Scrap management in Eyelit MES allows you to record and analyse losses associated with the scrapping of materials of all types, i.e., raw material, parent assemblies and sub-assemblies.

Where you are scrapping an item where you have child materials within it, then you also need to track the scrapping of the child components.

Scrap use cases

1. Scrap a quantity in WIP for which nothing's being consumed yet. 
2. Scrap a quantity of raw material that's not been used already. In this case, it just disappears from inventory.
3. Remove something that's been previously fitted and scrap it (i.e., remove and scrap). For example: You have a computer, where you fitted a motherboard, and then removed the motherboard. The motherboard can be used again. If you choose to scrap the motherboard, it will be a remove and scrap.
4. Scrap a parent quantity that had already consumed child quantities. You made 100 kg of cake mix and used 50 kg of flour. You scrap 1 kg of cake mix and in that 1 kg scrapped, you had 0.5 kg of flour. This is a parent quantity with child quantities scrapped.

Scrap

Scrap available items

To scrap an item in stock:

1. Navigate to the Stock Items screen and use the search filters to select the product you want to scrap.
2. Click the Scrap button to display the Scrap Available Qty pop-up.

Scrap Available Qty screen

Blue fields in the form are required and are flagged with an asterisk (*) in this document.

• Qty Scrapped*: Quantity to be scrapped.
• Reason Type*: Reason field below is filtered by Reason Type. The material reason must be assigned to the Product Type of the product being scrapped. For more information, see Material Reasons.
• Reason*: Reason for the scrap.
• Comments*: Leave additional information about the scrap.

Scrap Raw Material Qty

It is also possible to record the scrap of raw material when booked on to an operation action through the scrap raw material button. This allows the scrap of raw materials that have not yet been issued/consumed to the parent job.  

Scrap Raw Material screen

Blue fields in the form are required and are flagged with an asterisk (*) in this document.

• Product: Select a product.
• Serial No: Serial number of the item to be scrapped which filters the Item list below.
• Item*: Select the item to be scrapped.
• Scrap Qty*: Quantity to be scrapped.
• Unit*: Unit of Measure.
• Reason Type*: Reason field below is filtered by Reason Type. The material reason must be assigned to the Product Type of the product being scrapped. For more information, see Material Reasons.
• Reason*: Reason for the scrap.
• Comments*: Leave additional information about the scrap.

Scrap WIP item

For scrap to be allowed on an operation, the Allow Scrap checkbox must be ticked in the workflow Operation Node screen. The Scrap Mode field becomes active and you must choose to reduce the WIP quantity or reduce the WIP and job quantity.

As an example, if you have a batch of 10 and you scrap one, you have two options for handling this:

• Reduce WIP Qty: An additional one is still required to be made to replace the scrapped one so that you finish with 10.
• Reduce WIP and Job Qty: Reduces the job to 9 and you finish with 9.

Scrap WIP options

Scrap and Replenish

Typically, when a quantity of a manufactured batch is scrapped, the output from the process is reduced. For example, if an operator is working on a batch of 10 and scraps 2, we expect to only complete 8. However, there are business cases where the works order quantity must be hit, therefore, you have to make up the quantity (i.e., append the quantity).

If WIP scrap is performed and the job qty is not reduced, it will be necessary to make up the lost quantity by starting additional quantity.  You can manually append this quantity, if the workflow version and the operation scrap mode allow, which will start the appended quantity at the first operation in the workflow.

It is also possible to configure the scrap quantity to be automatically replenished as follows.

Workstation buttons that allow you to scrap are configured in the Button Profile and are:

• Scrap - Replenish at current op: This button is accessible from within an operation action. A quantity equivalent to the scrapped quantity will automatically be adjusted at the current operation in the workflow. For example, an operator is working on a batch of 1000 (for example cakes), scraps 2 and then continues to make 1000 at the current operation. In this scenario, the WIP quantity (cake mix) for making 1000 is readily available at the operation where the scrap occurred. 
• Scrap - Replenish at previous op: This button is accessible from within an operation action. A quantity equivalent to the scrapped quantity will be adjusted at a selected previous operation in the workflow. 
• Scrap - Replenish from start op: This button is accessible from within an operation action. A quantity equivalent to the scrapped quantity will automatically be appended and starts at the first operation in the workflow. For example, an operator is working on a batch of 10 (for example chairs), scraps 2, starts another 2 at the first operation to replace the 2 that were scrapped.  
• Scrap - No replenish: This button is accessible from within an operation action and from the workstation screen. The scrapped quantity will not be automatically replenished. You can manually append (if the workflow version and the operation scrap mode allow) which will start the appended quantity at the first operation in the workflow. 

Scrap WIP partial quantity

When a partial quantity of an item in WIP is scrapped, the parent will automatically be split. The quantity of child that is scrapped with parent depends on the quantity of child that's split off with the parent. For more information about the splitting logic that applies to scrapping a partial quantity in WIP, see Splitting.

To scrap items:

1. While in the operation on a workstation, click the scrap button you need in the right‑hand menu to display the Scrap Batch Qty pop-up. The pop-up appears when you scrap a parent quantity and at least one slot is not fully fulfilled. If all slots are fulfilled, no operator input is required (and the child material will be scrapped in proportion to the parent material).
2. In the pop-up, provide the Scrap Qty, Reason Type, Reason and Comment.
3. Manufacturing Root Cause: Select a previous operation that the WIP quantity passed through where the issue was caused. 
4. Configure Components toggle: When this toggle appears, the next screen after clicking the Scrap button (Scrap Component Handling) displays the child material issued to the parent being scrapped. If all slots are fulfilled, the Configure Components toggle is not displayed (and the child material will be scrapped in proportion to the parent material). If any slots are unfulfilled, it defaults to Yes where you need to manually confirm child components quantities to be scrapped. 

Scrap Component Pop-up

When scrapping parent quantities in a job, the UI displays the Scrap Component Handling pop-up to clarify or confirm the component scrap quantities. 

The popup appears when a user attempts to scrap parent quantity and at least one slot is not fully fulfilled. If all slots are fully satisfied, no operator input is required and the system applies ratio logic silently.

By default, only BoM slots that are partially satisfied will be displayed. The child components quantity to scrap will default to the same ratio as parent item. For example, if you are scrapping 10% of the WIP parent, 10% of the consumed child material will also be scrapped.  

Partially fulfilled slots are displayed to allow the operator to confirm or override the quantity to be scrapped. For example:

• You are building 10 tables and have fitted 12 legs.
• You want to scrap 5 tables (i.e. half of the batch).
• The default will be to assume that you have scrapped 6 legs (i.e. half of the consumed legs).
• The operator may override this value (for example if none of the tables scrapped had had legs fitted, and so no legs are scrapped).

Fully satisfied slots will also default to scrap in the same ratio as the parent item. Because this is usually a good assumption for fully satisfied slots, these will be hidden by default, but you can chose to view the quantities for all slots by selecting View All Slots.

Scrap Reports

Scrap by WO

This report gives the details of a scrap transaction that was carried out in a works order. It also calculates the value of scrap based on the the Per Unit Cost amount provided in the Products page.

Scrap by Work Centre Analysis

This report provides scrap details by Work Centre which you can then drill down to increasing levels of granularity for the scrap associated with it (Work Centre - Product - Work Centre Department - Work Centre - Activity).

Scrap by Period

This report presents scrap information for the selected criteria over the specified period.