We are currently experiencing an issue in our shop order processing where an Operation Deviation Qty appears, even though:
- No over‑reporting took place
- No bypass quantity was reported
- No additional scrap was recorded at the affected operation
- All previous operations provided consistent and correct quantities
The deviation was created solely because the Operation Qty of a downstream operation was probably automatically reduced by the system, without any corresponding user action, feedback transaction, or log entry explaining this adjustment.
As soon as the operator reported the correct Completed Qty, the system created a deviation. The downstream operation inherited the same reduced Operation Qty and continued to show the same deviation, even though the actual physical quantity was correct.
Here are some process details:
-
A prior operation reports 100 pcs, with 1 scrap, leaving 99 good pcs.
→ All data confirms the correct remaining quantity: 99 pcs. -
The next operation (let’s call it Operation A) should therefore have an Operation Qty = 99 pcs.
However, Operation A unexpectedly shows Operation Qty = 98 pcs.
→ No history record indicates this change. -
The operator then completes 99 pcs at Operation A.
→ This immediately produces Operation Deviation Qty = 1. -
The subsequent operation inherits the reduced operation quantity (98 pcs)
but again receives a Completed Qty of 99 pcs,
resulting in the same deviation.
Has anyone encountered a situation where IFS automatically reduces the Operation Qty of an operation, even though:
- All previous operations reported correct quantities,
- No scrap or bypass occurred,
- The real physical quantity is higher,
- and no change to Operation Qty is recorded in the IFS history?
Which system settings, background jobs, planning mechanisms, or configuration parameters could cause IFS to automatically adjust Operation Qty to a value lower than the actual quantity flow?
Any insights, known behaviors, or configuration points to check would be greatly appreciated.
