Continuous Flows - Rework and Temporary Off-Flow#

Overview#

Continuous Flows support scenarios where a Material temporarily leaves the main flow and later returns.

This can happen through:

• Rework Flows
• Temporary Off-Flow Paths

To preserve flow continuity, MES manages Material ranks during these transitions.

When a Material leaves the main flow, it is assigned a dedicated rank:

When the Material returns, MES may automatically restore its rank according to its position relative to the remaining Materials.

Changing Rank Names#

The default rank names are:

• InRework

To change these values:

Configuration Entry#

• /MedDev/ContinuousFlows/ReworkRankName

Rework Scenarios#

Material is Sent to Rework#

When a Material participating in a Continuous Flow is sent to Rework:

• The Material rank is updated to InRework.
• MES evaluates the remaining Materials in the group.
• Additional rank updates may be performed to preserve flow continuity.

Additionally, MES prevents the Track-In of a Material with rank Tail if another Material of the same group is currently in Rework and is configured to return to that same Step.

The following logic is applied.

Original Rank = Head#

When a Head material is sent to Rework, MES attempts to reassign the Head rank to the next material in the flow.

• Material State = Queued

  MES searches for another material of the same group at the same Step with the same state.

  • If found, that material is promoted to Head.
  • If not found, no immediate change is made. The Head rank will be reassigned automatically once the next Middle material performs a Move-Next, provided Auto Re-Evaluation of Material Ranks is enabled.

• Material State = Processed

  • No immediate change is made.
  • The Head rank will be reassigned automatically once the next Middle material performs a Move-Next, provided Auto Re-Evaluation of Material Ranks is enabled.

Original Rank = Middle#

• No rank changes are made to other materials. Flow continuity is preserved as-is.

Original Rank = Tail#

The behavior depends on where the material is expected to re-enter the flow after Rework.

Rework Return Step is Ahead of Current Step

The material will re-enter the flow further ahead, so MES attempts to reassign the Tail rank.

• Material State = Queued

  MES searches for another material of the same group at the same Step with the same state.

  • If found, that material is assigned the Tail rank.
  • If not found, no immediate change is made.
  • The Tail rank will be reassigned automatically once the last Middle material performs a Move-Next, provided Auto Re-Evaluation of Material Ranks is enabled.

• Material State = Processed

  • No immediate change is made.
  • The Tail rank will be reassigned automatically once the last Middle material performs a Move-Next, provided Auto Re-Evaluation of Material Ranks is enabled.

Rework Return Step is Behind Current Step

• No immediate change is made.
• The Tail rank will be reassigned automatically once the last Middle material performs a Move-Next, provided Auto Re-Evaluation of Material Ranks is enabled.

Material Returns from Rework or Temporary Off-Flow#

When a Material returns from Rework or Temporary Off-Flow, its rank is updated from InRework to Head, Middle, or Tail based on its position relative to the remaining Materials in the flow.

Determining Whether a Tail Exists Behind#

Material Returns as Queued

1. Searches the same Step and Logical Flow Path.
2. Searches previous Steps and Logical Flow Paths if no Material is found.

Material Returns as Dispatched or *Processed*

1. Searches the same Step and Logical Flow Path for Materials with state less than or equal to the returning Material state.
2. Searches previous Steps and Logical Flow Paths if no Material is found.

Determining Whether a Head Exists Ahead#

Material Returns as Queued or *Dispatched*

1. Searches the same Step and Logical Flow Path.
2. Searches subsequent Steps and Logical Flow Paths if no Material is found.

Material Returns as Processed

1. Searches the same Step and Logical Flow Path for Materials with the same state.
2. Searches subsequent Steps and Logical Flow Paths if no Material is found.

Rank Assignment

Once MES determines the positions of surrounding Materials, the returning Material is ranked as follows:

• Tail behind AND Head ahead → ranked as Middle
• Head ahead only → ranked as Tail. If another Material already holds Tail, it is updated to Middle.
• No Head ahead → ranked as Head. If another Material already holds Head, it is updated to Middle.

Save In-Process Material Rank for Returns#

Some processes require a Material to preserve the rank it had when it entered processing, even if rank updates occur later due to Rework or Temporary Off-Flow returns.

Pre-Conditions#

Enable either:

• Global configuration /MedDev/ContinuousFlows/EnableGlobalKeepInProcessRankOnReworkMaterialReturn

• Context-Specific setting on the MedDevContinuousFlowFeaturesConfig Smart Table under KeepInProcessRankOnReworkMaterialReturnEnabled column

When enabled:

• MES stores the rank present during Track-In in the Material attribute:
• MedDevInProcessMaterialRank
• If rank changes later, the original in-process rank is preserved.
• Checklist and Data Collection resolution uses the saved value whenever it exists.

This guarantees continuity for Checklists and Data Collections configured against specific Material ranks.