Reprocess Limits#

Overview#

The Reprocess Limits feature allows defining the maximum number of times a material of a given product or product group can be reprocessed at a specific step.

Once the configured limit is reached, the material is blocked from being processed again at that step.

Concept#

In manufacturing, reprocessing (rework) is often necessary to correct defects. However, excessive reprocessing can:

• Degrade material quality
• Increase variability in production outcomes
• Lead to reliability issues in final products

The Reprocess Limits feature enables manufacturers to enforce controlled rework policies by defining how many times a material can return to a given process step and automatically preventing further processing once that limit is reached.

This ensures that:

• Quality standards are consistently enforced
• Risk of over-processing is minimized
• Operators are guided to take alternative actions (e.g., scrapping or escalation)

Functional Behavior#

Key Components#

SMTReprocessLimitContext (Smart Table)#

Defines where and how limits apply:

• Product / Product Group
• Flow
• Step
• Maximum Reprocess Limit

This table determines whether a material should be restricted at a given step.

System Actions#

Once triggered, the system evaluates how many times the material has already been processed at the step and:

• If within the allowed limit:

  • Processing continues
  • The internal counter is updated

• If the limit is exceeded:

  • The operation is blocked
  • An exception is raised

Important Behavior#

• The limit applies only to reprocessing attempts
• The first processing is always allowed
• Example
  • Limit = 0:
    • First processing: Allowed
    • Any reprocessing: Blocked

Key Capabilities#

• Enforces rework policies automatically
• Protects product quality and reliability
• Reduces risk of excessive processing
• Ensures consistent manufacturing control

You can find more detailed information in the Reprocess Limits tutorial.