Malfunctions, scrap and rework
Malfunctions describe equipment interruption. Scrap describes material that cannot be used as intended. Rework describes work to recover a product or material. They are separate records and need the correct work center, order/material, quantity and reason.
Report and resolve a malfunction
Use the work-center/machine view's malfunction control or the configured malfunction-report App component.
- Verify the work center before starting the report.
- Start/report the malfunction. The station can show an active alert and duration.
- Select the applicable configured reason and add useful details.
- If miscellaneous reasons are allowed, enter their required title and optional description.
- Resolve through the available control when the problem is resolved; inspect the saved station state and history.
If an unresolved malfunction already exists, open that record instead of starting a duplicate. Reasons are configured for the station. If no catalog reasons exist and miscellaneous entry is disabled, ask the administrator to configure the reason catalog; do not invent a reason through another screen.
The application timer describes recorded timestamps. Machine-derived downtime and calendar downtime can have different sources and should be reconciled according to your site's reporting rules.
Record material scrap
A configured Material Scrap Report component can operate on the active production order, general material, or both. Available reasons, quick materials, history and free material entry are App settings.
- Confirm the active order or select the material context.
- For order-related scrap, select the relevant BoM material line where offered.
- Enter the actual scrapped quantity and check its unit.
- Select the reason and add relevant details.
- Review, submit and inspect the saved history or record.
Do not report the same loss again as an unrelated general-material record. A production scrap record is not a Warehouse issue; book any required inventory movement through Warehouse. Exception totals and good-output calculations depend on the configured workflow.
Create rework or reproduction work
Open the order's exception panel where your surface provides it. Choose Rework to recover existing defective output or Reproduce to make replacement output.
- Check the order and enter a positive whole-number quantity.
- Choose the configured reason and describe the problem.
- Select the target work: rework repeats a target step; reproduction can repeat selected steps.
- Submit and inspect the linked exception and newly created execution splits.
- Schedule/execute those splits through the normal production workflow and verify the resulting quantities.
Current production exceptions use reported, approved, resolved and rejected states, with a disposition such as scrap, rework, reproduce or reuse. The ordinary create path currently creates an approved record; this is not evidence that a second person reviewed it. Rework/reproduction execution requires the approved disposition and linked order, creates queued splits, and records their identities on the exception. It can reopen a completed order into in progress.
“Resolved” on the exception can mean the rework/reproduction splits were created, not that their physical work is complete. Inspect the created splits and report actual production separately. The service rejects execution again when created split identities are already recorded.
If saving the exception succeeds but creating its execution work fails, inspect that existing exception before retrying or creating another. Ask the responsible supervisor to reconcile its state and splits. Legacy rework integrations can have a separate pending/in-progress/completed record with passed/scrapped outcomes; follow the actual integration contract rather than mixing it with the current order exception panel.
Permissions and recovery
Reporting, editing reasons, resolving problems and correcting records need their applicable permissions. A disabled control can also reflect record state or App configuration.
If a response is lost, inspect the existing record/history before repeating. If a quantity or reason is wrong, use the available authorized correction and retain enough context to explain it. If the expected status is missing, refresh the source and check whether another operator resolved it. For unavailable reasons or unclear quantity effects, involve the responsible supervisor or administrator.
Example: a jammed feeder produces an active malfunction; two damaged components are separate material scrap; three recoverable assemblies become rework. Resolving the feeder does not complete the rework or reverse the scrap.
See work centers, shop floor and order execution.