We will be demonstrating how to reposition a part that failed at a specific point in a process flow.  The reposition moves the failed part into a different 'Rework' flow.  We then run the part through it's 'Rework' flow and when the completed, the part may be repositioned back onto a new traveler at the same step where it had previously failed.

Note: Keep in mind that we will be configuring both items to reposition part to the 'Rework' flow, and items that will reposition back to the 'Standard Work' flow.

• Create Part Definition - Create a Part Definition for the example (Note: You can use an existing Part Definition)  
  

Part Name: Widget A

• Create Step Definitions - We will create Step Definitions for both the 'Rework' and Standard Work' flows.  For our example we will keep everything simple.  Create the following Step Names:
   

Step Name: Start Part

Step Name: Test 1

Step Name: Complete Part

Step Name: Rework Part

• Add Name Values to Step Definitions:  You must now create a Name Value for our Test 1 Step Definition.  This will be evaluated by our Trigger to fire our reposition Action.  The Trigger will be a simple checkbox asking if the part failed.
  

Step Definition: Test 1

Name Value Tab

Name: Fail?

Value Type: Checkbox

Edit addtional Name Value Parameter:  This option will clear the value so it will not activate the trigger when/if the part comes back into this step.

Clear Value on Move?: True (check the box)

Step Definition: Rework

Name Value Tab

Name: Pass?

Value Type: Checkbox

Edit addtional Name Value Parameter: This option will clear the value so it will not activate the Trigger when/if the part comes back into this step.

Clear Value on Move?: True (check the box)

• Create Flow Definitions - Create Flow Definitions for both our 'Standard Work' and the 'Rework' flow.
   

Standard Work Flow

Name: Standard Work Flow

Flow Definition Type: Make Part

Part State When Active: WIP

Part State When Done: FGI

Rework Flow

Name: Rework Flow

Flow Definition Type: User Part

Part State When Active: WIP

Part State When Done: Scrapped

• Add Step Definitions to the Flow Definitions  - You must now add your Step Definitions onto the Flow Definitions.  Add the Step Definitions as follows:

Standard Work Flow

reWork Flow

• Create New Actions: This new action will reposition the failed part to the 'Rework' flow and place it on the desired step (i.e. The first step).
  

Repostion to Rework action configuration

Action Name: Reposition To Rework Flow

Action Type: Reposition

Flow Definition to Change: Rework Flow

Step in Flow Definition: Rework Part

Repostion to Rework action configuration

Action Name: Reposition Back To Original Flow

Action Type: Reposition Back

• Create New Triggers: The Triggers will evaluate the Name-Values 'Fail?' or 'Pass?' and fire the Action only if they are true.  If the Name-Value is false, then the Trigger will not fire the Action and the process flow continues moving forward as normal.
   

Failed Test Step Trigger

Trigger Name: Failed Test Step

Variable NV: Fail? (choose the correct NV by verifying number)

Variable Name: TESTFAIL

(add variable by hitting the '+' icon.  New variable will display in 'Variables' box)

Done String Formula: [TESTFAIL]="true"

Failed Test Step Trigger

Trigger Name: Passed Rework

Variable NV: Pass? (choose the correct NV by verifying number)

Variable Name: TESTPASS

(add variable by hitting the '+' icon.  New variable will display in 'Variables' box)

Done String Formula: [TESTFAIL]="true"

• Create New Events: The Events Definitions we are about to create will be added to the Step Definitions that we wish to monitor (i.e. Test 1 and Rework Part).
    

Test 1 Event

General Tab

Event Name: Check Test Failure

Repeats: False

Trigger Tab

Add Trigger: Check For Failure

Action Tab

Add Action: Reposition To Rework Flow

Rework part Event

General Tab

Event Name: Check Passed Rework

Repeats: False

Trigger Tab

Add Trigger: Passed Rework

Action Tab

Add Action: Reposition Back To Original Flow

• Add Events To Step Definitions: You must now add the events to the proper Step Definitions you wish to monitor.

Test 1 Step definition

Add Event: Check Test Failure

Rework Part Step definition

Add Event: Check Passed Rework

• Configuration of this function is now complete.  You can verify that it works correctly by running the 'Standard Work' flow, select the new 'Widget A' Part Definition you created.  When the flow gets to the 'Test 1' step, set the checkbox Name Value to indicate a fail. 

When you complete the step (or after trigger evaluates on timer, whichever comes first), the part will now be repositioned to a new traveler that uses the 'Rework' flow. 

You can test the same reposition action event when you 'Pass' the part on the 'Rework' flow.  The part will move to a new traveler, using its original Flow Definition, and will be at the same step where it previously had failed.

If the part is failed on the 'Rework' flow then it will not be repositioned back to it's original flow and will be scrapped when the traveler is completed/signed off.