Counting results
Determine and distribute assigned tasks results to monitor
The data counters input into the system are the main driver for the resulting actions of audit planning: uncovering and resolving inventory discrepancies. When inventory counting data is recorded, further inventory analysis and resolving inventory discrepancies can then be handled appropriately.
The system records and analyzes all inventory count data submitted by the counters for each audit plan. The results collected from the assigned tasks for the bins or part number are compared with the data already in the system. Count results that align with the current inventory in the system are completed and no further processing or action is required.
Count issues
When inventory count results don't align with the current inventory data in the system, analysis of the cause of that discrepancy must be done before it is displayed in the Count Issues tab.
There are eight possible count issues identified in the Count Issues list:
Count Discrepancy – The count entered for a UID does not match the inventory quantity.
Expected UID Missing in Bin Location – A UID expected in the bin was not scanned/counted.
Wrong Bin Location for Scanned UID – A UID scanned for a bin for an assigned task didn't belong to the bin.
Damaged – Inventory is damaged (the damaged inventory is part of the total inventory).
UID Not Registered in System – FactoryLogix doesn't recognize the UID.
UID/PN Mismatch – The UID scanned doesn't match the expected part number.
UID/Owner Mismatch – The UID scanned doesn't match the expected owner.
Discrepancy – This count issue is being confirmed: a mismatched count on the bin was identified but the reason for that mismatch hasn't been determined.
The Count Issues list contains all count issues recorded for the entire duration of the audit plan and there can be multiple count issues per location.
When a counter scans a UID and enters the quantity, the system saves the quantity in a running total for that bin or part number. When the counter completes/submits the task, the system compares the results to what is expected for that inventory in that bin or for that part number. The system determines if there are any discrepancies, and which count issue caused the discrepancy.
A discrepancy becomes a confirmed count issue when the results of the counters don't equal the recorded inventory quantity in the system:
There might be a situation where none of the count results match each other or the inventory.
Two count results match each other but not the inventory.
At the point where two count results match, a discrepancy is changed to a confirmed count issue.
For example, if Counter 1 has a count mismatch and Counter 2 has the identical count mismatch, no further count is needed and the results of the two counts are analyzed by the system to determine which count issue caused the count mismatch.
Note
One exception to the previous example would be if a UID is marked as Damaged and the quantity matches what is in inventory. In such cases, no recount task is necessary and the count issue is verified for investigation purposes.
Schedule issues
For Random Sample or Continuous audit plans, the system relies on completed interval data. If a counting task wasn't completed during its defined interval, it is reported in the Count Issues table. The table displays only those counters who haven't completed their previous interval tasks.
Plan Overview
This area shows every interval in progress or completed to give the manager a view of what's currently in progress and what was previously completed/not completed in each interval.
Each task has a status that is only displayed in the Administration view:
Completed – Count results have been recorded.
Incomplete – Count results have not been recorded.
On Hold – The plan has been put on hold and any associated tasks are also on hold.
The default status for each task created is Incomplete and aren’t changed to complete until the counter selects Submit in the Assigned Task action window.
Accuracy and completion data in the Administration view
The results of assigned tasks for an audit plan are used to calculate the Accuracy % and Completion % for each plan in the Administration view.
Accuracy % - This column is controlled by a global option which gives a planner the ability to select which count issues will contribute to the calculation of the Accuracy %. (Some count issues affect the organization’s net profit/loss while others may not and can be easily fixed at the time of investigation.)
The system calculates only those count issues recorded for the previous intervals up to that point in the plan. The system uses the total tasks expected up to the point of the current task and divides that into the number of successful tasks to get the Accuracy %
For example, 100 tasks completed and 10 of them resulted in the selected count issues from the global option.
90/100 = 90% AccuracyScheduling % - This column calculates only those intervals whose durations are completed and takes into account how many tasks have been completed versus how many are expected to be completed up to the last complete interval and calculates the completion percentage.