Out of route operations and reroutes

Out of route operations and reroute flows during a process flow are important FactoryLogix concepts.

• An out of route operation is an operation that assemblies can be sent to—but are not necessarily required to satisfy the route.
  
  For example, a rework or repair operation may be needed when an assembly is identified as having defects that need to be fixed. However, not every assembly in the batch needs to be sent to this repair station—this is considered an out of route operation. The example in this topic features two out of route operations: Rework and Re-Test.
  

• When you combine several out of route operations into a "mini" process flow, it is referred to as a reroute flow. A reroute flow occurs when an assembly needs to be removed from the normal process flow to one or more alternate operations.
  
  The most common example of a reroute is a rework or repair operation. A defect is found at an inspection operation and the assembly must be rerouted to a repair operation, then to a supplemental test operation, and finally back to the original process flow.
  
  In addition, you can set up complex reroute flows for cases where assemblies should go to two or more out of route operations as a result of a failure. Upon failing an Exit Condition check, assemblies can be automatically forced to an out of route or a reroute flow.

Create an out of route operation

You configure out of route operations in the Entry/Exit area of an operation in the NPI Process Definition window.

1. Log into the NPI client application.

2. Select Templates and Standards  > Process Templates.

3. Open an existing process flow (or create a new one), then expand the Out of Route Operations section in the Process tree (under the main process flow).

4. Select Add > Out of Route Operation.

5. In the New Out of Route Operation dialog, enter a name such as Rework, select the option for Full Tracking, then select OK.
   
   

   

   
   
   

   The new operation will appear in the Out of Route Operations section of the Process tree. This procedure is adequate for most simple inspection/repair reroute situations where a defect is found, the assembly is rerouted to repair, then back to the original inspection operation for re-inspection. 
   
   
   

   

Note

You can also set up complex reroute flows for cases where assemblies should go to two or more out of route operations as a result of a failure. Upon failing an exit condition check, you can force assemblies to an out of route or a reroute flow automatically.

Once a reroute is satisfied, you can choose to return the assembly to the next operation in the process flow, to the current operation, or to a different operation you select.

Complex reroutes

In some cases, a more complex reroute may be necessary. Perhaps an additional test or x-ray operation is needed to further diagnose an issue. A complex reroute flow can be created to accommodate this.

1. Building on the previous example, select Add  > Out of Route Operation.

2. In the New Out of Route Operation dialog, enter a name such as Re-test with Full Tracking, select the option for Full Tracking, then select OK.
   
   
   

   

   
   
   Now that there are several out of route operations, you can put them into a reroute flow.
   

3. Select Process Flow in the Process tree.

4. Under Current Flow, select Add  > Reroute, enter the name Complex Reroute, then select OK.
   
   This new reroute flow displays in the Reroutes section of the Process tree.
   

5. Right-click the new reroute flow, select Create Operation Link, then select the rework Out of Route.

6. Repeat Step 4 for the Rework operation.
   
   The reroute flow will now behave as a sort of mini process flow. If an Assembly is rerouted to this flow, it must satisfy the route, in order, before returning to the main process flow.

Just In Time (JIT) reroute

A Just In Time (JIT) reroute allows a user in Production (with the appropriate rights) to construct a customized reroute flow "on the fly" that is appropriate for the work that needs to be done. With a JIT Reroute, a list of all possible out of route operations is defined in the process flow in advance. Then a reroute is created but the Route To option is defined as Just In Time (JIT) with any other applicable options. When this option is selected, users on the factory floor will be presented with an environment to create a custom reroute "on the fly". First, you create all possible out of route operations in the process flow that might be needed in a JIT reroute. Once operations are created along with the appropriate steps and activities for each, you can create a new reroute using the Route To option and set it to Just In Time Route.

Once a JIT Route is defined in Production, it remains available as a possible reroute for the life of that process so operators won't need to define the same route over again.