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When a subset of units on a run develops a problem, you can split those units off into a separate location and keep the rest of the run moving. You create an issue ticket for the affected units, assign them a location such as an MRB cage, and continue running the remaining units. For how ION divides inventory by install state, see the Overview. For example, during receiving you inspect 10 parts from a supplier and find that 3 have visual defects. You split those 3 parts onto an issue, move them to a separate location, and let the other 7 continue through your process. For more information, see Issues.
The video below shows this workflow in the run execution window.
Watch: split off defective parts during a run

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Split off units mid-build with partial installs

This case covers a parent inventory item with multiple child components, defined by the aBOM build requirements. The example produces five New York cheesecakes and splits 2 off mid-process. Watch: split off 2 cheesecakes mid-build with partial installs The video follows these steps:
  1. Create the run to produce the five cheesecakes.
  2. Confirm the five cheesecakes appear in inventory as WIP, assigned to a location of your choosing. In this example, the location is “Great Place”.
  3. Review the build requirements (aBOM) for a single cheesecake: 3 Sugar, 2 Cream Cheese, and 1 Egg. These requirements matter when you create a split WIP issue with partially installed quantities.
  4. Confirm the total build requirements for the five cheesecakes: 15 Sugar, 10 Cream Cheese, and 5 Eggs.
  5. During the procedure, install 2 Sugar and 1 Cream Cheese, then notice an issue with two of the cheesecakes. The installed goods are in the “Great Place” location, where the cheesecakes were originally destined.
  6. Create an issue ticket to split those two cheesecakes off the run and move them to a location called “Bad Place”.
  7. On the inventory page, confirm the two split cheesecakes now appear in “Bad Place”. If “Bad Place” is an Unavailable inventory location, you can use it to make split-off inventory unavailable for use elsewhere.
  8. Confirm that all components installed into the split-off inventory also move to the new location “Bad Place”.
  9. Review the aBOM for this run, which now shows additional information:
    • Build requirements that had inventory installed before the split show a UI indication that they are shared between the two parent part inventories. In the video, the build requirement is linked to inventory ID 12 and 15.
    • The quantity reads Qty: 1 of 6 (10). The tooltip shows that 1 inventory is still installed on the build requirement, 6 is the quantity the build requirement currently requires, and 10 was the original build requirement quantity. Because ION cannot know whether the 1 was a component of the newly split-off inventory or still attached to the run, the previously installed inventory stays visible on the run’s aBOM after the split.
    • 6 total Sugar are needed for the remaining three cheesecakes, down from the original 10.

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How inventory splits by install state

When you split units off a run, ION divides inventory based on how far each unit has progressed: no installs, full or partial installs, or a mix. The final locations of child inventory reflect the locations of the child parts after the split.

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No parts installed yet

Nothing has been installed onto the units being produced. When you split off some units, ION divides all required parts between the two groups. Each split-off group gets its own list of parts to install, and because nothing was installed beforehand, each group’s requirements are independent.

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Some or all parts installed

Work has started and some parts are installed. When you split off a few units, ION cannot tell which installed parts belong to which group. ION links both sets of units, the ones staying in production and the ones you split off, to the already-installed parts. Each group shows the installed parts as shared, meaning the parts could belong to either set. This keeps every part accounted for and gives both groups the components they need.

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Mix of installed and uninstalled parts

Some parts are installed and others are not. ION handles the installed parts as in the previous case, linking them to both groups and showing them as shared. ION allocates the uninstalled parts separately to each group based on the split. Production continues for the unaffected units while the split-off units stay accounted for.

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aBOM installation sharing among parent assemblies

When aBOM installations are shared across split parent assemblies, calculate how much quantity and cost to attribute to one aBOM by dividing the shared installation across the parent assemblies it could belong to.