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Warehouse Enhancements

Implementation Warehouse Enhancements Philippe Jacobsen Sr. Program Manager Application Team August 2012. Warehouse Enhancements. Summary. Integration

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Warehouse Enhancements

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  1. ImplementationWarehouse EnhancementsPhilippe JacobsenSr. Program Manager Application TeamAugust 2012

  2. Warehouse Enhancements

  3. Summary Integration • In Microsoft Dynamics NAV 2013, we have improved the integration between warehousing and other product areas, such as manufacturing, order processing, and service. Improved Areas • All three types of warehousing have been improved • Basic warehousing – bin mandatory with order-by-order picking • Advanced warehousing – WMS • The combined offering of advanced and basic warehousing with all documents with bin mandatory

  4. Partner Benefits • Implementation is easier so partners can focus on their specific solution in warehousing, manufacturing, assembly, or service. • Code is more robust and less prone to needing be debugged.

  5. Customer Benefits • More flexibilty in functionality means a better match to current processes and higher productivity. • Customers do not need to set inventory aside at different ”internal” areas of their plant – movement of goods between areas of consumption is easier and more visible. • Allows for more acurate inventory, which allows customers to: • Free up capital to allow investment of other mission critical areas. • Enhance customer service. • Motivate employees when they have a system that fits their requirements, is logical to understand, and easy to use.

  6. What are the Enhancements? • Inventory movement (order-by-order locations) • Defaults bin extended to machine centers and work centers • Flexible output flow from manufacturing (WMS) • Fully integrated assembly-to-order and assembly–to-stock) • Service – shipment of service lines added to WMS • Redesign of ADCS functionality • Better integration with item tracking and reservation

  7. How it was changed • Added a Dedicated property for bins. • Refactored the calculation of quantity available to pick and total available quantity to reserve. • ADCS updates replace ComCom and socketbus, and use web services instead. NAS now runs on the service tier, and database users are no longer used. • Lot Numbers Per Bin FactBox uses the new query object. • Several additional feature updates based on customer feedback

  8. Integration to Manufacturing

  9. Pick to Production Microsoft Dynamics NAV 2009 R2 Location with Bin and Inventory Pick/Put-Away • Mix of roles: Warehouse posts production consumption or production registers warehouse activities. • Not able to set aside items for dedicated activities. • Not able to have a document for movements (needed to use reclassifcation journal).

  10. Pick or Move to Production Microsoft Dynamics NAV 2013 Location with bin and inventory pick/put-away • No mix of roles. • Ability to set aside items for dedicated activities. • Inventory movement document available for planning and handling. • Process with existing inventory pick ”co-exists”. • Requires separate posting of Consumption journal.

  11. Pick or Move to Production Microsoft Dynamics NAV 2013 Location with bin and inventory pick and put away • Dedicated: Bin content is not available for pick • Dedicated bin property has been added. • Bin content is available for posting, for example, sales posting removes item from any dedicated bin. • You can reserve items on a dedicated bin. • NB: WMS – existing functionality: Bin Type Code takes items out of ”Available to Pick Qty.”

  12. Pick to ProductionMicrosoft Dynamics NAV 2009 R2 Location with WMS (directed put-away and pick) • No mix of roles. • Ability to set aside items for dedicated activities (POC lines) • Bin Type Code (QA) takes items out of ”Qty Available to Pick” • Prevents the over-pick and incorrect set aside of items

  13. Default Bin Structure • Default: To fill the POC lines with information about where to place goods • Prioritized default for POC lines: Machine Center, Work Center, Location Card. • For each machine or work Center, a ”To-Production”, ”From-Production”, and an ”Open Shop Floor Bin” can be assigned. • Integration with routings: To-Production bin is for first operation, From-Production is for last operation, Open Shop Floor Bin is for all automatic flushing and respects the routing link code.

  14. Output from Production Microsoft Dynamics NAV 2009 Location with WMS (directed put-away and pick) • Simplicity

  15. Output from Production Microsoft Dynamics NAV 2013 Location with WMS (directed put-away and pick) • Flexible • Combination of manual update and default setup

  16. Integration with Manufacturing • Summary • Introduces Inventory Movement document • Allows for stage bin for inventory pick locations • Establishes a more flexible defaulting system • Provides a flexible outbound flow back to the warehouse

  17. New Areas – Assembly and Service

  18. Integration with Assembly All warehouse configurations are supported • Assemble –To-Stock (ATS) flow, easy: • To Assembly: Invt. movement, Warehouse pick • From Assembly: Post Assembly to a default bin, warehouse processes pick it up from there • Assemble-To-Order (ATO) flow, more difficult: • Only one posting - this implies that components are available prior to ”auto-consuming” • Default bins widely used • To-Assembly Bin: Inventory movement, Assembly lines bin code • From-Assembly Bin: Default per location card or change on Assembly header

  19. Integration with Assembly • Mixed ATS and ATO flow, difficult: • Designed so that both flows are defined on one sales order line. This meets customer requirements for efficient sales order tracking and price calculation. Limitations of ERP solutions (like create two lines, one ATS and one ATO) does not surface. • The solution includes certain rules about the sequence of operation, such as to ship the ATO quantity before the inventory quantity.

  20. Integration with Service • Service order lines is now a source document for the warehousing system (similar to Production Order Component lines) • Release-to-Ship status added to service orders. • Only supported in WMS. • Service invoice can ship and invoice line items as long as a bin with type Pick wiith the property Dedicated is specified. This allows for a process where spare parts moved to a Service Pick bin and dedicated bin can be used for servicing ”on site”. The dedicated property ensureS that it does not interfere with existing pick processes.

  21. Service Line Integration to WMS Service Order • Release to ship • Create Whse. Shipment Service Lines • Service lines defined for items are now accessible from the warehouse Warehouse Shipment • Part of outbound source documents After inclusion on Warehouse Shipment, the pick process is identical to other outbound order lines, create pick, or use pick worksheet.

  22. Additional Improvements

  23. Refactoring • Refactoring of integration between Reservation and Quantity available to Pick. • ”Reserved Pick and Ship Qty.” field replaced by a function. • Clarification of concepts with ”Qty. available to Reserve” and ”Qty. Allocated in Warehouse”. • New Location Option – E.g. White without Directed Put-Away and Pick • Added default bins and made adjustments to avoid errors when two bins are equal on take and place lines. • Added to all tests.

  24. Visibility Enhancements – New FactBox • FactBoxfor Warehouse Pick, Put-Away, etc • Lot quantity per bin, using query

  25. Item Tracing • Item Tracing • Ability to skip already traced branches has been added. • The time is so much faster, the report so much cleaner.” • Exponential redundant records are fixed.    • Example improvements with transfers and production: • Item Trace No Components = from 831 lines to 52 Lines after applying the fixItem Trace with ALL Components = from 5,480 lines to 60 Lines after applying the fix

  26. Item Tracking and Reservation • One critical scenario with deletion of warehouse shipment after registration of pick with IT • Sales Order has no IT (Item Tracking specification) • Whse. Shipment created, still with no IT • Whse. Pick created, IT is specified during picking, the pick is registered • The IT is automatically synchronized with Sales Order (existing functionality) • At late inspection, the personel decides not to ship the item picked, the ususal procedure is to delete the warehouse shipment, and create a new warehouse shipment. But the ”faulty” IT specification was resilient to deletion as it was synchronized with sales order meaning that new warehouse shipment was created with the exact IT that the warehouse personel did not want to ship. The work around was to delete the IT from the sales order, which is not a standard procedure for warehouse employees. • In Microsoft Dynamics 2013, you can delete IT populated by pick from sales order when deleting the warehouse shipment. • Ability to cancel reservations before creating negative adjustments • Several bug fixes

  27. Automated Data Capture System (ADCS)

  28. Reasons for technical changes • Platform changes that impacted the ADCS solution • No support for server-side COM components: • Socketbus adapter, ComCom • Discontinued the concept of database users • Classic Application server => NAS on NST • Goals for refactoring • Simplifying installation • Performance

  29. Microsoft Dynamics NAV 2009 Implementation User setup

  30. Microsoft Dynamics NAV 2013 Implementation • True Queue optimization: Tasks get assigned to first available NST, unlike Microsoft Dynamics NAV 2009 round robin implementation, where tasks are slotted and might wait for a time out if waiting for a long task.

  31. Installation and Setup • Install the additional ADCS components – VT100 • VT100 changes • web.config file – specifies the location of the web service • Multiple service tiers setu p in the Web.config file • Changed Queue-mechanism to central queue • Create and publish ADCS Web Service – exposing Code Unit 7714 • Create users that need access through a handheld device • Setup the warehouse employee needs to be set for using ADCS • All other NAV specific settings are as usual • Still not supporting warehouse scenarios with dialog boxes that requires user interaction such as warnings if the Bin Capacity Policy is set to Prohibit more than Max Capacity

  32. Setup ADCS users

  33. Summary

  34. Source document changes – Summary Location with Invt. Pick (Bin + Pick) Source Documents for Inventory Pick: Source Documents for Inventory Movement: Released Sales Order Released Transfer Order Negative Quantity on Released Purchase Order Released Return Purchase Order Released Sales Order with Asmb. Order (ATO) [new] • Released Production Order/Comp. Lines [new] • Released Asmb. Order/Asmb. Order Lines (ATS & ATO) [new]

  35. Changes to source docs. for Warehouse Location with WMS (Directed Put-away & Pick) Source Documents for Warehouse Shipment: Documents acting as Warehouse Source Document: • Released Warehouse Shipment • Released Production Order/Comp. Lines • Released Assembly Order/ Assembly Order Lines (ATS & ATO) [new] • Released Sales Order • Released Transfer Order • Negative Quantity on Released Purchase Order • Released Return Purchase Order • Released Sales Order with Assembly Order (ATO)[new] • Released To Ship Service Order [new]

  36. Summary of Each Location Type

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