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Epicor ERP
Quality Assurance Course
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Disclaimer
This document is for informational purposes only and is subject to change without notice. This document and its
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Quality Assurance Course Contents
Contents
Quality Assurance Course......................................................................................................5
Before You Begin....................................................................................................................6
Audience.........................................................................................................................................................6
Prerequisites....................................................................................................................................................6
Environment Setup..........................................................................................................................................7
Workshop Constraints..............................................................................................................................7
Overview.................................................................................................................................8
Application Setup.................................................................................................................10
Company Configuration................................................................................................................................10
User Account Security Maintenance...............................................................................................................11
User Security...........................................................................................................................................11
Security Group Maintenance..........................................................................................................................11
Workshop - Create a Security Group.......................................................................................................12
New Security Group and User.................................................................................................................12
Workshop - Authorize a Security Group..................................................................................................13
Reason Code Maintenance............................................................................................................................13
Define Reason Codes..............................................................................................................................14
Workshop - Define a Reason Code.........................................................................................................14
Set the Inspection Required Check Box..........................................................................................................15
Workshop - Modify a Supplier Record.....................................................................................................15
Workshop - Add a Warehouse to a Part Record......................................................................................16
Daily Quality Assurance Processing....................................................................................17
Inspect Purchase Order Receipts.....................................................................................................................18
Receipt Entry..........................................................................................................................................18
Workshop - Order and Receive Parts................................................................................................19
Create a Purchase Order...........................................................................................................19
Create a Purchase Order Receipt...............................................................................................19
Inspection Processing..............................................................................................................................20
Workshop - Inspect Received Material..............................................................................................20
DMR Processing......................................................................................................................................21
Debit/Credit.....................................................................................................................................22
Workshop - Process a DMR Record...........................................................................................22
Miscellaneous Shipment Entry.................................................................................................................23
Workshop - Return Rejected Quantities............................................................................................23
Inspect Job Materials from Inventory..............................................................................................................24
Issue Material.........................................................................................................................................24
Quality Assurance............................................................................................................................25
Workshop - Issue Material to a Job..................................................................................................25
Nonconformance....................................................................................................................................26
Workshop - Enter Nonconformance for Job.....................................................................................26
Part Tracker............................................................................................................................................27
Suspect Material Investigation.........................................................................................................28
Workshop - Use the Part Tracker.....................................................................................................28
Nonconformance for Inventory...............................................................................................................29
Workshop - Enter Nonconformance for Inventory............................................................................29
Nonconformance Inspection Process.......................................................................................................30
Workshop - Inspect Nonconformance for Inventory.........................................................................30
Workshop - Inspect Nonconformance for Job..................................................................................31
Open DMR Status Report........................................................................................................................32
Workshop - Review the Open DMR Status Report............................................................................32
Non-Conformance Analysis Report.........................................................................................................32
Workshop - Review the Nonconformance Analysis Report................................................................33
DMR Processing......................................................................................................................................33
Workshop - Process DMR for Inventory............................................................................................33
Workshop - Process DMR for Job.....................................................................................................34
Labor Entry and Nonconformance..................................................................................................................36
This course discusses the flow of material through the Quality Assurance (QA) module and reviews the configuration
and maintenance setup. This course addresses various inspections and demonstrates how the Epicor application
processes them.
The course workshops guide you through the inspection process. This course covers how to dispose failed material,
return material to the supplier, and use report tools available in the QA module.
Upon successful completion of this course, you will be able to:
• Describe the material flow through the QA module.
• Configure the QA module options.
• Identify part classes, suppliers, and items that require inspection.
• Receive purchased items into inspection and disposition the items to stock or jobs.
• Move job material or job assemblies to inspection for analysis and disposition.
• Identify non-conforming material and move material to the Material Review Board (MRB) for analysis and
disposition.
• Receive returned material from a customer and dispose of it through inspection.
• Evaluate quality information through reports and trackers.
Read this topic for information you should know in order to successfully complete this course.
Audience
Prerequisites
To complete the workshops in this course, the necessary modules must be licensed and operating in your training
environment. For more information on the modules available, contact your Epicor Customer Account Manager
at EpicorCAM@epicor.com. It is also important you understand the prerequisite knowledge contained in other
valuable courses.
• Navigation Course - This course introduces navigational aspects of the Epicor application's user interface.
Designed for a hands-on environment, general navigation principles and techniques available in two user
interface modes - Classic Menu and Modern Shell Menu. Workshops focus on each of these modes and
guide you through each navigational principle introduced.
• Inventory Management Course - This course provides an overview of the entire inventory management
Environment Setup
The environment setup steps and potential workshop constraints must be reviewed in order to successfully
complete the workshops in this course.
Your Epicor training environment, in which the Epicor demonstration database is found, enables you to experience
Epicor functionality in action but does not affect data in your live, production environment.
The following steps must be taken to successfully complete the workshops in this course.
1. Verify the following or ask your system administrator to verify for you:
• Your Epicor training icon (or web address if you are using Epicor Web Access) points to your
Epicor training environment with the Epicor demonstration database installed. Do not complete
the course workshops in your live, production environment.
Note It is recommended that multiple Epicor demonstration databases are installed. Contact
Support or Systems Consulting for billable assistance.
• The Epicor demonstration database is at the same service pack and patch as the Epicor
application. Epicor's education team updates the Epicor demonstration database for each service pack
and patch. If your system administrator upgrades your Epicor application to a new service pack or patch,
he or she must also download the corresponding Epicor demonstration database from EPICweb > Support
> Epicor > Downloads and install it. If this is not performed, unexpected results can occur when completing
the course workshops.
• Your system administrator restored (refreshed) the Epicor demonstration database prior to
starting this course. The Epicor demonstration database comes standard with parts, customers, sales
orders, and so on, already defined. If the Epicor demonstration database is shared with multiple users
(that is, the database is located on a server and users access the same data, much like your live, production
environment) and is not periodically refreshed, unexpected results can occur. For example, if a course
workshop requires you to ship a sales order that came standard in the Epicor demonstration database,
but a different
restored user already
(refreshed), completed
then you will not bethis workshop
able and
to ship the theorder.
sales EpicorEpicor's
demonstration database
education was
team has not
written
the course workshops to minimize situations like this from occurring, but Epicor cannot prevent users
from manipulating the data in your installation of the Epicor demonstration database.
2. Log in to the training environment using the credentials manager/manager. If you are logged into your
training environment as a different user, from the Options menu, select Change User.
3. From the Main menu, select the company Epicor Education (EPIC06).
Workshop Constraints
All workshops in this course can be performed only once in each instance of a restored (refreshed) database. If
a user has already completed these workshops in the database, the database must be restored (refreshed) before
another user can complete this course.
Overview
The Quality Assurance module ties together all quality functions, including scrapping end parts, rejecting raw
materials, or tracking first article inspections. Review the general process flow of items inspected and dispositioned
through the Quality Assurance module.
Input to Inspection
Quality Assurance (QA) module processing begins with the purchase order receipt. Anything selected for inspection
is received in the QA warehouse. Inspection flags can be manually set in the Supplier Maintenance, Part Class
Maintenance, Purchase Order Entry, Job Entry, or Shipping and Receiving module.
• You receive returns through the QA area, although the major Return Material Authorization (RMA) interface
is owned by the Order Management module.
• If a particular article is used on a part, an operation for that purpose can be created. At the appropriate time,
the part is pulled off the line, checked, and returned to the job once it passes the inspection.
Non-Conformance Entry
Use the Non-Conformance Entry to add or update non-conforming materials during job production. Generally,
you enter non-conformance records because the material is bad, defective, or warrants an inspection. The material
can be an assembly, raw job material, scrap, items from a subcontractor, or parts from another source. The
information you enter is sent to an inspector, who then inspects the material and uses Inspection Processing
Entry to disposition it.
• A shop employee can create a non-conformance entry whenever a part displays off the line. The
non-conformance is entered during Labor Entry and the quantity in question can be moved to inspection.
• A discrepant assembly inspection can be requested off the floor.
Example John J. Labor discovers an assembly that is faulty and he wants an inspector to review it. He
generates a manual non-conformance, pulls the discrepant assembly off the floor, and sends it for
inspection. Once the inspection is complete and approved, it is returned directly to the job or sent to
DMR Processing for further evaluation.
Incoming materials are often received in QA before production ever knows they are there. QA completes the
inspection and returns the materials to inventory. This is called a discrepant inventory material inspection.
Discrepant subcontract items are pulled off at the operation and sent to QA.
• An item previously received to inventory can be removed from inventory if it is thought to be defective. A
non-conformance entry is required to make this happen.
• Discrepant Miscellaneous has no direct flow to QA. This can be used in a situation where an indirect corrective
action is required on an item that is not part related.
Application Setup
This section reviews the company configuration and goes through the maintenance program setup that affect
the Quality Assurance module.
To set up the inspection process, complete the following:
• Company Configuration
• User Account Maintenance
• Security Group Maintenance
• Identify inspection departments and inspectors.
• Define reason codes, shop warnings and global alerts.
• Set the Inspection Required check box in the appropriate programs.
Company Configuration
Use Company Configuration to define company options in the Epicor application. These options allow you to
customize the Epicor application to best fit each company.
Company configuration is usually done at the time of implementation. All Epicor application modules require
maintenance table definition, and the Quality Assurance (QA) module is no different. This section reviews
configurations and tables specific to the QA module.
(QA) module.
Receipt Inspection Options
The Receipt Inspection Options section contains the Default site and Default Inspection Warehouse fields.
Before material is received, an inspection warehouse and inspection bin must be defined in the QA module
configuration. The site must be valid and the warehouse does not have to be a physical warehouse. The warehouse
can be virtual, where the warehouse is actually a shelf in the back room.
It is recommended to use a descriptive name, such as Inspection Warehouse, to easily identify where materials
can be found. When items are selected as Inspection Required, the warehouse field populates with the name
defined in the QA module configuration.
Initialization Options
The Initialization Options section contains the Starting Non-Conformance ID and Starting Corrective Action
ID fields. All non-conformance and corrective action IDs are automatically assigned during their respective
processing. If a starting number is not defined, the Epicor application begins with number one.
Defaults
The Defaults section contains the Move Costs to DMR check box; this check box applies to assemblies and
controls the default action in the event of a failed assembly. By default, this check box is not enabled during
implementation; therefore, you can decide whether to move the cost of a failed item to the Discrepant Material
Report (DMR) after inspection or to leave the cost in the job.
When selected, costs for the failed assembly are moved from work in process (WIP) to the DMR pending accounts.
Keep in mind, the assembly costs are not removed from the job when the assembly moves to inspection. Those
costs are only removed when the assembly fails in inspection and is then moved to DMR. Material costs are
removed from the job as soon as the specific material is moved to inspection by default.
Menu Path
Navigate to this program from the Main Menu:
• System Setup > Company/Site Maintenance > Company Configuration
Use User Account Security Maintenance to enter basic information, security access, and application privileges
for users. Anyone who accesses the Epicor application must be set up in this program.
Users must have a defined user ID, name, and password. In this program, you can also define addresses, phone
numbers, and other company information.
Users are commonly created by the Epicor application implementation team. The System Administrator grants
security permissions based on the user's role in the company.
Menu Path
Navigate to this program from the Main Menu:
• ICE External > Security > User Security
• System Setup > Security Maintenance > User Account Security Maintenance
Important This program is not available in the Epicor Web Access.
User Security
User Account Maintenance > Security
Use
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a specific company. security
You then usegroups that define
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groups functions
to assign or limiteither throughout
access to various
areas within the Epicor application.
You can assign a user to a security group in User Account Maintenance, and then you can select security groups
on various security sheets in other programs. While optional, security groups are useful because they can categorize
employees by role or department.
Epicor recommends you create security groups and assign all users to specific groups. You then simplify your
security setup, as you do not need to assign security to individual users. This approach also ensures you implement
security through an organized and clearly defined method.
Before you begin assigning security, consider the various areas of security your company needs. You should then
design a security plan and enter security groups that reflect this plan. While you set up this plan, consider that
roles tend to be more generic, while job titles tend to be more specific. Several job titles can fulfill the responsibilities
of a single role.
Menu Path
Navigate to this program from the Main Menu:
• ICE External > Security > Security Group
• System Setup > Security Maintenance > Security Group Maintenance
Important This program is not available in the Epicor Web Access.
Menu Path: System Setup > Security Maintenance > Security Group Maintenance
Important This program is not available in the Epicor Web Access.
1. Click New.
4. Click Save.
In this workshop, authorize the security group you created in the Workshop - Create a Security Group.
Navigate to User Account Maintenance.
Menu Path: System Setup > Security Maintenance > User Account Security Maintenance
Important This program is not available in the Epicor Web Access.
3. From the Available list, select Quality Assurance and click the right arrow to move the group to the
Authorized list.
4. Click Save.
The Changes to security may take up to five minutes to take effect message displays.
Use Reason Code Maintenance to assign standard explanations for Customer Relationship Management (CRM)
events, labor scrap and rework, inventory adjustments, and Return Material Authorization (RMA) entries.
To use reason codes, select the appropriate options in Company Configuration. Next, set up the codes in Reason
Code Maintenance and select the reasons in the following programs:
• Count Discrepancy Reason Code Entry
• Time and Expense Entry
• Inventory Adjustment Entry
• RMA Processing
• RMA Dispositions
• Opportunity/Quote Entry
The following reason codes are used in manufacturing:
•
Scrap - This is used to identify a non-conformance quantity.
• Quality Assurance - This is used for inspection and corrective actions.
• Inventory Adjustments - This is used to identify items pulled from inventory that are non-conforming.
• Rework - This is used for items sent back to be re-worked.
Menu Path
Navigate to this program from the Main Menu:
• Financial Management > Deferred Revenue Accounting > Setup > Reason Code
• Material Management > Inventory Management > Setup > Reason Code
• Production Management > Job Management > Setup > Reason Code
• Production Management > Quality Assurance > Setup > Reason Code
• Sales Management > Customer Relationship Management > Setup > Reason Code
• Service Management > Field Service > Setup > Reason Code
For CRM users, the Main Menu appears as:
• Customer Relationship Management > Sales and Marketing Management > Setup > Reason Code
Example The Inspection section in Reason Code Maintenance includes check boxes which , when selected
for a specific reason code, ensure that the defined reason code displays in the Operations, Materials, PO
Receipts, and Inventory sheets in Inspection Processing Entry. The check boxes activate only if the DMR
reason type is selected in the Reason Type field.
In this workshop, define a new reason code for scrap due to rust or corrosion.
Navigate to Reason Code Maintenance.
Menu Path: Production Management > Quality Assurance > Setup > Reason Code
Since this new reason code is defined as scrap, the options listed under the Scrap section are automatically
selected. The options available depend on the Reason Code type selected. You can adjust the check boxes
as necessary for the specific code.
6. Click Save.
If the code is entered as part of the DMR or Inventory Adjustment types, you have the option to enter an
offsetting General Ledger (GL) account unique to that code.
When you select the Inspection Required check box, it indicates that the parts received must be inspected. The
Inspection Required check box controls inspection requirements for assemblies and materials in the following
programs:
• Part Class Maintenance
• Supplier Maintenance
• Job Entry
• Purchase Order Entry
• Requisition Entry
Note For more information about these programs, refer to the Application Help.
If the Inspection Required check box is selected in any of these programs, the part must be inspected. If an
inspection requirement is controlled at the maintenance program level, the field is not available at the transaction
entry level.
If you select
cannot changetheitInspection Required
anywhere in check
the Epicor box in either Supplier Maintenance or Part Class Maintenance, you
application.
• If the Inspection Required check box is set at a supplier level in Supplier Maintenance, all purchase items
from the supplier must be received to the inspection area before they can be released to the job or floor.
• If the Inspection Required check box is set at the part class level in Part Class Maintenance, it applies to all
class members and cannot be overridden. Although some General Ledger (GL) accounts are established in
the Company Maintenance > Control Account sheet, this sheet is one of the places where the default GL
accounts for inspection and Discrepant Material Report (DMR) can be overridden. In the Epicor application
hierarchy, part class has the highest override level.
Your company has decided to order part BS-CR-RD-150 from a supplied called Seaside Steel on a regular basis.
As a result, all of the ordered parts will have to go through an inspection process once they are received. In this
workshop, modify the Seaside Steel supplier record so all the received parts from this supplier go through inspection
before they are received to stock.
Navigate to Supplier Maintenance.
Menu Path: Material Management > Inventory Management > Setup > Supplier
As the BS-CR-RD-150 part requires inspection on receipt you have to link it to the warehouse used for the
inspection process. In this workshop, add the inspection warehouse for part BS-CR-RD-150.
Navigate to Part Maintenance.
Menu Path: Material Management > Inventory Management > Setup > Part
As reviewed in the Overview section, you can request inspections in several ways. This section focuses on the
quality assurance transactional processes for a purchase order receipt, receipt to inventory, non-conforming
quantity receipt, return material authorizations (RMAs), and first articles.
If the part number being received as material has been designated as Inspection Required, the items are sent to
the default inspection warehouse once Shipping and Receiving department receives the material. If all is well and
inspection
of order. approves the materials, they are transferred back to the job or into inventory, depending on the type
• If the material fails, it goes directly to the Discrepant Material Report (DMR) process. The DMR process has a
Material Review Board (MRB) that reviews the items and makes a second decision. If passed, the material
goes back to the job or to inventory.
• If the MRB fails the material, a corrective action is requested; the materials are rejected completely and returned
to the supplier. The MRB can also recommend to scrap the material rather than return it.
The Shipping and Receiving department and Quality Assurance department are not the same.
Receipt Entry
Use Receipt Entry to enter the receipt of inventory and non-inventory materials and subcontract parts.
Important Use RMA Processing to receive parts returned by the customer.
Receipt line items are either purchase order receipts (recorded against a purchase order) or miscellaneous receipts
(material received that is not associated with a purchase order). Receipt information updates the purchase order
and creates transactions to update inventory or job quantities and costs.
You cannot update invoice receipts.
If the Quality Assurance module is enabled in your environment, use Inspection Processing to inspect parts
you receive.
Receipt entries can be saved to generate accounts payable invoice entries. Use the Modules > Finance > Accounts
Payable sheet within Company Configuration to indicate whether you want to save receipt entries for accounts
payable.
If you have the Document Management module installed, you can add Certificate of Compliance documents
to the receipt line.
Menu Path
Navigate to this program from the Main Menu:
• Material Management > Shipping / Receiving > General Operations > Receipt Entry
Our company, ABC Shelving, has decided to order 50 units of part BS-CR-RD-150 (1 1/2" round bar) from the
Seaside Steel supplier. In this workshop, enter the purchase order for this part, select a buyer, and process the
receipt of the part.
The ordered items have arrived from Seaside Steel so the next step is to enter a new receipt. In this workshop
task, enter a new receipt for 50 units of part BS-CR-RD-150.
2. In the PO field, enter the PO number created in the Create a Purchase Order workshop task and press
Tab.
3. In the Packing Slip field, enter the PO number created in the Create a Purchase Order workshop task
and press Tab.
Inspection Processing
Use Inspection Processing Entry to inspect the non-conformance entries. You can also inspect purchase order
receipts and customer returns.
Important Once inspection information is entered for a non-conformance record, that record is considered
Closed; it cannot be updated or deleted.
For more information on the flow of discrepant/non-conformant material through the Quality Assurance module,
review the Quality Assurance module in the Application Help.
Menu Path
Navigate to this program from the Main Menu:
• Production Management > Quality Assurance > General Operations > Inspection Processing
The BS-CR-RD-150 parts are now in your warehouse waiting for inspection before they are used in production.
While the material was on truck, the steel straps holding the bundle of steel bars together broke. The outside
bars received nicks and scratches from hitting other steel bars on the truck. The inspector determines that 35 of
50 bars are okay and will be moved to stock, but 15 are questionable because of the nicks and scratches.
In this workshop, inspect the received items.
Navigate to Inspection Processing Entry.
Menu Path: Production Management > Quality Assurance > General Operations > Inspection Processing
2. In the Tran Type pane, select the All check box to disable check boxes.
3. In the Tran Type pane, select the PO Receipts check box and click Search.
4. Select the purchase order (PO) number created in the previous workshop and click OK.
5. In the tree view, expand the PO Receipts node. and select PO Receipts: PO: XXXX Line:1 Part:
BS-CR-RD-150 (where XXXX is the PO number created in the Create a Purchase Order Receipt workshop
task).
The PO Receipts > Detail sheet displays.
11. In the Application of Failed Quantity pane, in the Failed Qty field, enter 15.00.
This moves the remaining 15 bars to Material Review Board (MRB) pending.
12. In the Application of Failed Quantity pane, in the Reason field, select Failed, Shipping Damage.
16. In the Failed Comments pane, enter 15 pieces received nicks and scratches while in transit .
DMR Processing
Use DMR Processing to process job material, job assemblies, inventory, customer returns, or purchase order
receipts that fail inspection. These discrepant parts are then placed on the Discrepant Material Report (DMR).
In this program, you decide how to deal with discrepant parts. You can accept them, deciding they still can be
used, or you can reject them, sending them back to your supplier. You can create a debit memo request from
the supplier for the rejected parts.
Tip Packing slips for DMR rejected parts are processed in Miscellaneous Shipment Entry in order to
standardize shipping procedures and enable the tracking of parts returned to suppliers.
You can enter as many acceptances, rejections, and debit memo requests as necessary for a single DMR. For
example, you can accept a quantity into your stock, accept a quantity into a job material record, reject a quantity
and assign it an RMA number so you can return it to the supplier, and reject a quantity you will scrap. The rejected
and accepted quantity total must equal the discrepant quantity total on the DMR.
Important The Advanced Material Management (AMM) license automatically creates a Mtl queue
transaction to have the people on the floor move the goods from one area to another. At the DMR level,
whether the AMM license is installed or not, the user is able to process the DMR by accepting or rejecting
the material. Accepting means the defective material stays in the company for rework or is kept in stock
(even if defective). Rejecting means the company will take an extra action such as sending it back to the
supplier or asking for credit/refund.
For more information on the discrepant material flow through the Quality Assurance module, review the Quality
Assurance Module Flow topic in the Application Help.
Menu Path
Navigate to this program from the Main Menu:
• > DMR Processing
• Production Management > Quality Assurance > General Operations > DMR Processing
Debit/Credit
Use the Debit/Credit sheet to view debit/supplier credit memo information for a Discrepant Material Report
(DMR) quantity. You first request the debit memo or supplier credit memo using the Resolution field for the
DMR quantity in the Reject sheet, and process the actual demo or credit memo in AP Invoice Entry.
During the inspection process of part BS-CR-RD-150 the inspector found 15 damaged items and therefore had
to move them to another level of the quality assurance control process. The supplier offers to take the items
back, but the company decides to move five of them to stock because they can still be used, and return the ten
damaged ones back to the supplier. The supplier agrees to reimburse the company for the returned ones. In this
workshop, use DMR Processing to designate which quantities will be accepted or rejected, and suggest
reimbursement through a credit memo.
Navigate to DMR Processing.
Menu Path: Production Management > Quality Assurance > General Operations > DMR Processing
1. In the DMR Number field, enter the DMR number created in the Workshop - Inspect Received Material
and press Tab.
Use Miscellaneous Shipment Entry to enter packs for miscellaneous (non-billable) material. Use this program
to enter and print packs for the return of discrepant parts to a supplier from a Discrepant Material Report (DMR)
record.
Packs entered in this program are not invoiced, but they are tracked in the Miscellaneous Shipments Tracker.
You can also insert references to orders, jobs, or projects.
Tip Use Customer Shipment Entry to enter shipments to invoice.
Menu Path
Navigate to this program from the Main Menu:
• > Miscellaneous Shipment Entry
• Material Management > Shipping / Receiving > General Operations > Miscellaneous Shipment Entry
• Service Management > Field Service > General Operations > Miscellaneous Shipment Entry
In this workshop, return the rejected parts and generate a packing slip for the return of ten discrepant parts.
Navigate to Miscellaneous Shipment Entry.
Menu Path: Material Management > Shipping / Receiving > General Operations > Miscellaneous Shipment
Entry
2. In the Related To pane, in the PO Number field, enter the purchase order number created in the Create
a Purchase Order workshop task.
3. In the Related To pane, in the DMR Number field, enter the DMR number created in the Workshop -
Inspect Received Material and press Tab.
4. Click Save.
Field Data
Line 1
Part BS-CR-RD-150
Quantity 10.00
Occasionally, materials issued to a job or subcontracted parts are received to a job before a discrepancy is noticed.
Use the Quality Assurance (QA) module to move the parts from a job or from a subcontracted operation and
into QA for disposition.
Issue Material
Use Issue Material to issue material from inventory to a job. This program issues material to a job one part at
a time. To issue the required parts to a job at once, use Mass Issues to Manufacturing.
When you issue material to a job, several events occur:
• The IssuedQty and TotalCost values on the job material or assembly record update with the quantity issued
and the extended cost. Extended Cost is calculated as the issue quantity multiplied by the current inventory
Average, Standard, or Last unit cost (depending on the inventory costing method).
• The On Hand quantity and the Allocated quantity for the part in the part master file are reduced by the
quantity issued.
• A transaction history record is created for the part. The transaction type is STK-MTL (job material issue).
Important To use the Manufacturing Execution System (MES) to issue job material, the Advanced Material
Management (AMM) license must be installed in the Epicor application. Once you install this license, you
can define shop employees as Material Handlers in Shop Employee Maintenance; these users can then
issue or move material on the manufacturing center.
An AMM license must also be installed for proper access to the To Warehouse and To Bin fields in Issue
Material. If it is not, warehouse and warehouse bin numbers display in each respective field, but the fields
themselves are disabled and cannot be accessed. When this occurs, an Issue Material error displays when
you attempt to save the transaction. To save the transaction and get rid of the error message, you can use
the following workaround procedure:
4. Click into each warehouse field once; even if the field is empty and displays as disabled.
5. Change another control or field in the group (for example, by populating a field or selecting a check
box).
6. Click Save.
7. Navigate to the Resources sheet and repeat steps 2 - 5 for each resource that displays in the sheet.
Remember to click Save after changing a resource, and moving on to the next one. Do this for each
listed resource, and resource group.
Note If you complete this workaround properly, the error message should no longer display
in Issue Material and the To Warehouse field still displays as disabled, but also as empty (no
value). You can then click Save to complete the transaction.
Menu Path
Navigate to this program from the Main Menu:
•
Material Management > Inventory Management > General Operations > Issue Material
• Service Management > Maintenance Management > General Operations > Issue Material
Quality Assurance
Before quality assurance (QA) can inspect material from a job, material must be issued to a job. Issuing material
to a job is generally not a task of the QA department, but it is helpful to understand how materials are issued to
a job.
Assembly ADD-200-S needs 1,050 raw castings to be issued to job 2041. In this workshop, issue material to the
job.
Navigate to Issue Material.
Menu Path: Material Management > Inventory Management > General Operations > Issue Material
8. Click OK.
Important An Advanced Material Management (AMM) license must be installed for proper access
to the To Warehouse and To Bin fields in Issue Material. If it is not, warehouse and warehouse bin
numbers appear in each respective field, but the fields themselves are disabled and cannot be accessed.
When this occurs, an Issue Material error appears when you attempt to save the transaction. The
Application help for Issue Material contains a published workaround to use if this occurs.
Nonconformance
Use Nonconformance to add or update non-conformant materials during job production. Generally,
non-conformance records are entered because the material is bad, defective, suspect, or warrants inspection.
The material can be an assembly, raw job material, scrap, items from a subcontractor, or parts from another
source. The information you enter is sent to an inspector, who then inspects the material and uses Inspection
Processing to disposition it.
When non-conformant materials are reported through Time and Expense Entry as part of the employee’s work
record, and that record is saved, a non-conformance record is created that is then accessible in this program.
For these types of records, you can only modify the quantity and the reason fields in Nonconformance. The
other fields are unavailable.
For more information on the discrepant material flow through the Quality Assurance module, review the Quality
Assurance Module Flow topic in the Application Help.
Tip If your Epicor application is integrated with the IQS Advanced Quality Module (AQM), the AQM
application performs the inspection processes for jobs, inventory receipts, and purchase receipts.
To track these AQM records within Non-Conformance, Service Connect uses an identifier to link the AQM
record to the non-conformance record. This field, AQMNCMNum, is located on the List sheet. This label
is an abbreviation for Advanced Quality Module Non-Conformance Material Number and displays the
identifier originally generated by the AQM application.
Menu Path
Linda Carter (employee number 106) is working on part of a job and discovers there is a defective quantity of
150. In this workshop, enter a non-conformance quantity from a job and send the material to the inspection
area.
Navigate to Nonconformance.
Menu Path: Production Management > Quality Assurance > General Operations > Nonconformance
Part Tracker
Use the Part Tracker to access current information on parts in the database. This includes information such as
revisions, on-hand quantities, costs, locations, inspection, and planning data.
You can use the Part Search feature to pull multiple part records into the Part Tracker. The tracker displays only
one part at a time. You cannot add or edit records in this tracker.
Numerous sheets are available in the Part Tracker. Many of them are read-only versions of sheets that display in
Part Maintenance. The Part Tracker also pulls in Quality Assurance information for the part.
Use the Part field context menu to access additional programs. If you enter a part number in the Part field before
you select a program from the context menu, the program automatically populates with that part number. You
can access the following programs from the Part field context menu:
• Part Entry
• Part Transaction History Tracker
• Part Display
• Part Advisor
• Part Search
• Purchase Advisor
• Time Phase
• Job Manager
• Available to Promise
• Part On Hand Status
Additional information is available from the Part Tracker Actions menu, including:
• Approved Suppliers
• Forecast
• Configurator
• Where Used
• Master Production Schedule
• Price List
• Attachments
• Memos
• Change Logs
Tip To view inactive part records, create a special dashboard. To do this, copy the zPartTracker01 query
and change its filter settings to display parts that have the Inactive status. For more information, refer to
the Dashboard topic in the Application Help.
Menu Path
Navigate to this program from the Main Menu:
• Executive Analysis > Trackers > Part Tracker
• Material Management > Inventory Management > General Operations > Part Tracker
• Material Management > Purchase Contracts Management > General Operations > Part Tracker
• Material Management > Purchase Management > General Operations > Part Tracker
• Material Management > Shipping / Receiving > General Operations > Part Tracker
• Material Management > Supplier Relationship Management > General Operations > Part Tracker
•
Production Management > Engineering > General Operations > Part Tracker
• Production Management > Job Management > General Operations > Part Tracker
• Production Management > Material Requirements Planning > General Operations > Part Tracker
• Production Management > Quality Assurance > General Operations > Part Tracker
• Production Management > Scheduling > General Operations > Part Tracker
• Sales Management > Configurator Management > General Operations > Part Tracker
• Sales Management > Customer Relationship Management > General Operations > Part Tracker
• Sales Management > Order Management > General Operations > Part Tracker
• Sales Management > Quote Management > General Operations > Part Tracker
• Service Management > Field Service > General Operations > Part Tracker
For CRM users, the Main Menu appears as:
• Customer Relationship Management > Configurator Management > General Operations > Part Tracker
• Customer Relationship Management > Sales and Marketing Management > General Operations > Part Tracker
• Customer Relationship Management > Order Management > General Operations > Part Tracker
• Customer Relationship Management > Quote Management > General Operations > Part Tracker
If there is a discrepancy in the materials on a job, you may decide to check the materials that remain in inventory,
as well as material shipped to the customer. Both the Job Tracker and the Part Tracker are excellent tools to
review these jobs because they include the material and monitor transactions against the part.
The item under investigation is a lot number tracked item. The lot number is referenced throughout the process
of the parts and therefore, can help locate the parts down to the machine they came from. Any time a lot number
is active, it must be referenced throughout the Epicor application. In this workshop, review the transaction history
for part CS-87-4578 using the Part Tracker.
1. In the Part field, right-click CS-87-4578 and select Open With > Part Tracker.
3. Right-click the Part field, and select Open With > Part Transaction History Tracker.
The Part Transaction History Tracker displays.
Use the Inventory sheet to add, update, or delete non-conformance records that relate to discrepant material
in inventory. You can only update or delete open non-conformance records. Open non-conformance records
have not been processed through inspection yet.
Due to the problem with previously issued material, Linda Carter has been assigned to check the remaining
inventory for part CS-87-4578 to make sure that there are no any defective pieces. During the inventory check
she did not find any corroded pieces but discovered that further 150 items do not meet dimension standards. In
this workshop, enter nonconformance for material CS-87-4578.
Navigate to Nonconformance.
Menu Path: Production Management > Quality Assurance > General Operations > Nonconformance
Important An Advanced Material Management (AMM) license is required for the Request Move
check box to be selected by default. This check box is cleared and greyed out if the user does not
have the AMM license.
After non-conformance entries are made, notify the Epicor application to return the items by completing the
inspection process.
4. In the Search Results grid, select the inventory record for part CS-87-4578 and click OK.
5. In the tree view, select Inventory > Inventory: Part CS-87-4578 Qty 150.00.
The Inventory > Detail sheet displays.
10. In the Failed pane, in the Failed Qty field, enter 50 and press Tab.
13. In the Failed pane, in the Bin field, search for or verify bin MRB-1 displays.
15. In the Failed Comments pane, enter The specifications were incorrect when this product was
designed.
During the Inspection Process for the CS-87-4578 material, the inspector determines that 100 units can be
returned to job 2041 and 50 units do not comply with material standards. In this workshop, inspect 150 units
of part CS-87-4578.
3. In the Tran Type pane, select the Job Material check box and click Search.
4. In the Search Results grid, select the job 2041 record and click OK.
7. In the Application of Passed Quantity pane, in the Passed Qty field, enter 100 and press Tab.
10. In the Application of Passed Quantity pane, in the Bin field, verify bin MCH displays.
11. In the Application of Failed Quantity pane, in the Failed Qty field, enter 50 and press Tab.
12. In the Application of Failed Quantity pane, in the Warehouse field, verify MRB Pending displays.
16. In the Failed Comments pane, enter The specifications were incorrect when this product was
designed.
The DMR Number = XXXX (where XXXX is your DMR number) message displays.
Important For more information on how to review the status of a report you print, preview, or generate,
refer to the System Monitor Overview topic in the Application Help.
Menu Path
Navigate to this program from the Main Menu:
• Production Management > Quality Assurance > Reports > Open DMR Status
2. Use the right arrow at the top of the report to find the transaction history for both previously created DMRs.
3. Review the Transaction History section for both DMRs and close the Open DMR Status Report.
Use the Non-Conformance Analysis report to list all non-conformance entries within a particular date range.
This report is separated by defective units, material issues, and scrapped materials. Cost totals are also provided
for defective units, material issues, and scrapped materials.
Use the Selection sheet to select the report parameters. Use the Filter sheet(s) to select the specific records to
include on the report. For more information, refer to the Filters Overview topic in the Application Help.
Important For more information on how to review the status of a report you print, preview, or generate,
refer to the System Monitor Overview topic in the Application Help.
Menu Path
Navigate to this program from the Main Menu:
• Production Management > Quality Assurance > Reports > Nonconformance Analysis
DMR Processing
Now that the inspection process is complete, the Discrepant Material Request (DMR) must be processed.
The inspector failed 50 out of 150 castings due to the failed dimension specification so the castings must now
go through the Discrepant Material Request (DMR) process. In this workshop, process the DMR created in the
Workshop - Inspect Nonconformance for Inventory.
Navigate to DMR Processing.
Menu Path: Production Management > Quality Assurance > General Operations > DMR Processing
1. In the DMR Number field, search for and select the DMR for inventory created in the Workshop - Inspect
9. Click Save.
In this workshop, process the DMR created in the Workshop - Inspect Nonconformance for Job.
2. In the DMR Number field, search for and select the DMR for inventory created in the Workshop - Inspect
Nonconformance for Job.
Employees track their time through Time and Expense Entry. In addition to recording time against operations
and jobs, an employee can create a non-conformance if he discovers damaged materials during production. As
the employee enters time against a job or operation, any discrepant quantity can be entered in the
Non-conformance field.
Use Time and Expense Entry to enter labor into the Epicor application from the Job Management module.
You can also enter labor directly from the site floor using the Data Collection module and the Manufacturing
Execution System (MES).
Important Use Time and Expense Entry, to change labor entered through Office Data Collection and the
MES. However, multiple breaks are deducted from pay time only if the time is entered through Office Data
Collection.
Menu Path
Navigate to this program from the Main Menu:
• Production Management > Job Management > General Operations > Time and Expense Entry
• Service Management > Expense Management > General Operations > Time and Expense Entry
• Service Management > Field Service > General Operations > Time and Expense Entry
• Service Management > Maintenance Management > General Operations > Time and Expense Entry
• Service Management > Project Management > General Operations > Time and Expense Entry
• Service Management > Time Management > General Operations > Time and Expense Entry
7. Click Save.
3. In the Tran Type pane, select the Operations check box and click Search.
Corrective Action
Use Corrective Action to specify what actions to take on non-conforming items. These items are specified in
non-conformance entries in Nonconformance.
A corrective action entry consists of a description of the action to take, the non-conformance entry the description
applies to, the employee responsible, the date the action must occur, and the inspection information.
Example Non-conformance
The description entry
for the corrective 1255is:states
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Reprint three
the pens
labels do not
on the have
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in response to them as specified.
non-conformance
entry 1255. This action is assigned to the Printing department, to employee number 200 and has a due
date one week from today. An inspector can re-inspect these pens on a particular date.
This program interfaces with DMR Processing. When an entry is added or updated in DMR Processing, if a
Non-conformance entry number is specified, Corrective Actions entered in this program can be viewed or edited.
Corrective Action can be accessed from the following places:
• General Operations folder for the Quality Assurance module
• Inspection Processing
• DMR Processing
• RMA Dispositions
For more information on the flow of discrepant material through the Quality Assurance module, refer to the
Quality Assurance Module Flow topic in the application help.
Menu Path
Navigate to this program from the Main Menu:
• Production Management > Quality Assurance > General Operations > Corrective Action
At times, management can decide to look further into the reason why material fails inspection. Reasons why
material fails inspection can include a problem with the supplier or with material storage.
The Material Review Board (MRB) can open a corrective action to determine the cause of material failure and
how to fix the problem. The first step to initiate a corrective action is to have the MRB determine if the failed
parts must be returned, re-worked, or scrapped. The entry of a corrective action includes a description of the
action to take and provides a comment section to record steps taken to resolve the problem. Information including
the employee(s) responsible for the investigation, deadlines, and needed changes to the inspection format after
the correction are all part of the action itself.
Once the MRB creates a corrective action record, that record is accessible through DMR Processing where it can
be viewed and edited.
The MRB can investigate a non-conformance to determine if the faulty items are due to an internal process or
the supplier's process. A corrective action provides an action trail until the issue is resolved. At that time, the
corrective action is closed.
Note The initiation of a Discrepant Material Report (DMR) can also lead to an investigation of why the
problem occurred. This can be useful in the case of supplier materials.
Management opened a corrective action to determine if the cause of the corroded items is due to internal storage
and handling or if it is supplier related. This task is assigned to John J. Lewis. In this workshop, create a corrective
action for the corroded items and track the investigation results.
1. In the DMR Number field, search for and select the DMR number created in the Inspect Nonconforming
Entry workshop task.
5. In the Due Date field, enter the date one week from today.
8. In the Comments pane, enter Need to determine whether the cause of the corrosion is an internal
storage issue or a supplier material problem .
Response Tracking
John J. Lewis determined that the cause of the corrosion is due to a new process the supplier is using to extrude
the material. In this workshop task, record this information as an action comment.
2. In the Comments field, enter Spoke with Seaside Steel and they have just started a new process to
extrude materials.
3. Click Save.
8. Click Save.
RMA Processing
In most cases, a return material authorization (RMA) is issued to a customer by sales when there is a defective
materials complaint. Once the RMA is issued and the customer returns the defective material, the Shipping and
Receiving department receives the material.
The RMA is tied to the customer who returns the materials. The details are entered from the purchase order,
unless the RMA was received directly from the customer. The sales order must always be referenced but does
not have to be an open order, so the former sales order can become part of the new job created for rework of
the materials. In addition, the RMA order line must be tied to the original sales order for costing and credit
purposes. Job costs can be retrieved even if the sales order and job are closed.
Use Return Material Authorization to control and track customer returns. Enter information about the return
and communicate that information to the different groups that need to take action, such as inspection, billing,
and order processing.
The
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returns. does notprovides
RMA Processing automatically create credit ortools
the communication shipping transactions,
to ensure or rework
the necessary jobs
actions arebased
takenonfor
customer returns. Based on the reason for the return and customer needs, you can enter or change jobs, create
credit transactions in the Accounts Receivable module, or re-ship parts as necessary.
Menu Path
Navigate to this program from the Main Menu:
• Financial Management > Accounts Receivable > General Operations > RMA Processing
• Material Management > Shipping / Receiving > General Operations > RMA Processing
• Sales Management > Customer Relationship Management > General Operations > RMA Processing
• Sales Management > Customer Relationship Management > General Operations > RMA Processing with
Service Connect
• Sales Management > Order Management > General Operations > RMA Processing
• Service Management > Field Service > General Operations > RMA Processing
For CRM users, the Main Menu appears as:
• Customer Relationship Management > Sales and Marketing Management > General Operations > RMA
Processing
• Customer Relationship Management > Sales and Marketing Management > General Operations > RMA
Processing with Service Connect
• Customer Relationship Management > Order Management > General Operations > RMA Processing
You received a call from customer IMC. The customer says they are rejecting an order for 500 units of a proprietary
item. They noticed some of the cartons showed water damage and when they opened one of them, the top
layer of items was corroded. They are rejecting the entire shipment and sending the items back. In this workshop,
issue Return Material Authorization (RMA) for the units being returned and receive the units.
8. Click Save.
10. Remain in Return Material Authorization for the next workshop task.
The Return Material Authorization (RMA) is issued. Customer IMC returned the items and they are waiting in the
dock to be processed by the Shipping and Receiving department using the RMA Receipt functionality. In this
workshop task, receive the returned items.
5. Click Save.
Once the material is received, the items are moved to the Quality Assurance department. The material is visible
online in Inspection Processing Entry.
The inspector determines how to disposition the parts: stock, job, or fail. The disposition selected depends on
the status of the job and part.
Move Items to Stock
The inspector signs off on the quantity received and where it was sent. The transaction code becomes INS-STK.
Move Items to a Job
If the part needs rework and the job is still open, the items can be returned to the job for rework. An operation
is added to perform the rework. In addition, the operator should select the Rework check box in Labor Entry so
the rework activity is viewable in reports. Once items are reworked, they can be received to stock (if it is a stocked
item) and re-shipped to the customer.
Fail Items.
Line by line information is added with the quantity. An appropriate reason code is required, and, if applicable, a
corrective action can be created at the same time.
If the part must be scrapped, a new job must be opened to build replacement items. The sales order must be
re-opened with another line added to ship the items again. To avoid invoicing the customer again, enter the sales
order line at a zero price.
A non-conformance entry is not created if the item is dispositioned from inspection to stock or rework. A
non-conformance entry is created only if the item is scrapped. The non-conformance can also be created manually.
Note If the decision is made to credit the customer, a credit memo can be generated directly from the
Return Material Authorization (RMA). Each line detail is entered separately, and the amounts can be
overridden any time. Although this process creates a miscellaneous invoice with the job header information,
the invoice does not go through the Epicor application as a live credit memo at this point. Once a suggestion
is created, the request is sent to Accounts Receivable for processing.
Once Return Material Authorization (RMA) items are received, the inspector determines the items' disposition.
One hundred out of five hundred items passed inspection and will move to stock. The remaining defective items
will be corrected.
Navigate to Inspection Processing.
Menu Path: Production Management > Quality Assurance > General Operations > Inspection Processing
3. In the Tran Type pane, select the RMA's check box and click Search.
4. Select the RMA created in the Issue RMA for Material workshop task and click OK.
7. Click New.
The Disposition > Detail sheet displays.
13. Navigate to the Disposition > Comment sheet and enter 100 units accepted.
23. In the Assigned To field, search for and select John J. Lewis.
24. In the Due Date field, select the date one week from today.
A credit memo can be requested at any point during the Return Material Authorization (RMA) process. In some
organizations, a credit memo is requested immediately upon issuing an RMA. In other companies, the credit
memo request is held until after the inspection process.
After a request is processed, it is pulled into Accounts Receivable by a get RMA process similar to the get DMR
process.
First Articles
Engineering enters a First Article Sample Quantity on the job operation that requires first article inspection.
This entry provides Engineering the ability to determine where first articles are necessary and of what sample size
per operation.
When a job with such an operation is released to the site floor, the Epicor application generates a site floor
warning. In addition, you can specify to alert Inspection through email. When a shop employee clocks into such
an operation through Data Collection, a new first article record is added to the First Article Inspection queue.
You also can establish a shop warning that notifies Inspection electronically through e-mail.
Procedures
A QA inspector selects First Article inspection records from the inspection queue. If data collection was not used,
the inspector can manually add an inspection record. Either way, the QA inspector processes the first article and
determines the status based on external documents that may be tied to the first article record through document
management. Status options include Approved, Provisional, Resubmit, and Waiting. The status is marked
by a Job/Assembly/Operation combination and by machine/resource.
•
All quantity updates that are good, scrap, and non-conformance are done through labor processing and
tracked by an audit log. If the status is Resubmit, a new first article queue record is generated. Each time a
first article is processed, a new transaction is generated.
• If the first article status is Approved, shop employees can clock in to production for the Job/Assembly/Operation
and machine/resource. If the status is Resubmit or Waiting, this cannot be done.
• If the status is Provisional, shop employees can clock in to production for the Job/Assembly/Operation and
machine/resource; an option is that the employee can receive a shop warning to alert him or her of the status.
The responsibility lies with the shop employee and Quality Assurance personnel to document the provisional
status and ensure compliance.
An operation is coded when a first article inspection is necessary. To code an operation, complete a field with
the number of first articles that must be submitted. For this process to work correctly, the operation must also
have a setup time designated. When a site floor employee reports that setup has started, an entry is placed in
the inspection queue under the First Article sheet.
In this workshop, select a job in Job Entry and specify the number of first articles required. Clock in to setup in
the Manufacturing Execution System (MES), clock into Production on the job modified, and perform the inspection.
Navigate to Job Entry.
Menu Path: Production Management > Job Management > General Operations > Job Entry
2. In the tree view, right-click the job number and select Tree > Expand Tree.
4. Click OK.
The MES Menu displays.
9. Click OK.
The Inspection Pending Report lists all items you have received to inspection through Receipt Entry or Return
Material Authorization.
This report includes the value of each item received to inspection, as well as the total value of all items awaiting
inspection. It also indicates if there is a variance in the costs. If there is an asterisk (*) next to a cost, there is a
variance between the purchase order cost and invoice cost for the receipt.
Important For more information on how to review the status of a report you print, preview, or generate,
refer to the System Monitor Overview topic in the Application Help.
Menu Path
Navigate to this program from the Main Menu:
• Production Management > Quality Assurance > Reports > Inspection Pending
In this workshop, inspect and approve the first article for job 2094.
Navigate to Inspection Processing Entry.
Menu Path: Production Management > Quality Assurance > General Operations > Inspection Processing
3. In the Tran Type pane, select the First Articles check box and click Search.
5. In the tree view, select First Articles (1) > First Articles: Job: a2094 Part: DCD-100-SP Qty:5.00 .
The First Articles > Detail sheet displays.
Conclusion
Index
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