Quantity Tracking
Understanding how good parts, scrap, and rework are tracked throughout production.
The Three Quantity Categories
Every work order tracks parts produced in three categories: Good (parts that meet all specifications and are ready for the next operation or shipment), Scrap (parts that cannot be corrected and must be discarded), and Rework (parts that have a defect but can be corrected by returning to a previous operation). Maintaining accurate counts in all three categories is essential for yield tracking, cost analysis, and customer delivery commitments.
Updating Counts
Operators update quantity counts from the station panel as production proceeds. After inspecting a batch, enter the number of good parts, scrap, and rework. The system adds these to running totals for the work order. You can update counts as frequently as you like — some operators update after every piece, others after each batch or inspection interval.
The Running Total Bar
The station panel displays a progress bar and numeric summary showing: Good/Required (e.g., 42/100), plus Scrap and Rework counts. The system validates that Good + Scrap + Rework does not exceed a reasonable total (based on the order quantity plus allowable overrun). If the numbers seem inconsistent, a warning appears prompting you to verify your counts.
Yield Calculation
Yield (also called First-Pass Yield) is calculated as: Good / (Good + Scrap) × 100%. For example, if you produced 95 good parts and 5 scrap, your yield is 95%. This metric appears on the quality dashboard and is tracked per work order, per station, and per operator over time. High yield indicates consistent quality; declining yield signals a problem that needs investigation.
Impact on Work Order Status
When the Good count meets or exceeds the Required quantity, the work order can be marked as Complete. If significant scrap occurs and you cannot meet the required quantity with remaining material, notify your supervisor — they may need to order additional material or adjust the customer commitment. The system does not automatically complete orders based on counts; a human decision is always required.