advanced.material.management.pdf

Epicor ERP Advanced Material Management Course 10.0.700.2

Disclaimer This document is for informational purposes only and is subject to change without notice. This document and its contents, including the viewpoints, dates and functional content expressed herein are believed to be accurate as of its date of publication. However, Epicor Software Corporation makes no guarantee, representations or warranties with regard to the enclosed information and specifically disclaims any applicable implied warranties, such as fitness for a particular purpose, merchantability, satisfactory quality or reasonable skill and care. As each user of Epicor software is likely to be unique requirements in of thethis usedocument of such software andEpicor their business of this document are always advisedintotheir discuss the content with their accountprocesses, manager. users All information contai ned herein is subject to change without notice and changes to this document since printing and other important information about the software product are made or published in release notes, and you are urged to obtain the current release notes for the software product. We welcome user comments and reserve the right to revise this publication and/or make improvements or changes to the products or programs described in this publication at any time, without notice. The usage of any Epicor software shall be pursuant to an Epicor end user license agreement and the performance of any consulting services by Epicor personnel shall be pursuant to Epicor's standard services terms and conditions. Usage of the solution(s) described in this document with other Epicor software or third party products may require the purchase of licenses for such other products. Where any software is expressed to be compliant with local laws or requirements in this document, such compliance is not a warranty and is based solely on Epicor's current understanding of such laws and requirements. All laws and requirements are subject to varying interpretations as well as to change and accordingly Epicor cannot guarantee that the software will be compliant and up to date with such changes. All statements of platform and product compatibility in this document shall be considered individually in relation to the products referred to in the relevant statement, i.e., where any Epicor software is stated to be compatible with one product and also stated to be with another product, should notsame be interpreted that such Epicor Additionally software is compatible with both of compatible the products running at the same ittime on the platform or environment. platform or product compatibility may require the application of Epicor or third-party updates, patches and/or service packs and Epicor has no responsibility for compatibility issues which may be caused by updates, patches and/or service packs released by third parties after the date of publication of this document. Epicor ® is a registered trademark and/or trademark of Epicor Software Corporation in the United States, certain other countries and/or the EU. All other trademarks mentioned are the property of their respective owners. Copyright © Epicor Software Corporation 2014. All rights reserved. No part of this publication may be reproduced in any form without the prior written consent of Epicor Software Corporation.

ED821905 90521-10-9206-58310702 10.0.700.2 Revision: July 25, 2014 1:43 a.m. Total pages: 87 course.ditaval

Advanced Material Management Course

Contents

Contents Advanced Material Management Course.............................................................................6 Before You Begin....................................................................................................................7 Audience.........................................................................................................................................................7 Prerequisites....................................................................................................................................................7 Environment Setup..........................................................................................................................................8 Workshop Constraints..............................................................................................................................9

Overvie w...............................................................................................................................10 Application Setup Review....................................................................................................12 Company Configuration................................................................................................................................12 Company Configuration Fields................................................................................................................12 Site Configuration Control.............................................................................................................................14 Workshop - Define Advanced Inventory Parameters................................................................................16 Maintenance Programs..................................................................................................................................16 Warehouse Bin Maintenance..................................................................................................................16 Warehouse Bin Maintenance Fields..................................................................................................17 Warehouse Maintenance........................................................................................................................18 Warehouse Maintenance Fields.......................................................................................................19 Workshop - Create a Warehouse and Bins.......................................................................................19 Reason Code Maintenance.....................................................................................................................20 Reason Code Maintenance Fields.....................................................................................................20 Reservation Priority Maintenance............................................................................................................21 Reservation Priority Maintenance Fields............................................................................................21 Workshop - Create Reservation Priority............................................................................................22 Assign a Reservation Priority Code............................................................................................22 User Account Security Maintenance........................................................................................................22 User Account Maintenance Fields....................................................................................................23 Employee Maintenance...........................................................................................................................24 Employee Workshop Maintenance - Evaluate andFields..........................................................................................................25 Modify Employee Records........................................................................26 Resource Group Maintenance.................................................................................................................27 Resource Group Maintenance Fields................................................................................................28 Workshop - Evaluate and Modify Resource Groups..........................................................................29 Edit Resource Group Warehouse and Bin Information...............................................................29 Edit the Resource Warehouse and Bin......................................................................................29 Edit the Second Resource Group..............................................................................................30 Edit the Third Resource Group..................................................................................................30 Part Maintenance...................................................................................................................................31 Part Maintenance Fields...................................................................................................................32

Daily Processing....................................................................................................................34 Quality Assurance Inspection Process.............................................................................................................34

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Contents


Workshop - Create a Purchase Order......................................................................................................34 Workshop - Receive Purchased Materials.................................................................................................35 Receipt Tracker................................................................................................................................36 Workshop - Move Materials to Inspection...............................................................................................36 Workshop - Inspect Received Materials...................................................................................................37 Workshop - Move Material to the Production Floor.................................................................................37 Shop Floor Material Movement......................................................................................................................39 Workshop - Enter a Job..........................................................................................................................39 Review the Job................................................................................................................................41 Review the Part...............................................................................................................................42 Workshop - Create a Purchase Order Using the PO Suggestions..............................................................43 Assign a Buyer for a Non-Stock Part.................................................................................................43 Generate Suggestions......................................................................................................................43 New PO Suggestions.......................................................................................................................44 Workshop - Receive Direct Job Material..................................................................................................44 Workshop - Start the Job........................................................................................................................45 Select the Job to Work On...............................................................................................................46 Job Pick List.....................................................................................................................................47 Move Material.................................................................................................................................47 Complete Setup and Start Production..............................................................................................48 Complete an Operation...................................................................................................................50 Move Completed Parts....................................................................................................................50 Workshop - Review the Job Status..........................................................................................................51 Shop Tracker...................................................................................................................................51 Workshop - Complete the Job................................................................................................................51 Begin Production.............................................................................................................................52 Check Active Resources...................................................................................................................52 Complete the Operation..................................................................................................................53 Move the Completed Parts to Inventory...........................................................................................53 Workshop - Review the Job....................................................................................................................54 Replenishment Workbench............................................................................................................................55 Material Replenishment Methods............................................................................................................56 Replenishment Processing Setup.............................................................................................................56 Warehouse and Bin Setup...............................................................................................................57 Workshop - Set Up Warehouses and Bins.................................................................................57 Kanban Type Maintenance..............................................................................................................58 Create Replenishment Type Codes...........................................................................................58 Part Maintenance............................................................................................................................59 Workshop - Set Up Part Records...............................................................................................59 Daily Replenishment Processing..............................................................................................................64 Workshop - Adjust Stock Levels.......................................................................................................64 Auto Replenishment........................................................................................................................66 Workshop - Work with Auto Replenishment.............................................................................66 Manual Replenishment....................................................................................................................71 Workshop - Work with Manual Replenishment.........................................................................71

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Contents

Managed Replenishment.................................................................................................................73 Workshop - Work with Managed Replenishment......................................................................74 Completing Replenishment Move Requests.....................................................................................75 Workshop - Review the Material Queue Manager.....................................................................75 Fulfillment Workbench...................................................................................................................................76 Workshop - Enter a Sales Order..............................................................................................................76 Sales Order Pick List................................................................................................................................77 Workshop - Submit the Sales Order for Picking.......................................................................................77 Workshop - Move Parts to Shipping........................................................................................................78 Scheduled Shipments Report..................................................................................................................79 Workshop - Ship Parts.....................................................................................................................79 Customer Shipment Tracker............................................................................................................80

Conclus ion.............................................................................................................................81 Append ix...............................................................................................................................82 Cost Types.....................................................................................................................................................82 Backflushing..................................................................................................................................................82 Transaction Types..........................................................................................................................................84

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Advanced Material Management Course This course takes you through the features and functionality of the Advanced Materials Management (AMM) module. Hands-on workshops guide you through this module. AMMreceiving provides to theinventory. ability to Itelectronically process move requests inventory and shipping staging or from also allows you to allocate finished between parts in work in process or inventory. Upon successful completion of this course, you will be able to:

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Receive and inspect incoming material.

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Move finished products to inventory and purchase order receipts to inspection and to the job.

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Perform material replenishment tasks.

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Create sales order allocations using the Fulfillment Workbench.

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Before You Begin

Before You Begin Read this topic for information you should know in order to successfully complete this course.

Audience Specific audiences will benefit from this course. •

Shop Floor Managers

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Job Planners

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Buyers

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Material Managers

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Production Managers

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Schedulers

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Project Team Leaders

Prerequisites To complete the workshops in this course, the necessary modules must be licensed and operating in your training environment. For more information on the modules available, contact your Epicor Customer Account Manager at [email protected]. It is also important you understand the prerequisite knowledge contained in other valuable courses. •

Navigation Course - This course introduces navigational aspects of the Epicor application's user interface. Designed for a hands-on environment, general navigation principles and techniques available in two user interface modes - Classic Menu and Modern Shell Menu. Workshops focus on each of these modes and guide you through each navigational principle introduced.

•

System Flow Course - This course introduces a basic quote to cash scenario that includes the process from the initial customer quote to final cash receipts and payment of supplier invoices. This course emphasizes the series of processes that make up the quote to cash process by using a simple scenario to highlight various transactions. Your organization may have more complex processing routines than those described in this course.

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Manufacturing Foundations Course- The Manufacturing Foundations course introduces you to the principal building blocks in establishing a strong manufacturing environment. This course discusses the necessary prerequisites involved with efficient production floor configuration.

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Manufacturing Execution System Course - This course discusses the Manufacturing Execution System (MES), an easy-to-use, online application that allows you to enter labor and inventory transactions while work is done on the shop floor.

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Order Management Course - This course discusses the Order Management module and how it facilitates the flow of manufactured items from inventory or jobs to the customer. A shipping transaction is performed whether items are shipped from stock or from work in process (WIP). Shipping transactions are captured during invoicing in the Accounts Receivable (AR) module, creating financial transactions that post to the general ledger (GL). Order entry and shipping are directly affected by the nature of the product and the process, specifically whether the items are built-to-order or shipped from stock.

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Before You Begin


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Job Management Course - This course describes the features and functionality of the Job Management module. Job Management provides a comprehensive manufacturing control system designed for routing, scheduling, costing, and tracking custom or repetitive parts produced for inventory or shipped to the customer from the site floor.

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Inventory Management Course - This course provides an overview of the entire inventory management process. Use this module to update and maintain raw materials, work in process (WIP) as well as finished goods inventory quantities and costs.

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Purchase Management Course - This course focuses on the Purchase Management process. This process includes the creation and approval of purchase orders (POs) and requisitions, managing suppliers and their

price lists, working with purchase order suggestions, and monitoring the purchase order process using related reports and trackers. The advanced functionality in the Supplier Relationship Management and Purchase Contract modules also aids in managing purchase orders.

Environment Setup The environment setup steps and potential workshop constraints must be reviewed in order to successfully complete the workshops in this course. Your Epicor training environment, in which the Epicor demonstration database is found, enables you to experience Epicor functionality in action but does not affect data in your live, production environment. The following steps must be taken to successfully complete the workshops in this course. 1.

Verify the following or ask your system administrator to verify for you: •

Your Epicor training icon (or web address if you are using Epicor Web Access) points to your Epicor training environment with the Epicor demonstration database installed. Do not complete the course workshops in your live, production environment. Note It is recommended that multiple Epi cor demonstration databases are installed. Contact Support or Systems Consulting for billable assistance.

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The Epicor demonstration database is at the same service pack and patch as the Epicor application. Epicor's education team updates the Epicor demonstration database for each service pack and patch. If your system administrator upgrades your Epicor application to a new service pack or patch, he or she must also download the corresponding Epicor demonstration database from EPICweb > Support > Epicor > Downloads and install ti . If this is not performed, unexpected results can occur when completing the course workshops.

•

Your system administrator restored (refreshed) the Epicor demonstration database prior to starting this course. The Epicor demonstration database comes standard with parts, customers, sales orders, and so on, already defined. If the Epicor demonstration database is shared with multiple users (that is, the database is located on a server and users access the same data, much like your live, production environment) and is not periodically refreshed, unexpected results can occur. For example, if a course workshop requires you to ship a sales order that came standard in the Epicor demonstration database, but a different user already completed this workshop and the Epicor demonstration database was not restored (refreshed), then you will not be able to ship the sales order. Epicor's education team has written the course workshops to minimize situations like this from occurring, but Epicor cannot prevent users from manipulating the data in your installation of the Epicor demonstration database.

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Log in to the training environment using the credentials manager/manager. If you are logged into your training environment as a different user, from the Options menu, select Change User.

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From the Main menu, select the company Epicor Education (EPIC06).

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4.

Before You Begin

From the Main menu, select the Main Site.

Workshop Constraints The workshops in this course can be performed only once in each instance of a restored (refreshed) database. If a user has already completed these workshops in the database, the database must be restored (refreshed) before another user can complete this course.

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Overview


Overview Advanced Material Management (AMM) enables manufacturers to produce electronic requests for materials, dispatch those materials, and track inventory movements including raw materials and work in process (WIP).

Using wireless terminals and bar codingtechnology, manufacturers can track inventory in real-time. A manufacturer that uses the Epicor application has complete control and visibility of raw materials and WIP as it travels throughout the application. Review this list for information on key features in the Advanced Material Management (AMM) module. •

Pick and pack orders ahead of time, then relieve inventory when the order actually ships.

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Optionally create an invoice in Accounts Receivable following shipment to a customer.

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Print tags on demand enabling employees to properly label containers or to create custom labels to meet customer requirements.

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Print tags on demand enabling employees to properly label containers or to create custom labels to meet customer requirements.

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Print customizable bill of lading forms for your shipments.

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Track shipments sent to customers.

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Divert planned receipts into inventory to receive directly to a job, or vice versa.

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Labels canlabels be automatically from a transaction assemble that srcinateprinted from the Material Queue. that occurs within AMM. The Bartender can also •

Optionally mass release shipping lines from orders with same ship-to addresses.

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Use an online queue of raw material and WIP parts to manage requests to locate and deliver the right parts to the correct resource at the appropriate time.

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View information about miscellaneous shipments.

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Enter online miscellaneous receipts to a job or into inventory.

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Print packing slips to fill orders to customers or ship parts to subcontractors with general or detailed line comments.

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Quickly and accurately identify WIP and inventory containers with system-generated bar codes.

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Create online payment vouchers in Accounts Payable from purchase order receipts.

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Set up pick face inventories and manage inventory levels automatically for replenishment.

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Treat your customers with the highestfrom priority byor automatically inventory to the highest orders first.best Reserve or allocate materials stock directly fromallocating a linked job to make certain thatpriority you ensure your highest priority customers the greatest care. •

Track receipts for goods that you have received.

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Report pieces to good, scrap, and non-conforming product from one window while still clocked into the job.

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Reserve specific parts in inventory for designated orders.

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Manage sales order allocations with greater efficiency and create more effective picking and shipping.

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Eliminate data entry mistakes and increase transaction speed by simply scanning a bar code tag to complete an entire transaction.

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Ensure that only the right employees are able to update inventory information, including requesting material and reporting pieces.

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Shipping and Receiving provides a central application within the application to monitor incoming and outgoing items, whether they are shipments against an order, subcontract parts being sent to a vendor, raw material being received from a purchase order to a job or into inventory, or filling an order from stock.

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Overview

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Optionally print customized shipping labels for each order. Labels include the customer's name and address. They can also include the purchase order number, sales order number, ship via, number of packages, shipping comment and weight fields.

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Generate executive summary of company trends regarding delivery performance, including number of shipments made, percentage of on-time delivery and average daily variance between customer promise and delivery.

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Request raw materials or WIP product to be moved into the materials handler's queue online and in real-time.

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Track shipments and receipts of subcontract items online, with graphical, point-and-click entry.

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Automatically create packing slips from open order releases selected for picking. Designate orders to be picked based on the staging warehouse and unique bin location, or view the orders available for shipping by staging warehouse.

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Create customizable packing slips and shipping labels.

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Display the WIP parts buffered in front of the resource (or resource group) on screen with the ability to zoom in to container detail.

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Move WIP parts into inventory storage locations or stage WIP at the next resource based on available space and time. WIP staging provides flexibility and convenience when an operation in a high volume resource is followed by an operation in a low volume resource, or when the next resource is currently busy running another job.

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Once inventory becomes WIP, monitor the movement of inventory and access online detailed movement records as well as current location status. Drill down into the detail for lot and serialized traceability. In addition to inventory, the Epicor application offers this traceability for consumable tooling, semi-finished products and non-stocked items.

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Fulfillment Workbench Reserves specific parts in inventory for specific sales orders. • •

Prioritizes orders to allocate stock to the highest priority customers first.

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Provides more efficient picking and shipping of sales orders.

WIP Movement and Tracking •

Requests raw material or WIP to be moved in real-time.

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Monitors WIP movement.

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Obtains the current location of WIP.

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Drill-downs for serial or lot tracking numbers.

Other Features • A material queue is available of parts to deliver to resource groups or resources. •

Bar codes can be printed at various times to label containers in order to identify WIP and inventory.

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Application Setup Review


Application Setup Review This section of the course reviews common company configuration factors and master file factors applicable to the Advanced Material Management module.

Company Configuration Use Company Configuration to define the module options for companies in the Epicor application. Use these options to define how this company will interact with the module licensed for it. When you install the Epicor application, one company record is created by default. You first use Company Maintenance to define overall options like email setup, document attachments, and external BAQ sources. You then use Company Configuration to define how the company interacts with the various modules you have licensed. Tip You can purchase a Multi-Site license that enables you to set up multiple companies within Company Configuration. To do this, first create the company within the Epicor Administration Console. You can then display the new company in this program and configure it as necessary. Menu Path

Navigate to this program from the Main Menu: •

System Setup > Company/Site Maintenance > Company Configuration

Company Configuration Fields Some of the fields in Company Configuration are not discussed in this course; to learn more about these fields, refer to the Application Help. All Modules Configuration

Navigate to the Modules > All Modules > General sheet to see where you can define general application defaults. General

Select the general warehouse for the company in this field. This defaults into each part record as it is entered, but it can be changed. Receiving

Select the default receiving warehouse and bin in this field. This is where incoming shipments are placed when they are received. Shipping

Select the default warehouse and bin used when products are staged for production in this field. Inventory Module Configuration

Navigate to the Modules > Materials > Inventory > General sheet. Print Bar Codes

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You can print selected bar codes in several modules. To print bar codes, you must select this check box. Bar codes are of particular importance in the AMM module when you print labels. Use Inventory Adjustment Reasons

Select this check box if you require reason codes be used when you adjust inventory balances. Inventory reason codes can have General Ledger (GL) codes attached for accounting reasons. Quality Assurance Module Configuration

Navigate to the Modules > Production > QA sheet. Default Inspection Warehouse

This warehouse defaults into transactions that are moved to Quality Assurance for inspection.

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Site Configuration Control Use the Advanced Material Management (AMM) sheet in Site Configuration Control to define advanced inventory parameters you use within the current site configuration. This sheet allows you to define how the Fulfillment Workbench sorts sales orders, jobs, and transfer orders on search results. You also define several Material Queue default values and indicate how warehouses linked to this site configuration replenish their material supply levels. Many of these defaults can be overridden when processing allocations in the Fulfillment Workbench or when defining allocation templates in Allocation Template Maintenance. Available fields include: SO Inventory Search Sort

This field defines how quantity search results for sales orders within the Fulfilment Workbench are sorted for the current site configuration. The available options are: •

FIFO - Sorts results in order by First In, First Out records.

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LIFO - Sorts results in order by Last In, First Out records.

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Lot Ascending - Sorts results by lot i n ascending order.

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Lot Descending - Sorts results by lot i n descending order.

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Bin Ascending - Sorts results by bin in ascending order.

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Bin Descending - Sorts results by bin in descending order.

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Quantity Ascending - Sorts results by quantity in ascending order.

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Quantity Descending - Sorts results by quantity in descending order. Note The option you select on this sheet is the default setting for the current site configuration. You can override this value when you define allocation templates in Allocation Template Maintenance and use the allocation templates in the Fulfillment Workbench.

Job Inventory Search Sort

This field defines how quantity search results for jobs within the Fulfilment Workbench are sorted for the current site configuration. The available options are the same as for the SO Inventory Search Sort. Xfer Inventory Search Sort

This field defines how quantityThe search resultsoptions for transfer orders Workbench are and sorted the current site configuration. available are the samewithin as forthe theFulfilment SO Inventory Search Sort Jobfor Inventory Search Sort. Replenishment Section

Indicates how materials are restored to the warehouses linked to this site configuration. The available options include: •

Replenish by Quantity - Select this option to restore materials based on the number of parts available.

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Replenish by Volume - Select this option to restore materials based on the size of the material available.

Pick Transaction Priority

This field indicates the priority level pick transactions inserted in the Material Queue from the Fulfillment Workbench are assigned within this site configuration. Nine levels are available from this drop down list; 1 has the highest priority while 9 has the lowest priority. The default value is 5.

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Putaway Transaction Priority

This field indicates the priority level stock, or putaway, transactions inserted in the Material Queue from the Fulfillment Workbench are assigned within this site configuration. Nine levels are available from this drop down list; 1 has the highest priority while 9 has the lowest priority. The default value is 5. Replenish Bin to Bin Priority

This field indicates the priority level bin to bin move transactions inserted in the Material Queue from the Fulfill ment Workbench are assigned within this site configuration. Nine levels are available from this drop down list; 1 has the highest priority while 9 has the lowest priority. The default value is 5. Lock Orders On Pick

This option determines whether the lines on sales orders are frozen, or locked, so that no other user can access these detail lines after a pick transaction is placed against one line. You can then pick material quantities for the entire sales order. Select this check box if you wish to activate this functionality. Sort Queue by Priority

This option indicates whether the Material Queue is automatically sorted by priority. When you select this check box, the Epicor application sorts the Material Queue in the following order: •

Priority

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Bin

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Sequence Number

Handheld Auto-Select Transactions Max

This field defines the number of material queue transactions automatically selected through use of the Handheld Manufacturing Execution System (MES) functionality. Default Net Weight UOM

This field specifies the default UOM (Unit of Measure) code used to calculate new weights that display in the Selected Weight field in the workbench for the current site. Select the UOM code from the Weight UOM codes defined in UOM Maintenance. This denotes the unit of measure (for example, Grams, Kilograms, Pounds) that the weight is expressed. Default Net Volume UOM

This field specifies the default UOM (Unit of Measure) code used to calculate new volumes that display in the Selected Volume field in the Fulfillment Workbench for the current site. Select the UOM code from the Volume UOM codes defined in UOM Maintenance. This denotes the unit of measure (for example, Cubic Centimeters, Cubic Inches) that the volume is expressed. Menu Path: System Setup > Company/Site Maintenance > Site Configuration Important This program is not available in the Epicor Web Access.

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Workshop - Define Advanced Inventory Parameters Navigate to Site Configuration Control. Menu Path: System Setup > Company/Site Maintenance > Site Configuration Important This program is not available in the Epicor Web Access.

1. In the Site field, search for and select Main. 2. Navigate to the Modules > AMM sheet. 3. In the SO Inventory Search Sort field, select or verify Quantity Ascending is set as the parameter. 4. In the Job Inventory Search Sort field, select or verify Quantity Ascending is set as the parameter. 5. In the Xfer Inventory Search Sort field, select or verify Quantity Ascending is set as the parameter. 6. In the Replenishment pane, select or verify Replenish by Quantity is set as the parameter. 7. In the Handheld Auto-Select Transactions Max field, enter or verify 10 is set as the parameter. 8. Click Save and exit Site Configuration Control.

Maintenance Programs This section of the course covers maintenance programs necessary for the Advanced Material Management (AMM) module. In some instances fields on a specific master file do not apply to AMM.

Warehouse Bin Maintenance Use Warehouse Bin Maintenance to identify the specific bins where inventory is stored in a warehouse. You use the Detail sheet to define operating characteristics (such as the description, zone, size, sequence, type, location and fulfillment parameters) for each bin, and use the Attributes sheet to assign user-defined warehouse bin attributes (previously defined in Warehouse Bin Attributes Setup) as needed. Important At least one bin location is required for a warehouse.

Menu Path


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Material Management > Inventory Management > Setup > Warehouse Bin

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Warehouse Bin Maintenance Fields Some of the fields in Warehouse Bin Maintenance are not discussed in this course; to learn more about these fields, refer to the Application Help. Bin

This field specifies the code that uniquely identifies the bin. Description

This field specifies the full description of the bin. Zone

This field specifies the warehouse zone is which this bin is located. A zone is a group of bins within the specified warehouse. Select the warehouse bin zone from a listing of bin zones previously established in Warehouse Bin Zone Maintenance. This is an optional entry. Size

This field specifies the bin size group. The bin size group code contains measurements that designate the size (height, width, length) and volume of the bin. Bin size group codes are defined in Warehouse Bin Size Group.

Sequence This field specifies a numeric sequence number used for sorting and reporting within the Epicor application. Inactive

Select this check box if the bin is inactive. Bins can only be marked as Inactive if they are empty (contain no inventory balance). Once marked Inactive, you cannot use the bin in new transactions. Non-Nettable

Select this check box if parts in this bin should not be included in on-hand quantities. Inventory stored in a non-nettable bin is not available in the Fulfillment Workbench. Portable

Select this check box if this bin is portable and is not in a fixed location. Portable bins do not have a dedicated physical location. The Epicor application uses this in fulfillment processing. Replenishable

Select this check box if this bin is replenishable. The Epicor application uses this in fulfillment processing. Standard

The standard bin stores normal inventory balances (owned by the company, not a customer or supplier). This is the default setting. Customer Managed

This field specifies the inventory in this bin is customer-owned; special processing rules apply to this inventory. If you select this option, use the field below it to enter the assigned customer ID, or click Customer to search for and select a customer The customer name contain inventory fromrecord. one assigned customer ID. displays in the next field. A customer-owned bin can only

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Supplier Managed

This field specifies the inventory stored in this bin is suppli er owned; special processing rules apply to this invento ry. If you select this option, use the field below it to enter the assigned supplier ID, or click Supplier to search for and select a supplier record. The supplier name displays in the next field. A supplier-owned bin can only contain inventory from one assigned supplier ID. Aisle

If the Portable check box is cleared, specify the aisle in which the bin is located. This is an optional entry. Face

If the Portable check box is cleared, specify the face in the aisle in which the bin is located. The Epicor application uses this in fulfillment processing. This is an optional entry. Elevation

If the Portable check box is cleared, specify the bin elevation within the specified aisle and face in which the bin is located. A bin on ground level typically has an elevation of 1, while the bin above it has an elevation of 2. The Epicor application uses this in fulfillment processing. This is an optional entry. Max Fill

This field specifies the maximum fillable quantity for this warehouse bin. The default is zero, but you can override it. The Epicor application uses this in fulfillment processing. Percent Fillable

This field specifies the fillable percentage for this warehouse bin. The default is zero, but you can override it. The Epicor application uses this in fulfillment processing.

Warehouse Maintenance Use Warehouse Maintenance to set up warehouses. You can group items in your inventory in each warehouse. You must set up at least one warehouse before you can enter parts in Part Maintenance. When you set up a warehouse, it is automatically set up in the site into which you are currently logged. You can also share the warehouse with other sites. You can do this on the System Setup > Company/Site Maintenance > Site Configuration Control > Modules > Inventory Management > Shared Warehouses sheet. A shared warehouse is a warehouse that belongs to one site in particular, but when you share it with one or more other sites, you can directly issue parts from or receive parts into the warehouse from the sites with which it has been shared. In order to set up more than one warehouse in this program, you must license the Advanced Material Management (AMM) module. Note Even if you do not physically have separate warehouses with multiple bins, you should still set up logical warehouses and bins that can help you keep track of inventory within the same location. Menu Path

Navigate to this program from the Main Menu:

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Material Management > Inventory Management > Setup > Warehouse

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Production Management > Quality Assurance > Setup > Warehouse

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Warehouse Maintenance Fields Some of the fields in Warehouse Maintenance are not discussed in this course; to learn more about these fields, refer to the Application Help. Warehouse

This 10 character field is used as a unique identifying code for each warehouse. Examples are RAW for raw materials or FIN for finished goods. Description

This is the full description for the ID. Name, Address, City, and State

These fields are for reporting and informational purposes.

Workshop - Create a Warehouse and Bins Navigate to Warehouse Maintenance. Menu Path: Material Management > Inventory Management > Setup > Warehouse 1. From the New menu, select New Warehouse. 2. In the Warehouse field, enter Site. 3. In the Description field, enter Site Floor. 4. Click Save. 5. From the Actions menu, select Bins. Warehouse Bin Maintenance displays. 6. Click New. 7. In the Bin field, enter MACH. 8. In the Description field, enter Machining. 9. Click Save. 10. Repeat steps 6 - 9 to create two additional bins. Use the following table as a data entry guide: Bin

Description

ASSY

Assembly

FGS

Finished Goods Staging

11. Exit Warehouse Bin Maintenance and Warehouse Maintenance.

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Reason Code Maintenance Use Reason Code Maintenance to assign standard explanations for Customer Relationship Management (CRM) events, labor scrap and rework, inventory adjustments, and Return Material Authorization (RMA) entries. To use reason codes, select the appropriate options in Company Configuration. Next, set up the codes in Reason Code Maintenance and select the reasons in the following programs: •

Count Discrepancy Reason Code Entry

• •

Time and Expense Entry Inventory Adjustment Entry

•

RMA Processing

•

RMA Dispositions

•

Opportunity/Quote Entry

The following reason codes are used in manufacturing: •

Scrap - This is used to identify a non-conformance quantity.

•

Quality Assurance - This is used for inspection and corrective actions.

•

Inventory Adjustments - This is used to identify items pulled from inventory that are non-conforming.

•

Rework - This is used for items sent back to be re-worked.

Menu Path Navigate to this program from the Main Menu: •

Financial Management > Deferred Revenue Accounting > Setup > Reason Code

•

Material Management > Inventory Management > Setup > Reason Code

•

Production Management > Job Management > Setup > Reason Code

•

Production Management > Quality Assurance > Setup > Reason Code

•

Sales Management > Customer Relationship Management > Setup > Reason Code

•

Service Management > Field Service > Setup > Reason Code

For CRM users, the Main Menu appears as: •

Customer Relationship Management > Sales and Marketing Management > Setup > Reason Code

Reason Code Maintenance Fields Some of the fields in Reason Code Maintenance are not discussed in this course; to learn more about these fields, refer to the Application Help. Reason Code

This is a unique identifier of the reason for scrapping or reworking parts, adjusting inventory, or accepting a customer return. Description

The description of reason. Count Discrepancy Reason

Select this check box to indicate that this Reason Code can be used for counting discrepancy.

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Reservation Priority Maintenance Reservation Priority Maintenanceis used by the Advance Material Management (AMM) module to automatically reserve on-hand quantity of an item for specific customers.

Customers that have a higher reservation priority code have stock quantities allocated to their orders first. Tip If the Advanced Material Management(AMM) module is installed, this special maintenance program becomes available. Menu Path


Sales Management > Order Management > Setup > Reservation Priority


Customer Relationship Management > Order Management > Setup > Reservation Priority

Reservation Priority Maintenance Fields Code

The field identifies allocation priority. For example: •

High

•

Low

Description

The brief description of the allocation priority. This description displays in the Allocation Priorityfield in Customer Maintenance. For example: •

High Priority

•

Low Priority

Priority

This is the value that assigns part allocations. The Priority value indicates how many days, plus or minus the Order Due Date, by which the allocations should be ranked. A Zero (0) priority indicates that no special allocation needs to be applied around the Due Date. A negative entry, like -3, means that the priority is less than the Order Due Date. Orders with this priority should not be fulfilled until orders with a greater priority are finished. Example Customers assigned this code need to have their orders arrive at least 4 days before the Order Due Date. This is a good setting for a High Priority code. 0 = Customers assigned this code do not need special consideration; these orders should ship on the Order Due Date. This is a good setting for a Normal Priority code. You probably will use this code for new customers. -3 = Customers assigned this code can have their orders slip by as many as three days without causing a problem. This is a good setting for a Low Priority code. You would use this code for replenishing stock.

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Workshop - Create Reservation Priority Navigate to Reservation Priority Maintenance. Menu Path: Sales Management > Order Management > Setup > Reservation Priority Tip The CRM menu path is: Customer Relationship Management > Order Management > Setup > Reservation Priority 1. Click New. 2. In the Code field, enter HIGH. 3. In the Description field, enter High Priority. 4. In the Priority field, enter 1. 5. Click Save. 6. Click New. 7. In the Code field, enter LOW. 8. In the Description field, enter Low Priority. 9. In the Priority field, enter 2. 10. Click Save and exit Reservation Priority Maintenance.

Assign a Reservation Priority Code Navigate to Customer Maintenance. Menu Path: Sales Management > Order Management > Setup > Customer Tip The CRM menu path is: Customer Relationship Management > Order Management > Setup > Customer

1. In the Customer field, enter Dalton and press Tab. 2. In the Reservation Priority field, select High Priority. 3. Click Save and exit Customer Maintenance.

User Account Security Maintenance Use User Account Security Maintenance to enter basic information, security access, and application privileges for users. Anyone who accesses the Epicor application must be set up in this program. Users must have a defined user ID, name, and password. In this program, you can also define addresses, phone numbers, and other company information. Users are commonly created by the Epicor application implementation team. The System Administrator grants security permissions based on the user's role in the company.

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Menu Path


ICE External > Security > User Security

•

System Setup > Security Maintenance > User Account Security Maintenance Important This program is not available in the Epicor Web Access.

User Account Maintenance Fields Some of the fields in User Account Maintenance are not discussed in this course; to learn more about these fields, refer to the Application Help. Detail Sheet User ID

The code that uniquely identifies a particular user. Each user in the application will be prompted for this ID when he or she attempts to sign on. If possible, assign users their own names as their User IDs, so that their IDs will be easy for them and others to remember. If names conflict, then add initials to make them unique. Require Single Sign-On

Select this check box to indicate that this user has to use his/her operating system (Windows, Unix, and so on) logon information as the logon for Epicor. Security Sheet Allow Enterprise Search

Select this check box to specify that the user can access the Epicor Enterprise Search functionality. Enterprise Search is an optional search application which you can use to retrieve indexed content from within your Epicor application and then quickly launch specific programs to display the data returned from the search. The data is indexed using a series of delivered Business Activity Queries (BAQs) that provide a starting point for the primary data available when you first install the application. You can, however, extend this functionality by adding user-defined BAQs into the indexing service. Allow Epicor Web Access

Select this check box to indicate that the current user can display the Epicor application through a web browser. This separate web format is called Epicor Everywhere. These web forms are generated from Epicor application programs. Because of this, the appearance and functionality of the Epicor Everywhere forms is nearly identical to the Epicor smart client programs, but do not require that you install the Epicor client. You can run Epicor Everywhere programs on multiple operating systems and on multiple devices - including handheld devices. Allow Main Menu Tabs

Select this check box to indicate that the current user can create and edit tabs on the Main Menu. Users access this function from the Main Menu by clicking Options > Preferences. Within the Preferences window, users create new tabs to display on the Main Menu using the Tabs sheet. Allow Mobile Access

Select this check box to specify that the user can access the Epicor application on supported mobile devices.

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Group Sheet

Use these group panes to select which security groups are assigned to the current user record. When you move a group to the Authorized pane, the user is included within this security group and will have the privileges assigned to this group. For example: •

Office Manager

•

Sales

•

Shop Employees

Company Sheet

Use the Company > Detail sheet to indicate to which companies the user has access. The following are important fields: Company

Use this drop-down list to select the internal company for which the current user has access. After you click the New menu and select New Company, this field activates. Select the company you need from the available options. Employee

This field defines the name this user will enter as a shop employee within the selected company. A required field, either enter or select the shop employee name you need within this field. Workstation

This field defines the identifier for the workan station the user within the the work station identifier directly or select identifier fromlogs theinto drop-down list.current company. Either enter

Employee Maintenance Use Employee Maintenance to create an employee record. Employees perform work on jobs and enter labor in Time and Expense Entry. If an employee is connected to a User ID, the associated password is required for the employee to log into the Handheld functions or the Manufacturing Execution System (MES). Employee Maintenance is most valuable if you do not have the Payroll module. The Job Management module uses an employee file separate from the Payroll module. •

•

If the Payroll module is installed, enter employees. They automatically display in the Employee file, where you can activate other fields. If necessary, update the employee details. When you update employee details in the Payroll module, the employee record updates automatically. An Payroll Employee Maintenance cannot beMaintenance, added again the in Employee If youemployee select theadded ActivetoEmployee check box in Payroll Employee employeeMaintenance. is automatically part of Employee Maintenance. You can always return to Payroll Employee Maintenance to select this check box.

An employee can start a shift when the payroll administrator is unavailable. In this scenario, the employee is entered in Employee Maintenance to allow them to record time. The payroll administrator can pull the entry into the Payroll module at a later time. Temporary employees who report time must also be entered in Employee Maintenance. Menu Path

Navigate to this program from the Main Menu:

24

•

Material Management > Data Collection > Setup > Employee

•

Material Management > Inventory Management > Setup > Employee

•

Production Management > Data Collection > Setup > Employee

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•

Production Management > Job Management > Setup > Employee

•

Service Management > Expense Management > Setup > Employee

•

Service Management > Field Service > Setup > Employee

•

Service Management > Field Service > Setup > Employee

•

Service Management > Project Management > Setup > Employee

•

Service Management > Time Management > Setup > Employee


Employee Maintenance Fields Some of the fields in Employee Maintenance are not discussed in this course; to learn more about these fields, refer to the Application Help. Detail Sheet Employee ID

This field specifies the employee ID. Status

In this field select active or inactive. Payroll Employee

Select this check box if this is a payroll employee. This enables the Payroll module to access this employee. Service Technician

Select this check box if this employee is a Service Technician and the Field Service module is installed. Material Handler

Select this check box if this employee is a Material Handler. This provides access to material handling functions in the Manufacturing Execution System (MES). Shop Supervisor

Select this check box if this employee is a Shop Supervisor. Shipping/Receiving

Select this check box if this employee is a Shipping and Receiving person. This provides access to the shipping and receiving functions in the MES. Production Worker

Select this check box if this employee is a Production Worker. This provides access to specific functions in the MES. Warehouse Manager

Select this check box if this employee is a Warehouse Manager. This provides access to specific functions in the MES. Production Info Sheet Shift

Select the employee's shift in this field. Expense

Select the default expense code for this employee ’s labor in this field. Department

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Select the employee's home department in this field. Labor Rate

This is the dollar amount that applies to labor transactions. If the Payroll module is installed, this field is unavailable and you must maintain the rate in the Payroll module. User Name

This option allows a shop employee to use another employee's ID if they are not in security as a system user. Request Material

Select this check box if this employee is a production worker and can request material. This provides access to request material functions in the MES. Report Quantity

Select this check box if this employee is a production worker and can report quantity. Override Job

Select this check box to allow the user to override his/her current job and report quantity for another job. Report Scrap Quantity

Select this check box if this employee is allowed to report scrap quantities. Report Non-Conf Quantity

Select this check box if this employee is allowed to report non-conformance quantities. Employee Records Used in this Course Role

Name

ID

Resource/Activity

Password

Material Handler

John J. Lewis

197

Moving material

Shop Worker 1

Zeke Graham

600

VM3

Shop Worker 2

Jack Sawyer

101

ASMB

Shipping Manager

Cory V. Snyder

700

Shipping/receiving

Supervisor

Charles L.Johnson

105

Purchasing

Henry Crabtree

none

Purchasing

hcrabtree

Inspector

Inspector Closseau

none

Inspector

iclosseau

zgraham

Workshop - Evaluate and Modify Employee Records Important Due to necessary database setup and specific data used to set up default warehouses and bins, this workshop can only be performed by one person on a shared database. If you are unable to complete this workshop, this prohibits you from completing some of the workshops to follow.

Navigate to Employee Maintenance. Menu Path: Production Management > Job Management > Setup > Employee 1. In the ID field, search for and select the foll owing employees: •

Charles Johnson

•

Cory Snyder

•

26

Jack Sawyer

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•

John Lewis

•

Linda K. Carter

•

Zeke Graham


Tip: To select the above employees at once, hold down the Ctrl key, select each employee, and click OK. 2. On the Detail sheet, verify or select the following information for each employee. Use the tree view to navigate between employee records. If changes are made to an employee record, click Save before moving to the next employee record. Name

Material Handler

Shop Supervisor

Shipping and Receiving

Production Worker

Payroll Employee

Charles Johnson

Select

Select

Select

Select

Select

Cory Snyder

Select

Select

Select

Jack Sawyer

Select

John J. Lewis

Select

Linda K. Carter

Select

Zeke Graham

Select Select

Select Select

Select

Select

3. Navigate to the Production Info sheet. 4. Verify or select the following ni formation for each employee. Use the tree view to navi gate between employee records. If changes are made to an employee record, click Save before moving to the next employee record. Name

Department

Request Material Report Quantity

Charles Johnson

blank

Select

Select

Cory Snyder

Sheet Metal Department

Jack Sawyer

Assembly Department

Select

Select

John Lewis

Assembly Department

Zeke Graham

Machining Department

Select

Select

5. Exit Employee Maintenance.

Resource Group Maintenance Use Resource Group Maintenance to set up resource groups and resources to be assigned to operations and used during job entry for scheduling purposes. Each resource group must have at least one resource and is inac tive until a resource is created for it. Resource groups and resources carry labor and labor burden cost estimates. They define where and how to perform operations. Resource groups can also be used to build part routings in the Engineering Workbench and in Quote Entry.

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Menu Path


Production Management > Engineering > Setup > Resource Group

•

Production Management > Job Management > Setup > Resource Group

•

Production Management > Scheduling > Setup > Resource Group

•

Sales Management > Configurator Management > Setup > Resource Group

•

Service Management > Expense Management > Setup > Resource Group

• •

Service Management > Field Service > Setup > Resource Group Service Management > Maintenance Management > Setup > Resource Group

•

Service Management > Project Management > Setup > Resource Group

•

Service Management > Time Management > Setup > Resource Group


Customer Relationship Management > Configurator Management > Setup > Resource Group

Resource Group Maintenance Fields Some of the fields in Resource Group Maintenance are not discussed in this course; to learn more about these fields, refer to the Application Help. Note Each resource group must have at least one resource, which can be a person, place, or object used during production. Example •

A specific machine, such as a CNC machine

•

A specific place in the site, such as Shipping

•

A tool used during production

•

A person, such as an inspector

Input Warehouse and In Bin

These fields indicate the location where work in process (WIP) material is stored when moved to this resource group. Output Warehouse and Out Bin

These fields indicate where the WIP material is moved when it leaves this resource group. Auto Move

Select this check box when WIP material can be moved automatically. Note If WIP material is automatically moved, the application first looks at the resource and if it finds a warehouse and bin, it automatically moves the WIP material to the resource. If no warehouse and bin are found or if the resource fields are defaulted to the resource group, the WIP material is moved there.

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Material Moves

The Epicor application can automatically move material from one WIP warehouse and bin to another WIP warehouse and bin. Note Below is an example of a move, using a job with the following operations: Operation Number

Name

Input Warehouse Output Warehouse In Bin

Out Bin

10

CNC

Site Floor

Site Floor

CNC

ASSY

20

ASMB

Site Floor

Site Floor

ASMB

ASMB

In this example, when you report parts as complete at operation 10, a move request is placed in the move queue for the material to move from the CNC bin to the ASSY bin. If the user does not want a move request placed in the queue but wants the WIP material moved, he/she must select the Auto Move check box to accomplish this. If the input bin of operation 20 is different from the output bin of operation 10, a move request occurs. If the input bin of operation 20 and the output bin of operation 10 are the same, a move request does not occur.

Workshop - Evaluate and Modify Resource Groups During this course, the VM3 and Assembly Blue Crew resource groups are used. In this workshop, evaluate the resource group and determine how the Advanced Material Management module responds to the warehouses set up.

Edit Resource Group Warehouse and Bin Information Navigate to Resource Group Maintenance. Menu Path: Production Management > Job Management > Setup > Resource Group 1. In the Resource Group field, search for and select VM3 Vertical Mill 3x Matsuura . 2. In the Backflush Warehouse field, select Production Floor. 3. In the Backflush Bin field, search for and select MCH. 4. Verify the Location check box is selected. 5. Verify the Auto Move check box is cleared.

This ensures a move request is created in the material move queue. 6. Click Save.

Edit the Resource Warehouse and Bin 1. Navigate to the Resources > Detail sheet. 2. Select the following information:

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Field

Data

Input Warehouse

Production Floor

Input Bin

MCH

Output Warehouse

Production Floor

Output Bin

MCH

Backflush Warehouse

Production Floor

Backflush Bin

MCH

3. Verify the Auto Move check box is cleared. 4. Click Save.

Edit the Second Resource Group 1. Navigate to the Detail sheet. 2. In the Resource Group field, search for and select Assembly Work Force. 3. Verify the Location check box is selected. 4. Select the following information: Field

Data

Input Warehouse

Production Floor

Input Bin

ASM

Output Warehouse

Inspection Area

Output Bin

INSI

Backflush Warehouse

Main

Backflush Bin

01-02-01

5. Verify the Auto Move check box is cleared. 6. Click Save.

Edit the Third Resource Group 1. In the Resource Group field, search for and select Asm Bench. 2. Select the following information:

30

Field

Data

Input Warehouse

Production Floor

Input Bin

ASM

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Field

Data

Output Warehouse

Inspection Area

Output Bin

INSI

Backflush Warehouse

Main

Backflush Bin

01-02-01

3. Verify the Location check box is selected. 4. Verify the Auto Move check box is cleared. 5. In the tree view, expand the Resources node and select Assembly Bench #1.

The Resource > Detail sheet displays. 6. Select the following information: Field

Data

Input Warehouse

Production Floor

Input Bin

ASM

Output Warehouse

Inspection Area

Output Bin

INSI

Backflush Warehouse

Main

Backflush Bin

01-02-01

7. Verify the Auto Move check box is cleared. 8. Click Save and exit Resource Group Maintenance.

Part Maintenance Use Part Maintenance to enter or update part information. Parts are either purchased i tems you use for raw materials or subassemblies or manufactured items you use to fill sales orders. Each part record contains crucial data you may need for purchase or production needs. A part record contains general information such as part number, description, and search criteria. Also, a part record defines inventory information, which includes unit of measure (UOM) options for sales, purchases, inventory, non-stock classifications, serial number tracking, and weight values. You also define wareho use and bin information for each part, including Minimum, Maximum, and Safety Stock quantities. If this part is included in a sales kit, define these parameters as well. When you set up a part, you can access it from each site within the company, and use it on jobs. You can also select parts as materials on quote, job, or part methods of manufacturing. If you use the Engineering module, purchased or manufactured parts on a bill of material must have a record set up in Part Maintenance. Tip Most modules do not require parts to exist in Part Maintenance, but it is recommended that you enter parts in this program, as each record requires little data and can save you data entry time later.

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Menu Path


Material Management > Inventory Management > Setup > Part

•

Material Management > Purchase Contracts Management > Setup > Part

•

Material Management > Purchase Management > Setup > Part

•

Material Management > Supplier Relationship Management > Setup > Part

•

Production Management > Engineering > Setup > Part

• •

Production Management > Job Management > Setup > Part Production Management > Material Requirements Planning > Setup > Part

•

Production Management > Quality Assurance > Setup > Part

•

Sales Management > Configurator Management > Setup > Part

•

Sales Management > Demand Management > Setup > Part

•

Sales Management > Order Management > Setup > Part

•

Service Management > Field Service > Setup > Part


Customer Relationship Management > Configurator Management > Setup > Part

•

Customer Relationship Management > Order Management > Setup > Part

Part Maintenance Fields Some of the fields in Part Maintenance are not discussed in this course; to learn more about these fields, refer to the Application Help. Part

This is made up of alphanumeric characters that uniquely identify a part. Description

This is the part description. Text in this field is used in the Where the Part Description Contains field in the Part Search window. Search

The first eight characters of the Description field default in this field but can be edited to reflect a customized search. Type

Select the type code that indicates if you normally purchase or manufacture this part, or sell it as a sales kit.

32

•

Purchased - These are parts you normally purchase from external suppliers and use as raw materials.

•

Manufactured - These are parts you normally manufacture and sell to your customers.

•

Sales Kit - These are sales kit parts that are sold together as a sales kit. Selecting Sales Kit activates fields on the Sales Kits sheet. Use the Sales Kits sheet to select configuration options for the kit. When you select Sales Kit as the part type, you are effectively setting up the part as the kit parent item. To add other parts to the sales kit, create a new bill of materials for the kit parent item.

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Group

This identifies the product group to which this part is assigned. A product group classifies groups of finished goods inventory parts. Note Product groups are not required in the Epicor application, but you can use them to classify your products for reporting purposes. For example, you may manufacture two distinct product lines. In this case, you would assign different product groups to track the sales of each product. Class

This identifies the part class to which this part is assigned. The Epicor application uses the part class to identify various types of inventory parts. Note Part classes are not required in the Epicor application, but you can use them to classify inventory materials for reporting purposes. For example, if you use three distinct types of raw materials, you can assign different classes that allow you to review the stock status of parts assigned to each of the three classes. Run Out

Select this check box to indicate that you want to phase this part out of your business. This check box is valuable if you are replacing an older version of a part with a newer version, but the older part is still useful. A substitution is made if a substitute is defined on the Substitutions sheet and enabled as the default. The Epicor application does not mix primary part and substitute part lots but allows manual mixing of lots. Non-Stock Item

When this check box is selected it indicates that this part is not normally stocked within your inventory. Both purchased and manufactured parts can be either stocked or non-stocked. If you enter a non-stocked part in the Part Master file, its default description displays (just like stocked items) when you enter the associated part number on an order or a job. •

The Non-Stock Item indicator controls the default Manufacture value for order releases in Sales Order Entry and the default Purchase value for material requirements in Job Entry. Non-stock items default as Make or Purchase when they are entered in these programs.

•

If a part is selected as Non-Stock, the item defaults as a Pull as Assembly and View as Assembly if it is involved with a bill of material when processing material requirements planning and when the Epicor application generates PO suggestions. If you choose, you can exclude non-stocked parts from various inventory reports. Example You take an order for a part you have not made before and do not expect to make again. The

part should be entered into the Epicor application and designated as a Non-Stock part. The part displays in the parts search browser when you enter the order. When you select the part from this browser, the associated part description automatically displays in the order. By default, the Epicor application marks the item as a manufactured part in the order, indicating that you do not have the part on hand but must make it.

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Daily Processing


Daily Processing This section of the course reviews inventory transaction processing that takes place during a typical work day. It discusses processing of sales order allocations using the Fulfilment Workbench, Shop Floor Material Movements, and QA Inspection Process. Business Scenario

ABC Manufacturing produces cabinets and shelving units for industrial use. They stock a variety of hardware in inventory with which to build drawers and cabinets for heavy duty storage units. ABC Manufacturing uses the features and functionality of the Advanced Materials Management module to electronically process move requests between inventory and shipping staging, or from receiving to inventory. They use the Fulfillment Workbench to submit orders for picking, move parts to shipping and, ultimately, to ship parts.

Quality Assurance Inspection Process This section of the course leads you through the quality assurance inspection process.

•

Create a purchase order. Receive materials.

•

Move the material to inspection.

•

Inspect the material.

•

Move the material to inventory.

•

If the part number being received as material has been designated as Inspection Required, the items are sent to the default inspection warehouse once Shipping and Receiving department receives the material. If all is well and inspection approves the materials, they are transferred back to the job or into inventory, depending on the type of order.

Workshop - Create a Purchase Order Navigate to Purchase Order Entry. Menu Path: Material Management > Purchase Management > General Operations > Purchase Order Entry 1. From the New menu, select New PO. 2. In the Supplier field, search for and select Seaside Steel. 3. In the Buyer field, select Henry Crabtree. 4. Navigate to the Lines > Detail sheet. 5. From the New menu, select New Line. 6. In the Part/Rev field, enter BS-CR-RD-150 and press Tab. 7. In the Due Date field, enter tomorrow's date.

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Daily Processing

8. In the Our Qty field, enter 50. 9. Navigate to the Summary sheet. 10. Select the Unapproved check box.

The PO status is changed to Approved. 11. Click Save. 12. Note the PO Number ______________. 13. Exit Purchase Order Entry.

Workshop - Receive Purchased Materials The 50 units of part number BS-CR-RD-150 ordered from Seaside Steel has arrived at the dock and must be received. 1. On your desktop, double-click the MES icon. 2. In the User name field, enter manager. 3. In the Password field, enter manager. 4. Click OK. 5. In the Employee ID field, enter 700 (Cory V. Snyder) and press Tab.

Cory Snider is the shipping/receiving person. 6. Navigate to the Shipping/Receiving sheet and click the Receipt Entry button. Receipt Entry displays. 7. From the New menu, select New Receipt. 8. In the PO field, enter the purchase order number from Workshop - Create a Purchase Order and press Tab. 9. In the Packing Slip field, enter the purchase order number and press Tab. 10. Click Save. 11. From the New menu, select New Stock Line.

The Stock > Detail sheet displays. 12. In the PO/Line fields, enter the purchase order number from Workshop - Create a Purchase Order and 1, then press Tab. 13. In the Our Qty field, verify that 50 displays. 14. In the Stock Location pane, note that you are receiving the units into Receiving Area and Bin RCV-1. 15. Select the Line Received check box.

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35

Daily Processing


16. Navigate to the Summary > Received Lines sheet. 17. In the Received Lines grid, verify the purchase order line for part BS-CR-RD-150 displays. 18. Click Save. 19. Exit Receipt Entry. 20. In MES, click the Log Out button. 21. Remain in MES for the next workshop.

Receipt Tracker The Receipt Tracker is helpful when you review purchase order receipts to resolve receiving issues. Menu Path: Material Management > Shipping / Receiving > General Operations > Receipt Tracker

Workshop - Move Materials to Inspection John Lewis, material handler, is monitoring the material queue regularly throughout the day and moving material as required. In this workshop, he indicates that the materials are ready to be moved to the inspection area. 1. Click the Log In button. 2. In the Enter Employee ID field, enter 197 (John J. Lewis) and click OK.

John Lewis is the material handler. 3. Navigate to the Material sheet and click the Material Queue button.

The Material Request Queue displays. 4. In the Unselected List grid, select the Seq for part BS-CR-RD-150 (50 units) and click the Tags button.

The Print Tags window displays. 5. Click Print Preview. 6. Close the preview and exit the Print Tags window. 7. Click the Process button.

The WIP/Material Movement Transaction window displays. 8. In the To Location section, in the Warehouse field, select Inspection Area. 9. In the Bin field, search for and select INSI. 10. Click OK. 11. Click the Close button. 12. In MES, click the Log Out button. 13. Remain in MES for the next workshop.

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Daily Processing

Workshop - Inspect Received Materials Charles Johnson, shop supervisor, inspects the materials. 1. Click the Log In button. 2. In the Enter Employee ID field, enter 105 (Charles Johnson) and click OK.

Charles Johnson is the shop supervisor. 3. Navigate to the Supervisor sheet and click the Inspection Processing button. Inspection Processing Entry displays. 4. Click the binoculars (search) icon and search for and select the PO receipt for part BS-CR-RD-150. 5. In the tree view, select the PO Receipts line.

The PO Receipts > Detail sheet displays. 6. In the Quantity field, verify 50 displays. 7. In the Inspector ID field, select Inspector Closseau. 8. In the Passed Quantity field, enter 50 and press Tab. 9. Select the Request Move check box. 10. Click Save and exit Inspection Processing Entry. 11. Click the Log Out button. 12. Remain in MES for the next workshop.

Workshop - Move Material to the P roduction Floor John Lewis, material handler, continues to monitor the material queue regularly throughout the day, and moves material as required. In this workshop, he moves inspecte d material from the previous workshop to the production floor. 1. Click the Log In button. 2. In the Enter Employee ID field, enter 197 (John J. Lewis) and click OK.

Recall that John Lewis is the material handler. 3. Navigate to the Material sheet and click the Material Queue button.

The Material Request Queue displays. 4. in the Unselected List grid, select the entry for part number BS-CR-RD-150 and click the Tags button.

The user has the option to print one tag for this move, a tag for each container, or a tag for each part. The Print Tags window displays.

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Daily Processing


5. Click Print Preview. 6. Close the preview and exit the Print Tags window. 7. Click the Process button.

The WIP/Material Movement Transaction window displays. 8. In the From Location section, in the Warehouse field, verify Inspection Area displays. 9. In the From Location section, in the Bin field, verify INSI displays. 10. In the To Location section, in the Warehouse field, verify Production Floor displays. 11. In the To Location section, in the Bin field, verify SHT displays. 12. Click OK. 13. Click Save. 14. Click the Close button. 15. Click the Log Out button. 16. Exit MES. 17. Log back into to the normal training environment using the credentials manager/manager.

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Daily Processing

Shop Floor Material Movement This section of the course describes how to complete the job process, up to receiving the parts into inventory, using the functionality available in the Advanced Material Management (AMM) module. •

Enter a job.

•

Create a purchase order.

•

Receive direct job material.

•

Start the job.

•

Investigate the AMM job status.

•

Complete the job.

Workshop - Enter a Job In this workshop, enter a job to issue 100 pieces of part number H-4600 (Slide Standoff 1") to stock in two weeks time. This job covers various aspects of the Advanced Material Management (AMM) module. This job uses the resource groups and resources you reviewed and modified in the Workshop - Evaluate and Modify Resource Groups. Navigate to Job Entry. Menu Path: Production Management > Job Management > General Operations > Job Entry

Job operations are set up as follows: Operation

Description

Resource Group

Setup Time

Pieces per Hour

10

Mill Point to Point

VM3

0.50

30

20

Assemble per Print

ASMB

N/A

25

Material for this job is as follows: Material

Part

Description

Related Operation

Quantity per Parent

Stocked

Backflush

10

CS-036

CRS Sheet .036” X

10

0.25

Yes

No

”

”

20

516FW

48 X 120 Flat Washer

20

4

Yes

Yes

30

516LN

Nut

20

4

Yes

Yes

40

516x100B

Bolt

20

4

Yes

Yes

50

8400S-611

Slide Stand off 1”

20

2

No

No

The job issues 100 pieces of part number H-4600 (Henwood Gear Case) and is due two weeks from today. 1. From the New menu, select New Job.

The New Job Number window displays. 2. Click the Next Job button and click OK. 3. In the Part field, enter H-4600 and press Tab.

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4. In the Req By field, select the date two weeks from today. 5. Click Save. 6. From the New menu, select New Demand Link > Make To Stock . 7. In the Quantity field, enter 100. 8. Click Save. 9. Navigate to the Engineering > Operation Master sheet. 10. From the Actions menu, select Auto Load Engineering Data > Load Operation Master Details . 11. In the Operation Code field, enter letter M. 12. In the Operations grid, select operation Mill Point to Point and drag and drop it on the Operations node in the tree view.

This positions the operation as number 10. 13. In the Operation Code field, enter letter A. 14. In the Operations grid, select operation Assemble per print and drag and drop it on the Operations node in the tree view.

This positions the operation as number 20. 15. In the tree view, click operation Opr: 10 OP: MILL.

The Job Details > Operations > Detail sheet displays. 16. In the Hours field, enter 0.50. 17. In the Prod Std field, enter 30 and click Save. 18. In the tree view, click operation Opr: 20 OP: ASSEM. 19. In the Prod Std field, enter 25 and click Save.

Setup is not required for operation 20. 20. Navigate to the Engineering > Parts sheet. 21. From the Actions menu, select Auto Load Engineering Data > Load Parts . 22. Drag and drop the following parts onto the operations that will consume them:

40

Part

Description

Related Operation

CS-036

CRS Sheet .036” X 48” X 120

10

516FW

Flat Washer 5/16"

20

516LN

Nut Nylock 5/16"

20

516x100B

Bolt 5/16"x1.00"

20

8400S-611

Slide Standoff 1" high

20

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Note Each time you add material to an operation, it also displays in a material listing at the bottom of the tree.

23. Navigate to the Job Details > Materials > Detail sheet. 24. In the tree view, click each material sequence associated with operations 10 and 20 and enter the following values in each Qty/Parent field: Material

Part

Description

Qty/Parent

10

CS-036

CRS Sheet .036” X 48” X 120

0.25

20

516FW

Flat Washer 5/16"

4

30

516LN

Nut 5/16"

4

40

516x100B

Bolt 5/16"x1.00"

4

50

8400S-611

Slide Standoff 1" high

2

25. Click Save. 26. Navigate to the Job sheet and select the Released check box.

The Engineered check box selects automatically. 27. From the Actions menu, select Schedule > Job Scheduling .

The Schedule Job window displays. 28. Accept the default of Backward scheduling and click OK. 29. Click Save. 30. Record the job number_____________. 31. Exit Job Entry.

Review the Job The Job Tracker display-only version of the primary entry program. this Use tracker current information aboutisaaselected record. You cannot add or edit records in a Use tracker. the to Jobreview Tracker to evaluate the job you created in the workshop task - Create a Job. Navigate to the Job Tracker. Menu Path: Production Management > Job Management > General Operations > Job Tracker 1. In the Job field, enter the job number created in the Workshop - Create a Job and press Tab. 2. In the tree view, right-click the job number and select Tree > Expand Tree. 3. In the tree view, select operation Opr:10 OP: MILL. 4. Navigate to the Job Details > Operations > Labor Transactions sheet. 5. Click the Retrieve button.

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The Labor Transactions grid remains blank as there is no labor entered against this job so far. 6. Navigate to the Job Details > Materials > Material Transactions sheet. 7. Click the Retrieve button.

The Material Transactions grid remains blank as no material transactions have occurred. 8. Navigate to the Job Details > Materials > Detail sheet. 9. In the tree view, review the following parts: Part

Description

CS-036

This is a stocked part. You create a move request for this part once the first operation starts.

516-FW

This is a backflushed part and will be moved to the job automatically.

516-LN


516x100B


8400S-611

This is a non-stock part and must be ordered and received from J.I.T Machining & Fabricating before the job operation that requires it can start.

10. Exit the Job Tracker.

Review the Part The Part Tracker enables you to obtain current information on parts i n the database. This includes information such as revisions, on-hand quantities, costs, locations, inspection, and planning data. You can pull multiple part records into the Part Tracker via the Part Search feature, but the tracker can only display one part at a time. You cannot add or edit records in a tracker. Additional information is available from the Actions menu of the Part Tracker, including: •

Approved Suppliers

•

Forecast

•

Configurator

•

Where Used

•

Master Production Schedule

•

Price List

•

Attachments

•

Memos

•

Change Logs

Navigate to the Part Tracker. Menu Path: Production Management > Job Management > General Operations > Part Tracker 1. In the Part field, enter H-4600 and press Tab. 2. Navigate to the On Hand > Part Locations > WIP sheet.

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3. Click the Retrieve button.

There are no values in the WIP sheet because the job has not started. 4. Exit the Part Tracker.

Workshop - Create a Purchase Order Using the PO Suggestions Creating purchase orders is not part of the Advanced Material Management (AMM) process. However, the job created in the Workshop - Enter a Job has a material requirement for 8400S-611 (Slide Standoff 1”) that you must order directly to the job.

Assign a Buyer for a Non-Stock Part Assign Henry Crabtree as a buyer for part 8400S-611. Navigate to Part Maintenance. Menu Path: Production Management > Job Management > Setup > Part 1. In the Part field, enter 8400S-611 and press Tab. 2. Navigate to the Part > Sites > Detail sheet. 3. In the Buyer field, select Henry Crabtree. 4. Click Save and exit Part Maintenance. Note Henry is now a buyer for this part and receives purchase order suggestions related to this part.

Generate Suggestions Use Generate Purchasing Suggestions to automatically create a list of suggested purchases based on time-phased information. You can create actual purchase orders from these suggestions using Purchase Order Entry. Navigate to Generate Purchasing Suggestions. Menu Path: Material Management > Purchase Management > General Operations > Generate Suggestions 1. Select or verify the following information: Field

Data

Processing Options

Regenerative

Cutoff Date

Leave blank

Schedule

Now

2. From the File menu, select Process. Note When you submit the process, a message does not display that says the Epicor application is finished processing. To know when the application is finished processing, check the System Monitor.

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3. Exit Generate Purchasing Suggestions.

New PO Suggestions Use New PO Suggestions to process new purchase order suggestions generated by Generate Suggestions. Navigate to New PO Suggestions. Menu Path: Material Management > Purchase Management > General Operations > New PO Suggestions 1. On the standard toolbar, click the binoculars (search) icon.

The New Purchase Order Suggestion Search window displays. 2. In the Buyer field, select Henry Crabtree. 3. Click Search. 4. Select the line that relates to the job entered in the Workshop - Enter a Job and click OK. 5. In the Our Quantity and Supplier Qty fields, verify 200 displays. 6. Navigate to the Material List sheet. 7. Select the Buy check box. 8. From the Actions menu, select Generate Purchase Orders.

The Purchase Order Suggestion window displays. 9. Click OK.

The Continue with Generate? message displays. 10. To the message, click Yes.

A purchase order is now created. 11. Exit Purchase Order Suggestion Entry.

Workshop - Receive Direct Job Material The J. I. T. company truck has just arrived at the dock with part 8400S-611 (Slide Standoffs) for the job. In this workshop, Cory Snyder processes a receipt using the Manufacturing Execution System (MES). 1. On your desktop, double-click the MES icon. 2. In the User name field, enter manager. 3. In the Password field, enter manager. 4. Click OK to log in. 5. In the Employee ID field, enter 700 (Cory V. Snyder) and press Tab.

Recall that Cory is the shipping/receiving person.

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6. Navigate to the Shipping/Receiving sheet. 7. Click the Receipt Entry button. Receipt Entry displays. 8. From the New menu, select New Receipt. 9. In the PO field, search for and select the PO generated through New PO Suggestions (Henry Crabtree) in the workshop task - New PO Suggestions. 10. In the Packing Slip field, enter the PO number and press Tab. 11. Click Save. 12. From the New menu, select New Job Material Line. 13. Click PO/Line to search for and select PO line 1 of the PO selected in step 9.

The purchase order details display. 14. Verify the Mtl field is set to 50 (8400S-611). 15. In the Our Quantity and Supplier Qty fields, verify 200 displays. 16. In the Warehouse field, select Production Floor. 17. In the Bin field, search for and select ASM. Recall that the Production Floor warehouse and the ASM bin are the input warehouse and input bin for the resources for Operation 20. This ensures the parts are sent directly to the input area for that operation. 18. Select the Line Received check box. 19. Click Save. 20. Navigate to the Summary sheet.

The Received All check box is now selected. 21. Exit Receipt Entry. 22. In MES, click the Log Out button. 23. Remain in MES for the next workshop.

Workshop - Start the Job This workshop demonstrates how to start the job in the Manufacturing Execution System (MES) and move materials between operations. •

Select the job to work on.

•

Move the material.

•

Complete set up and start production for an operation.

•

Report a partial quantity complete for an operation.

•

Move complete work in process parts from operation to operation.

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Select the Job to Work On Zeke Graham, shop worker, reviews the work queue to see what operations he should perform and the order in which the operations should be done, based on the schedule. He selects the job created in the Workshop Enter a Job. 1. Click the Log In button. 2. In the Enter Employee ID field, enter 600 (Zeke Graham) and click OK. 3. To verify Zeke's shift, click OK.

Recall that Zeke is a shop worker. 4. Navigate to the Production sheet. 5. Click the Work Queue button. Note The work queue contains a listing of the operations scheduled at each resource group. This queue informs the shop worker what operations he/she should perform and in what order the operations they should be done, based on the schedule.

The Work Queue displays.

6. Click the binoculars (search) icon to access Resource Group Search . 7. In Resource Group Search, in the Department field, select . 8. Search for and select the VM3 resource group.

The Work Queue redisplays. 9. In the tree view, in theCurrent Work node, select the work order and operation you releas ed and scheduled in Workshop - Enter a Job. 10. Navigate to the Job Details > Staged Details sheet.

Notice that no material has been staged for this job operation. Recall that part CS-036 is required for operation 10. This is a stocked part, and it is in inventory. As the part is not coded backflushed, you must request the part to be sent to the input area. 11. Click the Get Request button.

The Get Request window displays. 12. In the Assembly field, verify 0 displays. 13. In the Seq field, verify 10 displays. 14. In the Request Qty field, verify 25 displays. 15. Click OK.

The Successfully Processed Request Lines message displays. 16. To the message, click OK. 17. Close the Get Request window.

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18. Navigate to the Current Work sheet. 19. In the Current Work grid, select the job li ne that relates to the job created in the Workshop - Enter a Job. 20. Click the Start Activity button.

The Start Activity From Work Queue window displays. 21. In the Resource field, select the first resource. 22. Click the Setup button. 23. Exit the Work Queue. 24. In MES, click the Log Out button. 25. Remain in MES for the next workshop.

Job Pick List Use the Pick List for Jobsas needed to list material requirements for selected jobs. You can include both inventory and purchased materials. Inventory materials are listed in a format useful when you enter issued quantities directly on the report. Menu Path: Material Management > Inventory Management > Reports > Job Pick List

Move Material John Lewis, material handler, has been monitoring the material queue regularly throughout the day. He selects the sequence for CS-036 and moves the requested material to the job. 1. Click the Log In button. 2. In the Enter Employee ID field, enter 197 (John J. Lewis) and click OK. 3. Navigate to the Material sheet and click the Material Queue button.

Recall that John is the material handler. Material Request Queue displays. 4. In the Unselected List grid, select the sequence for CS-036 and click the Tags button.

The sequence must relate to the job number created in the Workshop - Enter a Job. The Print Tags window displays. 5. Click Print Preview. 6. Close the preview and exit the Print Tags window. 7. Click the Process button. Issue Material displays. 8. In the Warehouse field, select Main. 9. In the Bin field, search for and select 02-03-02.

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10. Select or verify the Issued Complete check box is selected. 11. Click OK. 12. Exit Issue Material. 13. Exit Material Request Queue. 14. In MES, click the Log Out button. 15. Remain in MES for the next workshop.

Complete Setup and Start Production Zeke Graham completed setup and must now report it. 1. Click the Log In button. 2. In the Enter Employee ID field, enter 600 (Zeke Graham) and click OK.

Zeke Graham is a shop worker. 3. Click the End Activity button.

The End Labor Activity window displays. 4. In the Current field, accept the default of 0 (no parts were produced during setup). 5. Click OK. 6. Navigate to the Production sheet and click the Work Queue button. 7. Click the binoculars (search) icon to access Resource Group Search . 8. In Resource Group Search, in the Department field, select . 9. Search for and select VM3 Vertical Mill 3x Matsuura.

The Work Queue redisplays. 10. In the tree view, in theCurrent Work node, select the work order and operation you releas ed and scheduled in Workshop - Enter a Job. 11. Navigate to the Job Details > Staged Details sheet. 12. In the Stage Details grid, select the line for part CS-036, Quantity of 25. 13. Click the Select for Work button.

The Start Activity From Work Queue window displays. 14. In the Resource field, select the second resource. 15. Click the Production button.

Zeke started to produce parts.

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16. Exit the Work Queue. 17. Remain logged in as Zeke Graham.

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Complete an Operation 1. Verify the Production sheet displays. 2. In the grid, select the operation and click the End Activity button.

The End Labor Activity window displays. 3. In the Current field, enter 100 and press Tab.

The Request Move and the Complete check boxes are selected. 4. Click OK.

The 5. If the Transaction efficiency % is over limit. Do you want to continue? message displays, click Yes. 6. Click the Log Out button. 7. Remain in MES for the next workshop.

Move Completed Parts John Lewis, material handler, has been monitoring the material queue regularly and notices new entries that occur since the beginning of his shift. In this workshop, he moves the parts completed on operation 10 to operation 20. 1. Click the Log In button. 2. In the Enter Employee ID field, enter 197 (John J. Lewis) and click OK.

John J Lewis is the material handler. 3. Navigate to the Material sheet and click the Material Queue button.

The Material Request Queue window displays. 4. In the Unselected List grid, select the part completed on operation 10 (H-4600, quantity of 100) and click the Process button.

The WIP/Material Movement Transaction window displays. 5. In the To Location section, in the Warehouse field, verify Production Floor displays. 6. In the Bin field, seach for and select ASM. 7. Click OK. 8. Click the Close button. 9. Click the Log Out button. 10. Remain in MES for the next workshop.

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Workshop - Review the Job Status In this workshop, Charles Johnson, shop supervisor, reviews the current status of the job created in the Workshop - Enter a Job. 1. Click the Log In button. 2. In the Entry Employee ID field, enter 105 (Charles Johnson) and click OK.

Charles Johnson is the shop supervisor. 3. Click the Job Tracker button.

The Job Tracker displays. 4. In the Job field, enter the job number created in the Workshop - Enter a Job and press Tab. 5. In the tree view, right-click the job number and select Tree > Expand Tree. 6. In the tree view, navigate to Opr: 10 OP:MILL > Mtl: 10 CS-036 . The Job Details > Materials > Material Transactions sheet displays. 7. Click the Retrieve button. The STK-MTL transaction type details display. 8. Navigate to the Job Details > Operations > Labor Transactions sheet and click the Retrieve button.

Labor details for Operation 10 display. Labor is not posted against Operation 20, as this operation has not started. 9. Exit the Job Tracker. 10. In MES, click the Log Out button. 11. Remain in MES for the next workshop.

Shop Tracker Use the Shop Tracker to review current information about shop activity. This includes information on resources, labor activity, and shop warnings. Menu Path: Production Management > Job Management > General Operations > Shop Tracker

Workshop - Complete the Job This workshop demonstrates how to complete the job in the Manufacturing Execution System (MES) and move completed parts to inventory. •

Begin production on operations.

•

Complete operations.

•

Move completed parts to inventory.

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Begin Production Production can now begin on operation 20. The material ordered directly to the job was received and moved to the Assemble per print resource group. Jack Sawyer, a shop worker in the Assembly Department, is assigned to work on operation 20. 1. Click the Log In button. 2. In the Enter Employee ID field, enter 101 (Jack Sawyer) and click OK. 3. To confirm the shift, click OK.

Jack Sawyer is a shop worker assigned to the Assembly Department. 4. Click the Start Production Activity button.

The Start Production Activity window displays. 5. In the Job Number field, enter the job number created in the Workshop - Enter a Job and press Tab. 6. In the Assembly field, verify 0 displays. 7. In the Operation field, select 20. 8. Click OK. 9. Click the Log Out button. 10. Remain in MES for the next workshop.

Check Active Resources Charles Johnson, shop supervisor, checks on the active resources working on the job. 1. Click the Log In button. 2. In the Enter Employee ID field, enter 105 (Charles Johnson) and click OK.

Charles Johnson is the shop supervisor. 3. Navigate to the Supervisor sheet. 4. Click the Shop Tracker button.

The Shop Tracker displays. 5. Navigate to the Active Resources sheet and click the Active Resources button.

The Labor Detail Search window displays. 6. In the Job field, enter the job number created in the Workshop - Enter a Job and click Search. 7. In the Seach Results grid, select the job line and click OK. 8. In the Active Resources grid, review the information.

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9. Exit the Shop Tracker. 10. Click the Log Out button. 11. Remain in MES for the next workshop.

Complete the Operation Jack Sawyer has completed the assembly work and reports that the completed parts are ready to be moved to inventory. 1. Click the Log In button. 2. In the Enter Employee ID field, enter 101 (Jack Sawyer) and click OK. 3. Navigate to the Production sheet. 4. In the grid, select the operation 20 and click the End Activity button.

The End Labor Activity window displays. 5. In the Current field, enter 100 and press Tab. 6. Clear the Request Move check box.

You will not use the Material Queue functionality, but you will ship completed parts using Job Receipt to Inventory. 7. Click OK. 8. To the Operation was completed under estimate message, click Yes. 9. Click the Log Out button. 10. Remain in MES for the next workshop.

Move the Completed Parts to Inventory Now that the parts are reported as complete, they are moved to the proper inventory location. John J. Lewis, material handler, has been informed that 100 pieces should be moved to inventory. 1. Click the Log In button. 2. In the Enter Employee ID field, enter 197 (John J. Lewis) and click OK. 3. Navigate to the Material sheet and click the Mfg Receipts button. Job Receipt to Inventory displays. 4. In the From Job field, enter the job created in the Workshop - Enter a Job and press Tab. 5. In the Quantity field, enter 100.

A new lot number is assigned. Part H-4600 is a lot tracked part.

6. Click OK.

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7. Exit Job Receipt to Inventory. 8. Click the Log Out button. 9. Exit MES.

Workshop - Review the Job Navigate to the Job Tracker. Menu Path: Production Management > Job Management > General Operations > Job Tracker 1. In the Job field, enter the job number created in the Workshop - Enter a Job and press Tab. 2. In the tree view, right-click on the job number and select Tree > Expand Tree.

Each operation and material requirement has a green check mark, indicating the operations are complete and the material issued. 3. Exit the Job Tracker.

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Replenishment Workbench Use Replenishment Workbench as needed to perform material replenishment processing, and to review generated replenishment move requests. It can be used together with Kanban processes in the Epicor application to enable a complete material supply-to-replenish synchronous flow. Note The Replenishment Workbench functionality does not change or affect the Kanban processes, which

are primarily production replenishment functions. The Replenishment Workbench includes the following features and functions: •

Transaction based, fully directed processing driven through a fully managed queue.

•

Paper or paperless processing of transactions.

•

Automatic replenishment based on defined parameters.

•

Manually generate replenishment requests based on defined parameters with overrides.

•

Fully managed user-determined and generated replenishment with no predefined requirements.

•

Configurable Fill to Maximum or Use Replenishment Quantity concepts with overrides.

•

Minimum Threshold Quantity concept allowing for continuous replenishment execution.

•

Determination of supply (available net of allocations and in-process) to the discrete warehouse-bin.

Menu Path Navigate to this program from the Main Menu: •

Material Management > Data Collection > Advanced Material Management > Replenishment Workbench

•

Material Management > Inventory Management > General Operations > Replenishment Workbench

•

Production Management > Data Collection > Advanced Material Management > Replenishment Workbench

•

Sales Management > Order Management > General Operations > Replenishment Workbench


Customer Relationship Management > Order Management > General Operations > Replenishment Workbench

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Material Replenishment Methods Three material replenishment methods (Automatic, Manual, Managed) are available in the Epicor application. Automatic

The Automatic and Manual replenishment generation methods both use replenishment parameters you define at the: •

Part warehouse level in the Part Maintenance > Part > Sites > Warehouse > Detail sheet or

•

Part warehouse bin level using the Part Maintenance > Part > Sites > Warehouse > Bin Information > Detail sheet.

For a part in a given warehouse or warehouse bin location, if a replenishment type code with an Action type of Whse/Bin Replenishment (Auto) has been assigned in the corresponding part warehouse or part warehouse bin record, replenishment generation automaticall y takes place on acontinual basis within the Epicor application. •

This functionality runs in the background and monitors inventory balance levels in real-time.

•

Using replenishment parameters in the corresponding part warehouse or part warehouse bin records, it automatically generates replenishment move requests for those parts requiring material replenishment in specific warehouse (or warehouse bin) locations. Note Refer to the How Automatic Material Replenishment Generation Works topic in the Replenishment Workbench Application help for detailed information on how material replenishment requests are generated and then fulfilled.

Manual

For a part in a given warehouse or warehouse bin location, if a replenishment type code with an Action type of Whse/Bin Replenishment (Manual) has been assigned in the corresponding part warehouse or part warehouse bin record, you use the Replenishment Workbench > Manual sheet to review and manually generate replenishment move requests for those parts requiring material replenishment. This provides you with the ability to precisely control when and how generation of replenishment move requests occur for specific parts. Managed

This method differs from either the Automatic or Manual methods; you use the Replenishment > Managed sheet to create on-the-fly replenishment move requests as needed for parts that have no predefined replenishment parameters.

Replenishment Processing Setup Prior to using theAutomatic or Manual replenishment functions, you must define appropriate control parameters in Site Configuration Control, Warehouse Bin Maintenance, Kanban Type Maintenance and Part Maintenance. The required replenishment setup includes the following:

56

•

Site Configuration Control - Use the Replenish Bin To Bin Priority field in the Modules > AMM sheet to indicates the priority level that should be assigned to replenishment requests.

•

Warehouse Bin Maintenance - Define operating characteristics (description, zone, size, sequence, type, location and fulfillment parameters) for each bin in warehouses you are replenishing , and for bins in warehouses that are sources of replenishment materials. The Replenishment functionality uses the sequence number for bin sorting when determining available supply in a designated supply warehouse.

•

Kanban Type Maintenance - Define Automatic and Manual replenishment type codes.

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Part Maintenance - Define parameters that designate how the quantity requirements for the part should be replenished in specified warehouses (or warehouse bins) using the Automatic and Manual replenishment functions.

Warehouse and Bin Setup The following rules apply for the replenishment warehouse and bin setup: •

When replenishing inventory at the part warehouse bin level, the supply bin can be in the same warehouse as the destination bin.

•

When replenishing inventory at the warehouse level, the designated supply warehouse (in a part warehouse or part warehouse bin record) must be different than the destination warehouse.

•

If you select a supply warehouse, but do not specify a supply bin in the Supply Bin field, the Epicor application considers the total inventory in the supply warehouse as available replenishment stock.

•

If you specify both a supply warehouse and a supply bin, the Epicor application searches for available replenishment stock in the designated supply bin only.

Workshop - Set Up Warehouses and Bins In this workshop, set up warehouses and bins to explain the Replenishment process later in the course. Navigate to Warehouse Maintenance. Menu Path: Material Management > Inventory Management > Setup > Warehouse 1. From the New menu, select New Warehouse. 2. In the Warehouse field, enter XXX-PICK (where XXX are your initials). 3. In the Description field, enter XXX Picking Warehouse (where XXX are your initials). 4. Click Save. 5. Click the Bins button. Warehouse Bin Maintenance displays. 6. Click New. 7. In the Bin field, enter XXX-Pick1 (where XXX are your initials). 8. In the Description field, enter XXX Picking Bin 1 (where XXX are your initials). 9. In the Sequence field, enter 10.

The Replenishment functionality uses the sequence number for bin sorting when determining available supply. It then searches bins sorted by their assigned sequence number. If none have been assigned, it searches bins sorted by bin identifier. 10. Click Save. 11. Click New. 12. In the Bin field, enter XXX-Pick2 (where XXX are your initials). 13. In the Description field, enter XXX Picking Bin 2 (where XXX are your initials).

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14. In the Sequence field, enter 20. 15. Click Save. 16. Exit Warehouse Bin Maintenance. 17. Repeat steps 1 to 16 to add two more warehouses and their respective bins (where XXX are your initials): Warehouse ID

Warehouse Description

Bin 1 ID

Bin 1 Description

Bin 2 ID

Bin 2 Description

XXX-STOC

XXX Stock Warehouse

XXX-Stock1

XXX Stock Bin 1

XXX-Stock2

XXX Stock Bin 2

XXX-SUPP

XXX Supply Warehouse

XXX-Suppl1

XXX Supply Bin 1 XXX-Suppl2

XXX Supply Bin 2

18. Exit Warehouse Maintenance.

Kanban Type Maintenance Use Kanban Type Maintenanceto define the specific types of replenishment move requests the Epicor application should generate. You then select and assign Kanban types to part warehouse or part warehouse bin records. The following types are reserved for use in Replenishment Workbench processing: •

Whse/Bin Replenishment (Auto) - Designates that warehouse/bin replenishment move requests should be automatically generated for a part to which this Kanban type is assigned; you review these generated replenishment move requests using the Replenishment Workbench > Moves sheet.

•

Whse/Bin Replenishment (Manual) - Designates that warehouse/bin replenishment move requests should be manually generated for a part to which this Kanban type is assigned; you do this using the Replenishment Workbench > Manual sheet.

Menu Path


Material Management > Inventory Management > Setup > Kanban Type

•

Production Management > Job Management > Setup > Kanban Type

Create Replenishment Type Codes In this workshop, create Auto and Manual replenishment type codes. Navigate to Kanban Type Maintenance. Menu Path: Material Management > Inventory Management > Setup > Kanban Type 1. Click New. 2. In the Type field, enter XXX-Auto (where XXX are your initials). 3. In the Description field, enter XXX Warehouse/Bin Auto Repl (where XXX are your initials). 4. In the Action field, select Whse/Bin Replenishment (Auto).

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5. Click Save. 6. Click New. 7. In the Type field, enter XXX-Man (where XXX are your initials). 8. In the Description field, enter XXX Warehouse/Bin Manual Repl (where XXX are your initials). 9. In the Action field, select Whse/Bin Replenishment (Manual). 10. Click Save. 11. Exit Kanban Type Maintenance.

Part Maintenance Use the Part Maintenance > Part > Sites > Warehouse > Detail or Part Maintenance > Part > Sites > Warehouse > Bin Information > Detail sheets to define parameters that designate how the quantity requirements for the part should be replenished in specified warehouses (or warehouse bins) using the distribution replenishment (Replenishment Workbench) or Kanban functions in the Epicor application. These functions use the defined parameters to monitor on-hand inventory balances for the part at the warehouse (or warehouse bin) levels. These parameters include: 1.

Specifying the warehouse (or warehouse bin) being replenished.

2.

Assigning a code that indicates the type of replenishment (Automatic or Manual replenishment) being performed.

3.

Specifying the supply warehouse/bin, and the initial on-hand, maximum on-hand, threshold and replenish quantities for the warehouse (or warehouse bin) being replenished.

Workshop - Set Up Part Records In this workshop, set up three parts records you will use for operation of the three different material replenishment methods (Auto, Manual, Managed) later in the course. You define parameters that designate how the quantity requirements for the part should be replenished in specified warehouses (or warehouse bins) using the Automatic and Manual replenishment functions. Navigate to Part Maintenance. Menu Path: Material Management > Inventory Management > Setup > Part

Set Up an Auto Replenishment Part 1. From the New menu, select New Part. 2. In the Part field, enter XXX-Auto (where XXX are your initials). 3. In the Description field, enter XXX Auto Part (where XXX are your initials). 4. Click Save. 5. Navigate to the Part > Sites > Warehouses > Detail sheet.

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6. From the New menu, select New Warehouse. 7. In the Warehouse field, select XXX Picking Warehouse (where XXX are your initials) and click Save.

This is the warehouse created previously. 8. From the New menu, select New Warehouse. 9. In the Warehouse field, select XXX Stock Warehouse (where XXX are your initials) and click Save.

This is the warehouse created previously. 10. From the New menu, select New Warehouse. 11. In the Warehouse field, select XXX Supply Warehouse (where XXX are your initials) and click Save.

This is the warehouse created previously. 12. In the tree view, click on the XXX Picking Warehouse (where XXX are your initials). 13. From the New menu, select New Warehouse Bin.

The Part > Sites > Warehouses > Bin Information > Detail sheet displays. 14. In the Warehouse field, verify XXX-Pick displays (where XXX are your ini tials). 15. In the Bin field, search for and select the XXX-Pick1 bin (where XXX are your initials) and click Save. 16. In the tree view, click on the XXX-Pick1 bin to reselect it. In the Replenishment Type field, select XXX Warehouse/Bin Auto Repl (where XXX are your initials).

This is the auto replenishment type created previously. 17. In the Initial/Minimum Qty field, enter 10.

This field indicates the minimum quantity that must be on-hand for this part in this warehouse bin. When the existing on-hand quantity for this part in this warehouse bin falls below this quantity, the Epicor application performs calculations to determine whether a replenishment move request needs to be generated. 18. In the Threshold/Safety Qty field, enter 5.

This field allows you to control how often moves are updated, by entry of a specific floor quantity. When the on-hand inventory balance falls below the designated safety quantity, the Epicor application updates the replenishment move request each time inventory is removed from the warehouse or bin. 19. In the Maximum Qty field, enter 30.

This field indicates the maximum quantity that should be on-hand for this part in this warehouse bin. It is the quantity to which this warehouse bin should be filled when generating replenishment move requests. 20. In the Replenish/Kanban Qty field, enter 20.

This field indicates the replenishment quantity for this part inthis warehouse bin. The Automatic replenishment function always generates a replenishment move request for a quantity that fills the specified warehouse (or warehouse bin) to the quantity designated in the Maximum Qty field (Fill to Maximum). 21. In the Supply section, in the Warehouse field, select XXX Stock Warehouse (where XXX are your initials).

Designates the warehouse that contains an on-hand supply quantity from which inventory is being withdrawn for replenishment of the part in the designated destination warehouse (or warehouse bin).

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22. In the Supply section, in the Bin field, search for and select XXX-Stock1 (where XXX are your initials).

Designates the warehouse bin that contains an on-hand supply quantity from which inventory is being withdrawn to replenish the part in the designated destination warehouse (or warehouse bin). 23. Click Save. 24. Repeat steps 13 to 23 to add the second bin to the XXX Picking Warehouse (where XXX are your initials). Field

Data

Bin

XXX-Pick2

Replenishment Type

XXX Warehouse/Bin Auto Repl

Initial/Minimum Qty

10

Threshold/Safety Qty

5

Maximum Qty

30

Replenish/Kanban Qty

20

Supply Warehouse

XXX Stock Warehouse

Supply Bin

clear

25. Navigate to the Part > Sites > Warehouses > Detail sheet. 26. In the tree view, select XXX Stock Warehouse (where XXX are your initials). 27. Enter or verify the following information displays (where XXX are your initials): Field

Data

Warehouse

XXX Stock Warehouse

Replenishment Type

XXX Warehouse/Bin Auto Repl

Initial/Minimum Qty

100


75

Maximum Qty

500


200

Supply Warehouse


Supply Bin

clear

28. Click Save. 29. Remain in Part Maintenance for the next workshop task.

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Set Up a Manual Replenishment Part 1. From the New menu, select New Part. 2. In the Part field, enter XXX-Manual (where XXX are your initials). 3. In the Description field, enter XXX Manual Part (where XXX are your initials). 4. Click Save. 5. Navigate to the Part > Sites > Warehouses > Detail sheet. 6. From the New menu, select New Warehouse. 7. In the Warehouse field, select XXX Picking Warehouse (where XXX are your initials) and click Save.

This is the warehouse created previously. 8. From the New menu, select New Warehouse. 9. In the Warehouse field, select XXX Stock Warehouse (where XXX are your initials) and click Save.

This is the warehouse created previously. 10. From the New menu, select New Warehouse. 11. In the Warehouse field, select XXX Supply Warehouse (where XXX are your initials) and click Save.

This is the warehouse created previously. 12. In the tree view, click on the XXX Picking Warehouse (where XXX are your initials). 13. From the New menu, select New Warehouse Bin.

The Part > Sites > Warehouses > Bin Information > Detail sheet displays. 14. In the Warehouse field, verify XXX-Pick displays (where XXX are your ini tials). 15. In the Bin field, search for and select the XXX-Pick1 bin (where XXX are your initials) and click Save. 16. In the tree view, click on the XXX-Pick1 bin to reselect it. In the Replenishment Type field, select XXX Warehouse/Bin Manual Repl (where XXX are your initials).

This is the auto replenishment type created previously. 17. In the Initial/Minimum Qty field, enter 10.

This field indicates the minimum quantity that must be on-hand for this part in this warehouse bin. When the existing on-hand quantity for this part in this warehouse bin falls below this quantity, the Epicor application performs calculations to determine whether a replenishment move request needs to be generated. 18. In the Threshold/Safety Qty field, enter 5.

This field allows you to control how often moves are updated, by entry of a specific floor quantity. When the on-hand inventory balance falls below the designated safety quantity, the Epicor application updates the replenishment move request each time inventory is removed from the warehouse or bin. 19. In the Maximum Qty field, enter 30.

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This field indicates the maximum quantity that should be on-hand for this part in this warehouse bin. It is the quantity to which this warehouse bin should be filled when generating replenishment move requests. 20. In the Replenish/Kanban Qty field, enter 20.

This field indicates the replenishment quantity for this part inthis warehouse bin. The Automatic replenishment function always generates a replenishment move request for a quantity that fills the specified warehouse (or warehouse bin) to the quantity designated in the Maximum Qty field (Fill to Maximum). 21. In the Supply section, in the Warehouse field, select XXX Stock Warehouse (where XXX are your initials).

Designates the warehouse that contains an on-hand supply quantity from which inventory is being withdrawn for replenishment of the part in the designated destination warehouse (or warehouse bin). 22. In the Supply section, in the Bin field, search for and select XXX-Stock1 (where XXX are your initials).

Designates the warehouse bin that contains an on-hand supply quantity from which inventory is being withdrawn to replenish the part in the designated destination warehouse (or warehouse bin). 23. Click Save. 24. Repeat steps 13 to 23 to add the second bin to the XXX Picking Warehouse (where XXX are your initials). Field

Data

Bin

XXX-Pick2

Replenishment Type Initial/Minimum Qty

XXX Warehouse/Bin Manual Repl 10


5

Maximum Qty

30


20

Supply Warehouse

XXX Stock Warehouse

Supply Bin

clear

25. Navigate to the Part > Sites > Warehouses > Detail sheet. 26. In the tree view, select XXX Stock Warehouse (where XXX are your initials). 27. Enter or verify the following information displays (where XXX are your initials): Field

Data

Warehouse

XXX Stock Warehouse

Replenishment Type

XXX Warehouse/Bin Manual Repl

Initial/Minimum Qty

100


75

Maximum Qty

500


200

Supply Warehouse


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Field

Data

Supply Bin

clear

28. Click Save. 29. Remain in Part Maintenance for the next workshop task.

Set Up a Managed Replenishment Part 1. From the New menu, select New Part. 2. In the Part field, enter XXX-Managed (where XXX are your initials). 3. In the Description field, enter XXX Managed Part (where XXX are your initials). 4. Click Save. 5. Navigate to the Part > Sites > Warehouses > Detail sheet. 6. From the New menu, select New Warehouse. 7. In the Warehouse field, select XXX Picking Warehouse (where XXX are your initials) and click Save. 8. From the New menu, select New Warehouse. 9. In the Warehouse field, select XXX Stock Warehouse (where XXX are your initials) and click Save. 10. From the New menu, select New Warehouse. 11. In the Warehouse field, select XXX Supply Warehouse (where XXX are your initials) and click Save. 12. Exit Part Maintenance.

Daily Replenishment Processing This section of methods. the courseInexplains daily replenishment processing using the Auto, Manual, Managedand replenishment the Application Setup section you created replenishment codes,and warehouses, new part records that will be now used to explain each replenishment method. Note For the purpose of this course, you must first increase the stock levels for each previously entered part record so it is in line with the Maximum quantity defined in the Part Master file. The Epicor application monitors the inventory transactions being performed against the warehouse (or bin). When a transaction withdraws inventory, therefore reducing the on-hand quantity, and if there is an warehouse Automatic replenishment type code associated with the designated part warehouse or part warehouse bin record, the Epicor application executes Automatic replenishment move processing.

Workshop - Adjust Stock Levels In this workshop, adjust stock levels for the three master part records you created previously. Because they are purchased parts, you would normally place a purchase order with your supplier and receive the parts to stock.

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For the purpose of this course topic, you will use the Quantity Adjustment program to increase stock in the warehouses/bins you created previously. Navigate to Quantity Adjustment. Menu Path: Material Management > Inventory Management > General Operations > Quantity Adjustment 1. In the Part field, enter XXX-Auto (where XXX are your initials) and press Tab. 2. In the Warehouse field, select XXX Picking Warehouse (where XXX are your initials). 3. In the Bin field, search for and select XXX-Pick1 (where XXX are your initials). In the Warehouse Bin Search window, select the Display All Bins check box to display the available warehouse bins. 4. In the Quantity field, enter 30.

This is the Maximum Qty defined in the master part record for this part. 5. In the Reason field, select Add New Part. 6. Click Adjust. 7. In the Warehouse field, select XXX Picking Warehouse (where XXX are your initials). 8. In the Bin field, search for and select XXX-Pick2 (where XXX are your initials). 9. In the Quantity field, enter 30. 10. In the Reason field, select Add New Part. 11. Click Adjust.

Both warehouse bins now carry 30 units of part XXX-Auto (where XXX are your initials). 12. Repeat steps 1 to 11 to adjust quantities in the following warehouse/bins (where XXX are your initials): Note The Maximum Qty value for the XXX Stock Warehouse was 500 units. This value was defined in Part Maintenance at the warehouse level for the XXX-Auto part. Field

Data

Part

XXX-Auto

Warehouse

XXX Stock Warehouse

Bin1

XXX-Stock1

Bin 1 Qty

250

Bin 1 Reason

Add New Part

Bin 2

XXX-Stock2

Bin 2 Qty

250

Bin 2 Reason

Add New Part

13. Click the Part button and search for and select the XXX-Manual part (where XXX are your initials).

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14. Repeat the steps above and adjust the quantities in the warehouse bins as follows (where XXX are your initials): Warehouse

Bin

Quantity

XXX-Picking Warehouse

XXX-Pick1

30

XXX-Picking Warehouse

XXX-Pick2

30

XXX-Stock Warehouse

XXX-Stock1

250

XXX-Stock Warehouse

XXX-Stock2

250

15. Click the Part button and search for and select the XXX-Managed part (where XXX are your initials). 16. Repeat the steps above and adjust the quantities in the following warehouse bin (where XXX are your initials): Warehouse

Bin

Quantity

XXX-Stock Warehouse

XXX-Stock2

200

17. Exit Quantity Adjustment.

Auto Replenishment The key feature of the Automatic Material Replenishment method is that the inventory stocking is triggered by on hand quantity reduction in warehouses and warehouse bins. When the move is triggered depends on the warehouse replenishment values entered in Part Maintenance. Once stock quantities are reduced, a material replenishment move request is automatically generated and the move transaction goes directly to the Material Queue Manager where it is further processed.

Workshop - Work with Auto Replenishment In this workshop, reduce stock levels for the XXX-Auto (where XXX are your initials) part created previously to trigger the replenishment move transaction. Normally, and more often in a real time manufacturing environment, you would reduce stock levels through issuing material to jobs or directly satisfying sales orders, given the XXX-Auto part is marked as purchased. For the purpose of this course, you use the Issue Miscellaneous Material program to reduce the stock levels this part. Once the stock levels are reduced, review the generated replenishment transaction using thefor Replenishment Workbench. Note You will use the Issue Miscellaneous Material and the Replenishment Workbench programs interchangeably to see the relationship between the replenishment move generation and values set in the Part Maintenance > Part > Sites > Warehouses > Bin Information > Detail sheet.

Issue Material from Stock One of your sales representative takes trade show samples from stock on regular basis and gives them out to customers after each trade show. In this workshop, issue 5 trade show samples from stock. Navigate to Issue Miscellaneous Material. Menu Path: Material Management > Inventory Management > General Operations > Issue Miscellaneous Material

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1. In the Part field, search for and select part XXX-Auto (where XXX are your initials). 2. In the Quantity field, enter 5. 3. In the Reason field, select Marketing Trade Show Samples. 4. In the Warehouse field, select XXX Picking Warehouse (where XXX are your initials). Click OK to dismiss the displayed error message. 5. In the Bin field, search for and select the XXX-Pick1 bin. 6. Click OK. 7. In the Part field, right-click and select Open With > Part Tracker.

The Part Tracker displays. 8. Navigate to the On Hand > Bins sheet. 9. Click the Retrieve button. 10. In the Bins grid, in the On Hand column, 25 displays for the XXX-Pick1 warehouse bin (where XXX are your initials).

The srcinal stock quantity was 30 units. This was due tothe quantity stock adjustment performed previously. 11. Exit the Part Tracker. 12. Minimize Issue Miscellaneous Material.

Review Replenishment Workbench Transactions In the previous workshop task, you reduced the stock quantity from 30 to 25 units for a part that is linked to the Auto replenishment type code. In this workshop task, review the generated transactions that result from the stock depletion. Navigate to the Replenishment Workbench. Menu Path: Material Management > Inventory Management > General Operations > Replenishment Workbench 1. In the To Warehouse field, select XXX Picking Warehouse (where XXX are your initials). 2. Clear the Manual and Managed check boxes. 3. Verify the Auto check box is selected.

This check box specifies if replenishment move requests that have been automatically generated by the Epicor application should be displayed in the Moves sheet. 4. Click the Retrieve button to display replenishment move requests that match the specified warehouse criteria. 5. In the Replenishment Moves grid review the generated transactions.

No moves have been generated. This is because the reduced stock quantity for part XXX-Auto (where XXX are your initials) did not fall below the Initial/Minimum Qty value defined in the master part record. 6. Minimize the Replenishment Workbench.

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Issue Material from Stock A week later some of your sales representatives request more trade show samples so you issue additional quantity to satisfy their request. 1. Maximize Issue Miscellaneous Material. 2. In the Part field, verify part XXX-Auto displays (where XXX are your i nitials). 3. In the Quantity field, enter 16. 4. In the Reason field, select Marketing Trade Show Samples. 5. In the Warehouse field, select XXX Picking Warehouse (where XXX are your initials). Click OK to dismiss the displayed error message. 6. In the Bin field, search for and select the XXX-Pick1 bin. 7. Click OK. 8. In the Part field, right-click and select Open With > Part Tracker.

The Part Tracker displays. 9. Navigate to the On Hand > Bins sheet. 10. Click the Retrieve button. 11. In the Bins grid, in the On Hand column, 9 displays for the XXX-Pick1 warehouse bin (where XXX are your initials).

This because 16 units were taken from stock that contained 25 units. 12. Exit the Part Tracker. 13. Minimize Issue Miscellaneous Material.

Review Replenishment Workbench Transactions In this workshop task, review the generated replenishment move transaction. 1. Maximize the Replenishment Workbench. 2. In the To Warehouse field, verify XXX Picking Warehouse displays (where XXX are your i nitials). 3. Click Refresh.

In the Replenishment Moves grid, a new move transaction displays. 4. In the Quantity field, 21 displays.

This is the sum of two stock reductions executed previously; 5 + 16 = 21. 5. In the From Warehouse field, XXX-Stock displays (where XXX are your i nitials).

This is the warehouse entered in the Supply section in Part Maintenance.

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6. In the From Bin field, XXX-Stock1 displays (where XXX are your ini tials).

This is the warehouse bin entered in the Supply section in Part Maintenance. 7. Minimize the Replenishment Workbench.

Issue Material from Stock In this workshop task, reduce the on hand stock quantity for part XXX-Auto (where XXX are your initials) further to see the changes in the replenishment move transaction for this part. 1. Maximize Issue Miscellaneous Material. 2. In the Part field, verify part XXX-Auto displays (where XXX are your i nitials). 3. In the Quantity field, enter 2. 4. In the Reason field, select Marketing Trade Show Samples. 5. In the Warehouse field, select XXX Picking Warehouse (where XXX are your initials). Click OK to dismiss the displayed error message. 6. In the Bin field, search for and select the XXX-Pick1 bin. 7. Click OK. 8. In the Part field, right-click and select Open With > Part Tracker.

The Part Tracker displays. 9. Navigate to the On Hand > Bins sheet. 10. Click the Retrieve button. 11. In the Bins grid, in the On Hand column, 7 displays for the XXX-Pick1 warehouse bin (where XXX are your initials). 12. Exit the Part Tracker. 13. Minimize Issue Miscellaneous Material.

Review Replenishment Workbench Transactions In this workshop task, review the replenishment move transaction quantity changes that occur after the stock levels were further reduced. 1. Maximize the Replenishment Workbench. 2. In the To Warehouse field, verify XXX Picking Warehouse displays (where XXX are your i nitials). 3. Click Refresh and review the Replenishment Moves grid. 4. In the Quantity field, 21 still displays.

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Despite taking an additional two samples from stock, the Quantity field still indicates you should move just 21 units. This is because the current on hand quantity is seven units, which is still not below five units, as srcinally defined in the Threshold/Safety Qty field in Part Maintenance. 5. Minimize the Replenishment Workbench.

Issue Material from Stock In thisit workshop reduce the quantity for part XXX-Auto XXX are your initials) one more time to see how will affect task, the replenishment move transaction quantity(where request. 1. Maximize Issue Miscellaneous Material. 2. In the Part field, verify part XXX-Auto displays (where XXX are your i nitials). 3. In the Quantity field, enter 4. 4. In the Reason field, select Marketing Trade Show Samples. 5. In the Warehouse field, select XXX Picking Warehouse (where XXX are your initials). Click OK to dismiss the displayed error message. 6. In the Bin field, search for and select the XXX-Pick1 bin. 7. Click OK. 8. In the Part field, right-click and select Open With > Part Tracker.

The Part Tracker displays. 9. Navigate to the On Hand > Bins sheet. 10. Click the Retrieve button. 11. In the Bins grid, in the On Hand column, 3 displays for the XXX-Pick1 warehouse bin (where XXX are your initials). 12. Exit the Part Tracker. 13. Exit Issue Miscellaneous Material.

Review Replenishment Workbench Transactions Now that the on hand quantity has been further reduced, review how it affects the replenishment move transaction quantity request. 1. Maximize the Replenishment Workbench. 2. In the To Warehouse field, verify XXX Picking Warehouse displays (where XXX are your i nitials). 3. Click Refresh and review the Replenishment Moves grid. 4. In the Quantity field, 27 still displays.

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You reduced stock by additional four trade show samples, which resulted in the current on hand quantity of three units. Because this value is below the five units defined in the Threshold/Safety Qty field in Part Maintenance, the value in the Quantity field reflects the difference between the current on hand quantity of three units and the Maximum quantity of 30 units; 30 - 3 = 27. 5. Exit the Replenishment Workbench.

Manual Replenishment Use the Manual sheet to view proposed replenishment moves, and manually generate actual replenishment move requests for parts that require material replenishment. These are parts for which a Kanban type code with a Replenishment type of Whse/Bin Replenishment (Manual) has been assigned at the part warehouse or part warehouse bin level. To generate manual replenishment move requests, enter the criteria used for the selection of parts in a destination warehouse or warehouse bins. Replenishment move request candidates display in the Replenishment Moves grid. •

Based on their current inventory quantity balances, and the replenishment parameters you have defined at the part warehouse or part warehouse bin levels, it displays the parts that require material replenishment.

•

You can override the calculated move quantities as required, and then generate replenishment move requests.

Workshop - Work with Manual Replenishment In this workshop, reduce stock levels for the XXX-Manual (where XXX are your initials) part created previously to trigger the replenishment move transaction. Normally, and more often in a real time manufacturing envi ronment, you would reduce stock levels through issuing material to jobs or directly satisfying sales orders, given the XXX-Manual part is marked as purchased. For the purpose of this course, you again use the Issue Miscellaneous Material program to reduce the stock levels for this part. Once the stock levels are reduced review the transaction using the Replenishment Workbench. Navigate to Issue Miscellaneous Material. Menu Path: Material Management > Inventory Management > General Operations > Replenishment Workbench 1. In the Part field, search for and select part XXX-Manual (where XXX are your initials). 2. In the Quantity field, enter 9. 3. In the Reason field, select Add a New Part. 4. In the Warehouse field, select XXX Picking Warehouse (where XXX are your initials). 5. In the Bin field, search for and select the XXX-Pick1 bin. 6. Click OK. 7. In the Part field, right-click and select Open With > Part Tracker.

The Part Tracker displays. 8. Navigate to the On Hand > Bins sheet. 9. Click the Retrieve button.

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10. In the Bins grid, in the On Hand column, 21 displays for the XXX-Pick1 warehouse bin (where XXX are your initials).

The srcinal stock quantity was 30 units. This was due tothe quantity stock adjustment performed previously. 11. Exit the Part Tracker. 12. Exit Issue Miscellaneous Material.

Review Replenishment Workbench Transactions In this workshop task, review the Replenishment Workbench transactions triggered by the stock depletion of part XXX-Manual (where XXX are your initials) performed previously. Navigate to the Replenishment Workbench. Menu Path: Material Management > Inventory Management > General Operations > Replenishment Workbench 1. In the Moves sheet, clear the Auto and Managed check boxes. 2. Verify the Manual check box is selected.

This check box specifies if replenishment move requests that have been automatically generated by the Epicor application should be displayed in the Manual sheet. 3. Navigate to the Manual sheet. 4. In the To Warehouse field, select XXX Picking Warehouse (where XXX are your initials). 5. In the Mode field, verify Fill To Maximum displays.

Generates a replenishment move request for a quantity that fills the specified destination location to the quantity designated in the Maximum Qty field (in the part warehouse or part warehouse bin record) for this part and destination location. Example You set the Maximum Qty field for this part to 30 units and reduced the stock levels by 9 units in the previous workshop. If the on-hand quantity in the destination location falls to 21, it generates an automatic replenishment move request for 9 (30 less 21).

6. Click the Retrieve button to display replenishment move requests that match the specified warehouse criteria. 7. Select the Include Above Minimum check box. 8. In the Replenishment Moves grid, review the generated transactions.

A new replenishment move transaction displays. 9. In the Move Qty field, 9 displays.

This is the proposed move quantity for a replenishment move request that would be generated for the transaction row. Once you review the proposed move quantity, you can override it as needed but you cannot enter a negative quantity, or a quantity greater than the quantity available as replenishment supply in the supply warehouse or bin (designated in the part warehouse or part warehouse bin record). 10. In the After Move field, 30 displays.

This is the calculated after-move on hand quantity that would exist in the destination warehouse (or warehouse bin) for the part candidate after the replenishment move request has been processed. It is the

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sum of the current on hand quantity and the replenishment move request quantity in the destination warehouse or warehouse bin. 11. In the Mode field, select Use Replenishment Qty and click the Retrieve button again.

This generates a replenishment move request with a move quantity equal to quantity specified in the Replenish / Kanban Qty field (in the part warehouse or part warehouse bin record) for this part and destination location. 12. In the Move Qty field, the value of 9 changed to 20.

You set the Replenish / Kanban Qty field for this part to 20 units so the Epicor application uses the specified replenishment quantity of 20 as the move quantity. 13. In the Mode field, select Fill To Maximum and click the Retrieve button again. 14. Unlike with the XXX-Auto part (where XXX are your initials), the stock move has not been generated automatically so the replenishment move transaction for part XXX-Manual would not be listed in the Material Queue Manager. 15. Select the item for processing by selecting the Select check box that appears at the beginni ng of the grid row. Alternately, you can select the grid row for processing by clicking it and then clicking the Select button. 16. Click the Generate Moves button.

This generates the actual replenishment move request. 17. In the Move Qty field, 0 now displays. 18. In the In Process field, 9 displays.

This field displays the current in-process move quantity on the resulting move request. It is the total quantity of in-bound material queue requests destined for the selected warehouse or bin. The replenishment move transaction would now display in the Material Queue Manager. 19. Exit the Replenishment Workbench.

Managed Replenishment Use the Managed sheet to create on-the-fly replenishment move requests for parts that have no predefined replenishment parameters. This eliminates the need to assign Kanban replenishment type codes or define specific replenishment parameters at the part warehouse or part warehouse bin levels. To create replenishment move requests: •

Use the Criteria sheet to enter the criteria used for the selection of parts in a destination warehouse or warehouse bins. Using the Part Filter field, you can also designate the specific part numbers, part classes or part groups being filtered in the search.

•

The Epicor application then retrieves matching parts with inventory balances in the designated locations and displays them in the Managed Moves grid. Enter the replenishment move quantity into the Move Qty field for specific transaction rows. The Epicor application does not calculate this quantity; you must manually enter it for each transaction row that requires material replenishment.

•

After specifying the move quantities, select the rows for which actual replenishment move requests are being generated, and then click the Generate Moves button.

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Workshop - Work with Managed Replenishment In this workshop, move 50 units of part XXX-Managed from the XXX Stock Warehouse to the XXX Picking Warehouse. The XXX Stock Warehouse carries 200 units as a result of the stock adjustment executed previously (where XXX are your initials). Navigate to the Replenishment Workbench. Menu Path: Material Management > Inventory Management > General Operations > Replenishment Workbench 1. In the Moves sheet, clear the Auto and Manual check boxes. 2. Verify the Managed check box is selected. 3. Navigate to the Managed > Criteria sheet. 4. In the To Warehouse field, select XXX Picking Warehouse (where XXX are your initials). 5. Click the Retrieve button. 6. In the Managed Moves grid, a replenishment move request line displays. 7. In the Avail field, 0 displays.

Remember that you have added three warehouses to part XXX-Managed; XXX Picking Warehouse, XXX Stock and XXX Warehouse, but increased the stock level only in the XXX Stock Warehouse by 200Warehouse, units (where XXX areSupply your initials). 8. In the To Warehouse field, select XXX Stock Warehouse (where XXX are your initials). 9. Click the Retrieve button again. 10. In the On Hand field, verify 200 displays. 11. In the To Warehouse field, select XXX Picking Warehouse (where XXX are your initials). 12. In the Move Qty field, enter 50.

You would like to move 50 units to your XXX Picking Warehouse. 13. Select the item for processing by selecting the Select check box that appears at the beginni ng of the grid row. Alternately, you can select the grid row for processing by clicking it and then clicking the Select button. 14. Click the Generate Moves button to generate the replenishment move transaction,.

The In Process field now shows the quantity of 50 units. 15. Exit the Replenishment Workbench.

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Completing Replenishment Move Requests Once the physical move of the materials associated with a replenishment move request has been completed, you process and complete the transaction in the following programs, located on the Advanced Material Management General Operations and Handheld Material Handing menus: •

Material Request Queue

•

Process by ID

• •

My Material Queue (Handheld) Material Queue (Handheld)

•

Process by ID (Handheld)

Workshop - Review the Material Queue Manager In this workshop, review the three material replenishment move requests. Navigate to the Material Queue Manager. Menu Path: Production Management > Data Collection > Advanced Material Management > Material Queue Manager 1. In the Manager's Queue grid, scroll down and find the three parts that begin with your initials; XXX-Auto, XXX-Manual, and XXX-Managed (where XXX are your initials). 2. In the Manager's Queue grid, highlight the XXX-Auto line (where XXX are your initials). 3. In the Quantity field, verify 27 displays.

This is the quantity that will be moved from the XXX-Stock to the XXX-Pick warehouse. This is because the XXX-Stock warehouse is set as a supply warehouse in the XXX-Auto master part record (where XXX are your initials). 4. Review the From and To warehouse and bin fields for part XXX-Auto (where XXX are your initials). 5. In the Manager's Queue grid, highlight the XXX-Manual line (where XXX are your initials). 6. In the Quantity field, verify 9 displays.

This is the quantity that will be moved from the XXX-Stock to the XXX-Pick warehouse. This is because the XXX-Stock warehouse is set as a supply warehouse in the XXX-Manual master part record (where XXX are your initials). 7. Review the From and To warehouse and bin fields for part XXX-Manual (where XXX are your initials). 8. In the Manager's Queue grid, highlight the XXX-Managed line (where XXX are your initials). 9. In the Quantity field, verify 50 displays.

This is the quantity that will be moved from the XXX-Stock to the XXX-Pick warehouse. You did not set up the XXX-Stock warehouse as a supply warehouse in the XXX-Managed master part record, but once you generate moves in the Replenishment Workbench the Epicor application searches through warehouses and warehouse bins that are assigned to the part record and pulls the required quantity from a warehouse or warehouse bin that has enough on hand quantities to satisfy the material replenishment move request. Previously, you quantity adjusted warehouse bin XXX-Stock2 and increased its stock levels by 200 units for part XXX-Managed. The application recognized that only warehouse bin XXX-Stock2 has the available quantity and therefore pulled 50 pieces from this bin.

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10. Review the From and To warehouse and bin fields for part XXX-Managed (where XXX are your initials). 11. Exit the Material Queue Manager.

Fulfillment Workbench Use the Fulfillment Workbench to reserve or allocate material to sales orders, job orders, and transfer orders. This functionality is valuable when you want to use jobs or stock in a sequence that matches the allocation priorities assigned to your customers to satisfy material quantity demand. Important

The Fulfillment Workbench is available only if your company uses the Advanced Material Management module. Menu Path


Material Management > Inventory Management > General Operations > Fulfillment Workbench

•

Production Management > Job Management > General Operations > Fulfillment Workbench

•

Sales Management > Order Management > General Operations > Fulfillment Workbench


Customer Relationship Management > Order Management > General Operations > Fulfillment Workbench

Workshop - Enter a Sales Order This morning Dalton Manufacturing submitted a purchase order for five pieces of DCD-300-OR (steel O rings) to be shipped two weeks from today. In this workshop, enter a high priority sales order for Dalton Manufacturing. Navigate to Sales Order Entry. Menu Path: Sales Management > Order Management > General Operations > Order Entry Tip The CRM menu path is: Customer Relationship Management > Order Management > General Operations > Order Entry 1. From the New menu, select New Order. 2. In the Customer field, enter DALTON and press Tab. 3. In the PO field, enter any number. 4. In the Need By, enter the date two weeks from today. 5. In the Ship By field, enter the date two days before the Need By date. 6. Navigate to the Header > Detail sheet. 7. In the Reservation Priority field, verify High Priority displays. 8. From the New menu, select New Line.

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9. In the Part/Rev field, enter DCD-300-OR and press Tab. 10. In the Order Quantity field, enter 5 and press Tab. 11. Click Save. 12. Navigate to the Summary sheet. 13. Record the sales order number_____________. 14. Exit Sales Order Entry.

Sales Order Pick List The Sales Order Pick List displays open sales order releases due within the selected date range. Menu Path: Material Management > Shipping / Receiving > Reports > Sales Order Pick List

Workshop - Submit the Sales Order for Picking In Fulfillment Workbench, you submit the sales order created in the Workshop - Enter a Sales Order for picking. Navigate to the Fulfillment Workbench. Menu Path: Material Management > Inventory Management > General Operations > Fulfillment Workbench 1. On the Standard toolbar, click the binoculars (search) icon.

The Fulfillment Workbench Search window displays. 2. In the Filter section, in the Sales Orders field, verify Include Only displays. 3. In the Filter section, in the remaining fields, select Exclude. 4. Click Search. 5. In the Search Results grid, select the sales order created in the Workshop - Enter a Sales Order and click OK. 6. Navigate to the Order Fulfillment sheet. 7. In the order line, select the Select check box. 8. From the Actions menu, select Reserve > Primary Warehouse Only.

The 1 Demand record(s) reserved message displays. 9. To the message, click OK. 10. In the order line, select the Select check box again. 11. Navigate to the Supply sheet. 12. From the Actions menu, select Reserve > Select and Release for Picking .

A message that indicates the demand record was selected for picking displays.

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13. To the message, click OK.

The Fulfillment Workbench Release For Picking Options window displays. 14. In the Pick date assignment option field, select Ship By Date. 15. Click OK.

A message displays that indicates that 1 Demand Record has been submitted for picking. 16. To the Do you want to print the released items? question, click No. 17. Click Save and exit the Fulfillment Workbench.

Workshop - Move Parts to Shipping John Lewis, material handler, accesses Manufacturing Execution System (MES) to indicate that the 5 pieces of DCD-300-OR have been moved from stock to the shipping dock. 1. On your desktop, double-click the MES icon. 2. In the User name field, enter manager. 3. In the Password field, enter manager. 4. Click OK to log in. 5. In the Employee field, enter 197 (John J. Lewis) and press Tab. 6. Navigate to the Material sheet. 7. Click the Material Queue button. Material Request Queue displays. 8. In the Unselected List grid, select the order line for 5 pieces of DCD-300-OR and click the Select button.

This moves the request to your queue. 9. Navigate to the My Selections sheet. 10. In the My Selection List grid, select the line for 5 pieces of DCD-300-OR and click the Tags button.

The Print Tags window displays. 11. Accept the defaults and click Print Preview. 12. Preview the tags. 13. Close Material Tags. 14. Close the Print Tags window. 15. Click the Process button.

This moves material from stock to the shipping dock. The WIP/Material Movement Transaction window displays.

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16. In the Type field, verify STK-SHP displays.

This indicates the part is being moved from its stock location to the shipping area. Note For a complete list of transaction types, refer to the Appendix Section - Transaction Types.

17. In the From Location section, click the Bin button and search for and select 01-01-03. 18. Click OK.

This finalizes this transaction. 19. Click the Close button. 20. Click the Log Out button. 21. Remain in MES for the next workshop.

Scheduled Shipments Report The Scheduled Shipments Report lists outstanding order releases. It displays them in order by Due Date, Order Number, Order Line, and Order Release. Menu Path: Material Management > Shipping / Receiving > Reports > Scheduled Shipments

Workshop - Ship Parts On the shipping dock, Cory Snyder accesses Manufacturing Execution System (MES) to view the picked orders. When he sees the new line for the 5 pieces of part DCD-300-OR, he begins to process the parts for shipment. When done, he indicates in MES that the parts have been shipped. 1. Click the Log In button.

The Select Employee window displays. 2. In the Enter Employee ID field, enter 700 (Cory Snyder) and click OK. 3. Navigate to the Shipping/Receiving sheet. 4. Click the Customer Shipment button. Customer Shipment Entry displays. 5. From the Actions menu, select Picked Orders.

The Picked Orders window displays. 6. In the Picked Orders grid, in the line that displays 5 pieces of part DCD-300-OR, select the Select check box. 7. Click the Create Pack button. 8. Select the Shipped check box.

This finalizes this transaction. 9. Click Save and exit Customer Shipment Entry.

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10. Click the Log Out button.

Parts have been shipped to Dalton Manufacturing. 11. Exit MES.

Customer Shipment Tracker The Customer Shipment Tracker is a display-only version of the primary entry program. Use this tracker to review current information about a selected record. You cannot add or edit records in a tracker. Menu Path: Sales Management > Customer Relationship Management > General Operations > Customer Shipment Tracker Tip The CRM menu path is: Customer Relationship Management > Sales and Marketing Management > General Operations > Customer Shipment Tracker

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Conclusion

Conclusion Congratulations! You have completed the Advanced Materials Management course.

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Appendix


Appendix This section of the course contains information that is useful during this course, as well as when you use the application in your organization. Topics of discussions include icons in the job tree, costing issues, and backflush information.

Cost Types There are four different cost types for inventory valuation that you use when an item unit cost is required in a transaction, such as an issue to manufacturing. Cost type is initially set in Company Maintenance, and typically you should not change it without consulting the Financial Department. The cost type for each item can be different, for instance, finished goods can be at a standard cost, while raw material at average cost. You can change part's cost type only when the balance falls below zero. You can always change the actual cost of an item using the Cost Adjustment menu option. Average

This cost type is the weighted average cost of an item in inventory. Costs are updated automatically when items are received to inventory. Last

This cost type infers that the last receipt to inventory updates the unit cost. Standard

Issues from, and receipts to, inventory are performed at the same cost. Purchasing or manufacturing variances from this cost are captured by the appropriate General Ledger (GL) accounts. Lot

This cost type is for lot tracked items. This gives you the ability to segregate the unit costs by purchased or manufactured lot. The overall inventory value for a specific item is the average of all lots.

Backflushing Backflushing is the automatic issuing of material. This can occur as you need material for specific labor operations on the site floor or as part of the job closing process. Backflushing can occur at two different points:

82

1.

When a quantity is reported against an operation and the prerequisites are met (see below).

2.

At job completion, when you must backflush unissued material.

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Appendix

Backflushing at Quantity Reporting

Backflushing is a process where the application actually issues materials on your behalf. Backflushing is very dependant on labor reporting. When labor is reported against a related operation, material is then added as operation detail. Prerequisites •

The part must be coded as backflush.

•

The part must have a primary warehouse and a primary bin.

•

The material requirement must be attached to a job operation.

•

The operation must have a labor quantity reported against it.

•

Labor entry must be accurate and timely.

•

Serial number controlled, lot controlled, or dimensionally controlled inventory cannot be backflushed.

Advantages •

Backflushing eliminates the need to manually issue material to each job operation where the material is needed. It happens automatically, eliminating manual efforts.

•

Backflushing takes the scrap factor into account when it computes the quantity used. The quantity required, plus the scrap factor, is backflushed when quantities eliminate manual efforts to calculate scrap.

Common Mistakes Situation

Result

Changing the Backflush flag on a material while transactions are in process

This causes errors in removing material from inventory

Issuing material and selecting the Backflush flag on a part

This causes material to be issued twice

Changing the Backflush flag on a part without running a Where Used report to determine the impact on other assemblies

The user will not know the extent of the manual effort required to issue these parts to jobs

Using substitute materials without informing the application about the substitution

The material called for on a job decreases while the substitute part does not decrease, causing inventory to be incorrect on both parts

Running rework and not reporting it as rework

Inventory is reduced by the amount of pieces reported while no parts were actually consumed

Labor reporting is not timely

Parts are shown in inventory when they have already been consumed

Backflushing at Job Completion or Closing

Backflushing at job completion or job closing is an unconditional backflush. You do not need to attach the material to an operation and do not need to select the Backflush check box on the Part > Site sheet for these parts to backflush. Job completion is a task you perform when the parts on a job are produced and the operations complete. Job completion should not be confused with job closing. Job completion removes the job from manufacturing and places it in a queue for the Accounting department as a candidate for closing. The Accounting department closes a job once the costs are received and recorded. Job completion performs two important tasks: •

Unused capacity on the job is removed. The job disappears from the job scheduling board.

•

Unused material is removed. Inventory or purchasing requirements disappear.

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Important Thoughts to Keep in Mind •

Were these parts actually used on this job? Perhaps they were not needed.

•

Has a cycle count been performed and inventory corrected since they were pulled from stock and today's date?

Assumptions

There is an unstated assumption regarding backflushing that assumes the amount of material you use equals the standard quantity called for on the job. This assumption is a result of the actual process the backflush follows. The application relieves inventory for the quantity per called for on the operation. Warning messages display before the backflush process begins. Users are asked if they want to run the backflush process. They are also warned if the complete quantity value is less than the planned production quantity. If you continue the backflush process, the material issue quantity calculations are based on the complete quantity. Once you backflush a job, the material records are considered issued complete. The process cannot be reversed, so the user should verify whether they are ready to run this process on the current job. Note If you backflush in error, you must adjust the inventory, job quantities, and costs to correct the mistake.

Transaction Types Transaction types classify part transactions. The following transaction types and their descriptions are used to identify each transaction type in a display window or printed report. This is very helpful when you need to research a part in the Part Tracker or when running the Material Transaction Detail report. Adjustments •

ADJ-MTL - Adjustment to job cost material

•

ADJ-SUB - Adjustment to job cost subcontract

•

ADJ-PUR - Adjustment to purchase cost variance

•

ADJ-CST - Adjustment to stock cost

•

ADJ-QTY - Adjustment to stock quantity

Discrepant Material Reporting • •

DMR-MTL - DMR to job material DMR-REJ - DMR to reject

•

DMR-SUB - DMR to subcontract

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STK-DMR - Stock to DMR

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SUB-DMR - Subcontract to DMR

•

DMR-STK - DMR to stock

Inspection Processing

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•

ASM-INS - Assembly to inspection

•

INS-ASM - Inspection to assembly

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INS-DMR - Inspection to DMR

•

INS-MTL - Inspection to job material

•

INS-STK - Inspection to stock

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•

INS-REJ - Inspection to reject

•

INS-SUB - Inspection to subcontract

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STK-INS - Stock to inspection

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SUB-INS - Subcontract to inspection

Appendix

Manufacturing •

MFG-WIP - Manufacturing receipt to job

•

MFG-PLT - Manufacturing receipt to site

•

MFG-STK - Manufacturing receipt to stock

•

MFG-VAR - Manufacturing variance

•

MTL-DMR - Job material to DMR

•

MTL-INS - Job material to inspection

Site •

PLT-ASM - Site to assembly

•

PLT-MTL - Site to job material

•

PLT-STK - Site to stock

Purchasing

•

PUR-INS - Purchase receipt to inspection PUR-MTL - Purchase receipt to job material

•

PUR-STK - Purchase receipt to stock

•

PUR-SUB - Purchase receipt to subcontract

•

PUR-UNK - Purchase receipt to unknown

•

Return Material Processing •

RMA-INS - RMA receipt to inspection

Salvage Material Processing •

SVG-STK - Salvage material receipt to stock

Shipments •

MFG-CUS - Shipment of manufacturing job to customer

•

MFG-VEN - Shipment of manufacturing job to supplier

•

KIT-CUS - Shipment of a kit component to customer

•

STK-CUS - Shipment of stock to customer

Stock Transactions •

STK-ASM - Stock to job assembly

•

STK-KIT - Stock to kit component

•

STK-MTL - Stock to job material

•

STK-MTL - Stock to site

•

STK-SRV - Stock to service

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•

STK-STK - Stock to stock transfer

•

STK-UNK - Stock to unknown

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advanced.material.management.pdf

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