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šŸ”§ How to record component replacements in RMA workflows

Alex Merkin avatar
Written by Alex Merkin
Updated this week

What this is

When a finished product returns from the field under an RMA (Return Material Authorization), you may need to replace one of its internal components (like a diode or circuit board).
In standard production workflows, serial numbers of sub-components are logged automatically as part of the assembly process. But in an RMA workflow, the original work order is already closed — making it tricky to track which serials were removed and which new ones were installed.

This article explains how to handle this scenario in Next Plus, so you can maintain full traceability of replaced parts.


How to do it

  1. Start the RMA workflow

    • Open the RMA work order for the returned device.

    • Confirm the top-level product serial (the parent device).

  2. Identify the faulty component

    • Check which sub-component needs replacement (e.g., a diode or PCB).

    • Note its current serial number for traceability.

  3. Use Disassembly / Assembly actions

    • Go to the Device Management section.

    • Select Disassembly to remove the old serial number from the parent device.

    • Then use Assembly to attach the new component serial.

    • āœ… This keeps the genealogy tree accurate.

  4. If the replacement component doesn’t yet exist in stock

    • Create a stock item for the new component (via Modeling > Parts & Stock).

    • Assign its correct part number and new serial.

    • Then return to the RMA workflow and perform the Assembly step to link it.

  5. Add context to the RMA

    • Document the reason for replacement in the workflow fields (e.g., ā€œReplaced diode due to failure – new serial attachedā€).

    • If required by compliance, request a manager e-signature on the replacement step.


Common Issues / FAQs

  • ā€œI can’t disassemble because the work order is closed.ā€
    → That’s expected. Use the Disassembly/Reassembly actions in Device Management, not the original work order.

  • ā€œThe new serial doesn’t exist in the system.ā€
    → Create it first in Stock Management, then attach it.

  • ā€œCan we do this directly inside the RMA workflow?ā€
    → Not yet. The current workaround is to use stock + assembly actions. A future update is planned to allow ā€œCreate Device on Replacementā€ directly inside RMA.

  • ā€œWhy is this important?ā€
    → Without serial replacements logged, genealogy is broken. Later, you cannot query which specific component is inside a product, which creates audit risks.

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