E1: 31A: PF31011 Orderless Completion Incorrectly Uses Item Master Round To Whole Number Causes Bogus Engineering Variance (Doc ID 2884268.1)

Last updated on JANUARY 03, 2023

Applies to:

Symptoms

The PF31011 Ad Hoc Ordeless Completions Incorrectly uses the Item Master Round To Whole Number field Alias: SNS functionality when its set to a U for an item. By rule this option is suppose to round an Item to the nearest whole number in the P3111 / F3111 Part List when the Part List is attached. This is working correctly for Standard Work Orders where the part list is attached to a work order header by R31410, or Interactively.  In In Orderless Manufacturing there is no work order header to attach to therefore the Part List FF31111 is attached / calculated on the fly by Lean Completions PF31011. The PF31011 is incorrectly doing the calculation which is causing bogus Engineering Variances in the FF31200 Lean Transaction Costs Table / Production Cost Inquiry.  When by rule when using the round to whole number functionality you are changing the part list and this change should “first” be correctly calculated and booked in the FF31200 Lean Transaction Costs Table / Production Cost Inquiry as a Planned Variance i.e. Current VS Planned, not Engineering Standard VS Current as the system correctly does for Standard Work Orders. Its Seems the PF31011 is rounding the P3002 BOM Qty to a whole number then doing the calculation to attach the P3111 / F3111 Part List.  Which results in the wrong Part List Qty for an item.

Ex: Standard Work Order R31410 & Inter Active Attach:
Item Master Round To Whole Number field Alias: SNS Set to U for Item A
P3002 BOM Qty Item A .05, Work Order Qty 9.
P3002 BOM Qty Item A .05 X Work Order Qty 9 = Part List Qty 4.5 Rounded to 5 (Correct) and Correct Units and Amounts will be Booked as a Planned Variance.

Ex: Lean Completion PF31011:
Item Master Round To Whole Number field Alias: SNS Set to U for Item A
P3002 BOM Qty Item A .05, Orderless Completion Qty 9.
P3002 BOM Qty Item A .05 ((Rounded To 1)) X Work Order Qty 9 = Part List Qty 9.0(Incorrect) When looking at the FF31200 Lean Transaction Costs Table / Production Cost Inquiry this causes a bogus Engineering Variance as the Current Units and Current Amount are incorrect i.e. based off of 9 not 4.5.  The system is also booking this as an Engineering Variance because it seems to have Changed / Rounded the P3002 BOM Qty of .05 To 1.00 first.

Steps To Duplicate:
1.  Create a Parent Item i.e. 7822 and a Purchased Component 7822C1
2.  Make sure in the Item Master Additional Systems Info for the component item 7822C1 the Round To Whole Number field Alias: SNS is set to U.
3.  Create a BOM for Parent Item 7822 with comp. item 7822C1 on the BOM Qty of .50.
4.  Create P4105 records for both items Sales Inv 07 / Purchased 08.  For the parent item 7822 07 = $0.00, and 08 = $0.00.  for comp. 7822C1 07 = $0.00 and 08 = $23.00.
5.  Roll up cost / Simulate R30812 and Freeze R30835 Cost for parent and component blowing through the BOM.
6.  Using P48013 create a standard work Order for parent item 7822 Qty of 9, and Attach the part list Interactively or by using R31410. Note the P3111 Part list Qty was correctly calculated and rounded to Qty 5. i.e. BOM Qty 7822C1 .5 X WO Qty 9 = 4.5 rounded up to 5.
7.  Check the P31022 Production Cost Inquiry for work order just created and notice the Units and Amounts are correct i.e. Units for comp 7822C1 = 4.5 Units, Amounts $103.5 for Standard and Current.
i.e. Standard Amount is Parent Frozen A1 11.5 X WO Qty 9 = $103.50
i.e. Current Amount is Comp BOM Qty .5 X  WO Qty 9 = 4.5 X Comp Frozen Cost $23 = 103.50.
8.  Go to menu GF3112 / PF31011 and perform a lean completion for the parent item Qty of 9.
9.  Check the PF31014 Lean Transaction then use the Production Cost Inquiry button to move to PF31200 / FF31200 Production Cost Inquiry for lean completion just created.  Notice the Units for the Parent Item 7822 are correct at 9.0.  However the Units for the component item are incorrect at 9.0. The Standard Amount is correct at $103.50 However the Current Amount is incorrect at $207.00  It seems the system calculated the units for the component 7822C1 by first Rounding the BOM Qty of .5 to 1.00 then doing the calculation. Comp BOM Qty 1.00 X WO Qty 9 = 9

This caused the following calculations:
i.e. Standard Amount is Parent Frozen A1 11.5 X WO Qty 9 = $103.5 (Correct)
i.e. Current Amount is Comp BOM Qty “Rounded” To 1.00 X WO Qty 9 = 9 X Comp Frozen Cost $23 = $207.00. (Incorrect) causes a Engineering Variance.  

10. Note: When the system does this correctly like the Standard work order test.  After processing the work order and running R31802A MFG Accounting. The fact that the P3111 / F3111 Part List will be correctly calculated as 4.5 Rounded To Next Whole Number = 5 not 9. This will correctly cause a Planned Variance i.e. Current VS Planned which is correct by rule because the part list P3111 / F3111 was changed / rounded from 4.5 To 5 (BOM Qty should not have been rounded from .5 To 1).
i.e. Planned Amount is Comp Current Part List Qty 5 X Comp Frozen Cost $23 = $115.  Current Amount $103.50 – Planned Amount $115.00 = $-11.50
Planned Variance which would be expected and correct.

Changes

Cause

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