Fine Chemical Flow Library ← Flow library

Repair / Rework + Defect Records — log defective goods to repair, record the repair result, return repaired goods to the next process

Fine Chemical (FC) · Module MES · v0.6 · 13/10/2026 · Standard flow — for implementation, testing and development

Process Flow (swimlane)

MES · Repair / Rework + Defect Records — Pending repair after Injection creates repair records automatically, the repair team reworks, QC records Repaired / A- / ScrapPhaseInputQCOperator (Repair team)OutputReport — Defect Records (grade C scrap recorded at POP, including Daily Injection)hand to repair teamrepairedYesNoNoPassSource "Spray Out · Pending repair" · "Packing Spray · Pending repair"Source "Trimming · Pending repair"Source "Stitching · Pending repair" · "Packing Logo · Pending repair"Downgrade to A- > 0Scrap > 0YesNoPending repair after Injection,each size with PR > 0 (Trimming ·Stitching · Spray Out ·Packing Logo · Packing Spray)Master data: Root Cause· Defect ReasonMaster dataGrade C (scrap) recorded at POPevery process (Injection ·Trimming · Stitching · Spray Out· Packing Logo · Packing Spray)▣ Repair / ReworkCreate Repair / Rework recordfor each size with PR > 0System (auto)Repair defective goodsAt repair area▣ Repair / ReworkOpen PENDING recordWeb▣ Repair / ReworkEnter Repaired · A-· ScrapWeb▣ Repair / ReworkSelect Root CauseWebScrap needingmake-up?▣ Repair / ReworkTick Re-plan WOWeb▣ Repair / ReworkSave repair resultWebTotal = Qty andRoot Cause set?▣ Repair / ReworkSet record statusSystem (auto)▣ Repair / ReworkMove Repaired OK goodsto Repair Inv ListSystem (auto)▣ Repair / ReworkBook the A- part toCommon StockSystem (auto)▣ Repair / ReworkBook the Scrap partas LossSystem (auto)TickedRe-plan WO?▣ Repair / ReworkCreate make-up demandfor the WOSystem (auto)▣ Defect RecordsWrite Defect Records rowsone row per reasonSystem (auto)▣ Defect RecordsFilter Defect RecordsWeb▣ Defect RecordsExport Defect RecordsWebSave blocked — error shownon the Repair Result modalRepair Inv List ofPacking Planning SprayStep 2 · Select Repair InventoryRepair Inv List → Step 2 ofOutsourcing Planning orPacking Planning Logo(by plan type)Repair Inv List — next processnot yet determined (Stitching ·Packing Logo)A- downgrade → Common StockScrap → LossMake-up demand → MasterPlan (re-plan WO)Closed record · view onlyFile Excel Defect RecordsThe system automatically creates one Repair / Rework record for each size with Pending repair in the processes after Injection; QC does not create records by hand. When: the user records output at Trimming Result, Process Worklist, Outsourcing Result, Packing Result Logo or Packing Result Spray and the "Pending repair" (PR) cell of that size is greater than 0. System: each size with PR > 0 creates one RW-nnnn record carrying LOT No. · WO No. · SO No. · Item · Size, Qty = the PR of that size, Source = "<Process> · Pending repair" (five labels: "Trimming · Pending repair" · "Stitching · Pending repair" · "Spray Out · Pending repair" · "Packing Logo · Pending repair" · "Packing Spray · Pending repair"). Result: the record is PENDING; the "PENDING … pairs" KPI adds the pairs; the Defect column of the record shows "Pending repair". Blocked when: grade C creates no record — C is scrap and is only written to Defect Records by reason; Daily Injection has no PR, so it creates no record either. Test: - Trimming Result PR = 40 (W7 30 + W8 10) → 2 records "Trimming · Pending repair": W7 qty 30, W8 qty 10 - The same entry has C = 20 → Repair / Rework gets no record, Defect Records gains 1 row Source: Q-20261013-01 · prototype v0.91The repair team reworks the goods according to the defect written on the record (e.g. "Cut edge rough", "Burr / flash"). System: a manual step, no screen action ("Operator/technician processes the fix/rework action"). Result: repaired goods go back to QC to record the result; the repairer and repair time are entered in "Repaired By" · "Repair Time (min)". Source: BRD §6.5 · prototype v0.91QC opens a waiting record to record the repair result. When: the record is PENDING. Action: screen subtitle "EXC-01 · Pending repair of every process after Injection, one record per size (created by the system) — repair result and WO re-plan"; filter "STATUS" (All · Pending · Repaired · Downgraded · Scrapped) / "SOURCE" (All · "Trimming · Pending repair" · "Stitching · Pending repair" · "Spray Out · Pending repair" · "Packing Logo · Pending repair" · "Packing Spray · Pending repair") / "SEARCH" › button "Record" on the row › box "Repair Result · RW-nnnn". Test: - A closed row → the button is "View", it reopens the saved numbers (e.g. 3 / 1 / 1) and cannot be recorded again Source: Q-20261013-01 · prototype v0.91QC splits the pairs of the record by repair result. Action: cells "Repaired OK (A/A-)" (default = Qty) · "Downgrade to A-" · "Scrap" (default 0); enter "Repaired By" · "Repair Time (min)". System: QC reviews the result and closes the quality decision ("QC reviews fix/rework result and closes the quality decision."). Source: BRD §6.5 · prototype v0.91QC selects the root cause of the defect. Action: required cell "Root Cause" — Mold wear · Machine setting · Material lot · Operator handling · Tooling / blade · Color batch · Other. Source: prototype v0.91Is make-up production needed for the Scrap part? Yes: tick Re-plan WO. No: just save the result. Open: who decides (Planner or QC) is not decided. Source: prototype v0.91QC requests make-up production for the Scrap part. Action: tick "Re-plan <WO> for the scrapped quantity (creates a make-up demand on the master plan)". Result: on save, the system records the make-up request for the WO (later step). Source: prototype v0.91QC saves the repair result. Action: button "Save Result". Result: the system checks the numbers (next step) and then closes the record. Open: editing a record after saving (reversing entry) has no path yet. Source: prototype v0.91 · convention Q3The system checks the result before closing the record. Pass: "Repaired OK" + "Downgrade to A-" + "Scrap" = the Qty of the record and "Root Cause" is selected. No: not saved, an error shows on the "Repair Result" box. Test: - Qty 10: Repaired 7, A- 2, Scrap 1 → can be saved - Qty 10: Repaired 7, A- 2, Scrap 0 → blocked - Numbers complete but no Root Cause → blocked Source: prototype v0.91The system closes the record and sets its status by the result; from PENDING there are only three branches, no way back. System: Scrap = Qty → SCRAPPED; Repaired OK > 0 → REPAIRED; otherwise → DOWNGRADED. Result: fields lock, the "Record" button becomes "View", the REPAIRED · A- · SCRAP columns show the quantities; message "RW-nnnn closed — n repaired, n downgraded A-, n scrapped". Test: - Qty 5, Scrap 5 → SCRAPPED - Qty 5, Repaired 0, A- 3, Scrap 2 → DOWNGRADED Source: Q-20260918-29 · prototype v0.91The system puts the Repaired OK part into the Repair Inv List so the next process can pick it up; the destination depends on the Source of the record. When: "Repaired OK" > 0. System: "Spray Out · Pending repair" and "Packing Spray · Pending repair" → Packing Planning Spray › Step 2 · Select Repair Inventory, not back to Step 2 of Outsourcing Planning; "Trimming · Pending repair" → Step 2 of Outsourcing Planning or Packing Planning Logo, by plan type; for "Stitching · Pending repair" and "Packing Logo · Pending repair" see Open. Test: - "Spray Out · Pending repair" W5 Repaired 10 → shows in Packing Planning Spray Step 2 (10 pairs), not in Outsourcing Planning Step 2 - "Trimming · Pending repair" W7 Repaired 20 → shows in Step 2 of Outsourcing Planning (W7 = 20) Open: "Stitching · Pending repair" has no destination Repair Inv List because the process after Stitching is not determined (OQ-122); "Packing Logo · Pending repair" has no destination either (OQ-126). Source: Q-20260918-29 · Q-20261013-01 · prototype v0.91The system writes the downgraded A- part into Common Stock. When: "Downgrade to A-" > 0. Result: the A- goods are split from the SO and go into Common Stock. Open: prototype v0.91 has no Common Stock figures for this step; whether A- into Common Stock goes through FG Receipt. Source: Q-20260918-29The system writes the Scrap part as loss (Loss). When: "Scrap" > 0. Result: the Scrap quantity is written as Loss. Open: prototype v0.91 only shows the number in the SCRAP column, it does not write Loss. Source: Q-20260918-29 · Q-20261012-04Did QC tick Re-plan WO when saving? Yes: create make-up demand for the WO. No: the record is closed, view only. Source: prototype v0.91The system creates the make-up production demand for the WO on the Master Plan. Result: make-up demand is sent to the Master Plan; the record row carries the chip "Re-plan requested" and the message "· re-plan requested for <WO>". Test: - Tick Re-plan, Scrap 3 → the Master Plan has a make-up demand of 3 pairs for the WO Open: prototype v0.91 only shows the chip "Re-plan requested", it does not create the make-up demand on the Master Plan. Source: prototype v0.91The system writes each defect reason of grade C as one Defect Records row, by process, WO and SO. When: the user records output with C > 0 at Daily Injection (Process "Injection"), Trimming Result ("Trimming"), Process Worklist ("Stitching"), Outsourcing Result ("Spray Out"), Packing Result Logo ("Packing Logo") or Packing Result Spray ("Packing Spray"). System: C must be fully split across reasons before writing; Packing Result with missing or mismatched reasons → "Grade C quantity recorded — map the defect quantity to a defect reason." and nothing is written. Pending repair is not written to Defect Records. Result: each row has Date · Shift · Process · WO No. · SO No. · Customer · LOT No. · Item · Defect Qty · Defect Reason · Detail · Operator; C is scrap, so it creates no Repair / Rework record in any process. Test: - Daily Injection C = 12, reason "Air bubble / porosity" → one row added, Process "Injection", qty 12, Repair / Rework gets no new record - Trimming Result C = 20, PR = 40 → Defect Records gains one row of qty 20 and Repair / Rework gains records for 40 Open: WO No. on Defect Records uses an alias (e.g. "WO-2608-02") while Repair / Rework uses the real WO code (e.g. "WO-20260803"). Source: Q-20261013-01 · prototype v0.91The user filters the defect list by time, shift and process. Action: filters "FROM" · "TO" · "SHIFT" (All · Shift A · Shift B) · "PROCESS" (All · Injection · Trimming · Stitching · Spray Out · Packing Logo · Packing Spray) · "SEARCH". Result: the KPI "Total defect … pairs" and the total per Process are recalculated by the filter; the screen is read-only, rows cannot be edited; the same data shows on the "Defects" tab of Work Order Detail. Source: Q-20261013-01 · prototype v0.91The user exports the defect list to Excel. Action: button "Export". Result: an Excel file by the current filter; message "Defect list exported to Excel." Source: prototype v0.91The record cannot be saved, the error shows on the "Repair Result" box. System: message "Repaired + scrap + downgrade must equal <Qty> pairs." or "Enter the root cause before closing this record." Source: prototype v0.91
Process steptop strip = screen used, colored tag = platform
Decisionevery outgoing branch carries its condition
Data / documentinputs in the Input lane, results in the Output lane
Main flowthe required order of steps
Tags on a boxMaster dataSystem (auto)At repair areaWeb

Status lifecycle

Repair / Rework recordRepaired OK > 0Repaired OK = 0, with A-Scrap = QtyPENDINGREPAIREDDOWNGRADEDSCRAPPEDOn Save Result the record takes exactly one of three branches from PENDING; Save Result happens once, there is no way back.
◻ PENDING ◻ REPAIRED ◻ DOWNGRADED ◻ SCRAPPED

Input

#InputTypeUsed in step
I-1Pending repair (PR) of the processes after Injection, each size with PR > 0 — Trimming Result (Trimming) · Process Worklist (Stitching) · Outsourcing Result (Spray Out) · Packing Result Logo (Packing Logo) · Packing Result Spray (Packing Spray)Production result — MESCreate a Repair / Rework record for each size with PR > 0
I-2Root Cause · Defect ReasonMaster dataSelect Root Cause
I-3Grade C (scrap) recorded at POP in every process, including Daily Injection (Process Injection), with Defect Reason; Pending repair does not go to Defect RecordsProduction result — MESWrite Defect Records rows, one row per reason

Step ↔ screen

StepRoleScreen · UI button
Open PENDING record · Enter Repaired · A- · Scrap · Select Root Cause · Tick Re-plan WO · Save repair resultQCRepair / Rework · Rework Records table (Record) · modal Repair Result (Save Result)
Create a Repair / Rework record for each size with PR > 0 · Set record status · Move Repaired OK goods to Repair Inv List · Write the A- part to Common Stock · Write the Scrap part as Loss · Create make-up demand for the WOSystem (auto)Repair / Rework
Repair defective goodsOperator (Repair team)At the repair area — no action on screen
Write Defect Records rows, one row per reasonSystem (auto)Defect Records · Grade C Records table; tab Defects of Work Order Detail
Filter Defect Records · Export Defect RecordsQCDefect Records (Export)

Output

#OutputProduced when
O-1Save blocked — error on the Repair Result modal: "Repaired + scrap + downgrade must equal <Qty> pairs." / "Enter the root cause before closing this record."Repaired OK + Downgrade to A- + Scrap differs from Qty, or no Root Cause selected
O-2Repair Inv List of Packing Planning Spray — Step 2 · Select Repair InventoryValid Save Result, Repaired OK > 0, Source Spray Out · Pending repair or Packing Spray · Pending repair
O-3Repair Inv List → Step 2 of Outsourcing Planning or Packing Planning Logo (by plan type)Valid Save Result, Repaired OK > 0, Source Trimming · Pending repair
O-4Repair Inv List — next process not yet determinedValid Save Result, Repaired OK > 0, Source Stitching · Pending repair or Packing Logo · Pending repair
O-5A- downgrade → Common StockValid Save Result, Downgrade to A- > 0
O-6Scrap → LossValid Save Result, Scrap > 0
O-7Make-up demand → Master Plan (re-plan WO for the Scrap quantity)Re-plan WO ticked before Save Result
O-8Closed record · view only (button View)Valid Save Result, Re-plan WO not ticked
O-9File Excel Defect RecordsQC presses Export on the Defect Records screen

Glossary

GlossaryMeaning in this flow
WOWork Order — production order created on Release in Master Plan; each WO brings its process plans
POPPoint of Production — output reported at the process, per shift and per size
Grade C"Reject" goods are scrap — only written to Defect Records by reason, no Repair / Rework record in any process
Pending repair (PR)Repairable goods in the processes after Injection — when PR is entered the system creates a Repair / Rework record per size automatically; not written to Defect Records; Daily Injection has no PR
SourceOrigin of a Repair / Rework record, in the form "<Process> · Pending repair" (five values)
Defect RecordsRead-only report: one row per grade C defect reason by Process, WO, SO
Rework RecordsList of RW-nnnn repair records, one record per size with Pending repair
Repaired OKPairs repaired to first quality (A / A-), returned to the next process
Downgrade to A-Pairs downgraded to A-, released from the SO into Common Stock
ScrapPairs scrapped, recorded as Loss
Repair Inv ListList of repaired goods waiting for the next process; only that process's Plan sees them
Common StockShared stock not tied to a P.O, re-allocated later
Make-up demandMake-up production need for the scrapped part, sent to Master Plan