2 (none) (none)
R1 C (none) I1 D2 3 (none)

In all scenarios, the following conditions are also assumed:

 The item being made for a work order is the same item made in each of its jobs.
 The entry for the dynamic routing parameter Label for work orders created by a dynamic route is
Dyn.
 The dynamic routing parameters Differentiate rework count by item reason and Differentiat e rework
count by WO ID are set to Yes.
 The dynamic routing parameters Differentiate rework count by job sequence number, Differentiate
rework count by operation I D, and Differentiate rework count by rework process are set to No.
 No lot or sub-lot numbers are being used.

Dynamic Routing is a separate WO from original Parameter Is

Set to No
Scenario 1
Assume work order ABC is created from process P1 to make item I1, and product ion is reported from the
job for operation 10 with a reas on code of R1. If the dy namic routing parameters Redo job originating
dynamic routing at end of dynamic proc ess and Use label in dynamic routing work order or operation IDs
are both set to No, the result is as follows, because the first row of the row of the dynamic routing usage
table applies.

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Scenario 2
Given the same conditions as in scenario 1, but assuming item I2 was being made instead of item I1, so
that the second row of the dynamic routing usage table applies, the result is as follows.

Scenario 3
Given the same conditions as in scenario 1, but assuming the dy namic routing parameter Redo job
originating dynamic routing at end of dynamic proc ess is set to Yes instead of No, the result is as follows.
Note that the new job for operation 10 will get a new sequenc e number (1) even though it is at least
initially scheduled to be done on the same entity as the original job for that operation.

Scenario 4
Given the same conditions as in scenario 1 except that the dynamic routing parameter Use label in
dynamic routing work order or operation IDs is set to Yes, and further assuming that production is
reported from the job for operation 100 with a reason code of R1, the result is as follows. The third row of
the row of the dynamic routing usage table applies to this latest production.

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Scenario 5
Given the same conditions as in scenario 4, and assuming that production is reported from the job for
operation 200-Dyn1 with a reason code of R1, the result is as follows. The fourt h row of the dynamic
routing usage table applies to this production.
This scenario illustrates the use of the dynamic routing parameter Use label in dynamic routing work
order or operation IDs. If this parameter had been set to No, the system would be instantiating a second
job with operation 200 as well as a second job for operation 210.

If the job for operation 200-Dyn2 was started and an attempt was made to report production from it using
reason R1, you might expect the system to create dynamic routing jobs for operations 200-Dyn3 and
210-Dyn3. It would except that the dynamic routing parameter Max Dynamic Rout es is set to 3 in the
fourth row of the dynamic routing usage table. Since rework is being differentiat ed by item reason and
work order ID, and this item reason has already been used three times to generate dynamic routing jobs
for this work order, the production transaction would fail. The operator would need to choose a different
reason (probably one that scrapped this production).

Dynamic Routing is a separate WO from original Parameter Is

Set to Yes
Scenario 1
Assume work order ABC is created from process P1 to make item I1, production is reported from the job
for operation 10 with a reason code of R1, and the following dynamic routing parameters are set to No:
 Redo job originating dynamic routing at end of dynamic process
 Use label in dynamic routing work order or operation IDs
 Combine dynamic routing from the same operations of different work orders
 Copy remaining jobs to end of WO created for dynamic routing

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The result is as follows, because the first row of the row of the dynamic routing usage table applies:

The dashed line represents the actual flow of the material to be reworked, though it will not appear on a
routing diagram for either work order. The "1" for the identifier of the new work order assumes no other
automatically-generated work orders have previously been created.

Scenario 2
Given the same conditions as in scenario 1, but assuming that the dy namic routing parameter Copy
remaining jobs to end of WO created for dynamic routing is set to Yes instead of No, the result is as
follows:

This is a more realistic scenario, because it is very unlikely that the work normally accomplished in
operations 20, 30, and 40 is somehow done in a different way in operations 100 and 110, in addition to
correcting the defect introduced in operation 10.

Scenario 3
Finally, assume work orders ABC and DE F are both created from process P1 to make item I1, and that
production is report ed from both jobs for operation 10 with a reason code of R1. Also assume that the
following dynamic routing parameter settings:
 Redo job originating dynamic routing at end of dynamic process is set to Yes
 Combine dynamic routing from the same operations of different work orders is set to Yes
 Copy remaining jobs to end of WO created for dynamic routing is set to Yes
 Use label in dynamic routing work order or operation IDs is set to No

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The result is as follows, provided no jobs of work order 1 are yet started:

Note that if work order DEF had been instantiat ed from process P2 instead of process P1, even if it were
to make the same it em, its rework could not be combined with that from work order ABC. This is because
that while it also contains operations 10, 20, 30, and 40 with the same routing codes, the operations in
the two processes are inherently different, regardless of their operation names. Therefore, the jobs
instantiated from those operations are assumed to be different. Because this scenario involves copying
the remaining jobs to the end t o the dynamic routing work order, the jobs copied from work order ABC are
different than those copied from work order DEF. Therefore, the requirement that all the jobs in the
dynamic routing work order be the same is not met.

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