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Batch Order Processing

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The function Batch Order Processing is a licensed function for which  a Specific Module Licence has to be obtained in order to use the function. The application was developed for specific industries where a component is either manufactured or mixed in a specific Batch or quantity and the complete order is packed into one or more container type until the complete batch has been transferred into it's containers.

The manufacturing process is driven from the need to supply the different types of end items or packed configurations of the part manufactured. An example hereof is the manufacture of paint where the requirements exists for packed volumes of eg. 20 liter and 5 liter containers of the same paint. When the paint is manufactured the whole vessel is decanted  into a number of 5 liter and 20 liter containers which are shipped separately on different part numbers. The Manufacturing batch number is however an important parameter which is to be carried on all the containers filled from this batch. It is therefore important to have a direct relationship between the order lines used to manufactured and packed on the same order so that close control can be kept over these items.

In order for the function to perform optimally, the following needs to be in place. The different end items as well as the components have to be linked in a product structure where the end (packed) items are the parents and the mixture is the common component with the quantity per as the packed quantity.

The items needs to be identified with a MPS class code where the packed items  has a MPS code of F for final product and the common manufactured component has a MPS class code of X. This makes the populate of the function and the calculation of values in the grid cleaner and it will give a better end result.

It is as the function implies also better to have both the manufacture mixture and the packed end items Lot controlled for better referencing.

The function was developed to intrepid the planned order demand as from MRP on the final packed products and to calculate the selected end product quantities as per the quantity per to get the sum of the quantity that is needed to be manufactured. The user may however override the quantities.

 

hmtoggle_plus1Actual SG

The Actual SG is calculated by selecting the unit of measure conversion of all the requirement parts on the order which is used to mix the part on line one. The unit of measure of all the requirement parts as well as the alternate unit of measure in the Part Unit of measure table is in either Kilogram or Liter. Using the Liter and Kilogram quantities of the requirements, the actual SG of the part will be re-calculated when the re-calculate button is clicked and the actual SG will be written to the Part Serial Number table for the appropriate Order Line and Lot Number in Column_1.

When the  the As Ord Qty button is clicked, a new order quantity will be calculated for the Order line of the Mixture and will be defaulted to the line quantity.This is only a suggested order quantity and the user can override the quantity as needed.

The purpose of this functionality is to suggest a new order quantity after the  requirements on the order line has been manipulated in order to get the right characteristics of the mixture and to update the quantity when a partial receipt of the Mixture is performed when not all the volume of the mixture can be decanted to determine the final volume or mass of the mixture.

hmtoggle_plus1Apply

The Apply button will processed any data of rows that has been selected and will perform inserts into Order Lines, Order Masters as well as updates of Order Lines after it has been Created. This is a one stop function whish allows the user to have a view on one screen of all the data relevant to the Manufacturing and or packing of a specific batch of material.

hmtoggle_plus1Description

The user can search on part description as well as part number. The Part Description will also populate with Descriptions and Part Numbers from Part Master where the Part is a component part on Product structure with a Source Code of Manufactured.

 

hmtoggle_plus1Division

The combo will populate with Divisions from the Division Table. The selected Division will be inserted as Division on the Order Master when new orders are created.

hmtoggle_plus1Function

The function Combo populates with a list of functions which will assist the user to go to the selected function populated with the relevant data of the selected row in the grid. This combo works in conjunction with the Goto Button next to the combo.

hmtoggle_plus1Goto

The Goto button will open the function selected in the Function Combo with the relevant data in the selected grid row.

hmtoggle_plus1Grid

When a Part to be manufactured is selected via either the Part Number, or  Part Description Column and planned orders exists for the selected part, and or it's Parent parts which has a MPS class code of F where the selected part has a MPS class code of X, lines will be populated for all the component parts and the Parent (Final Parts) will be populated with a proposed order quantity equal to the sum of the Planned orders up till the Horizon Till date. As these lines are selected and the quantities of selected lines are manipulated the quantity on the first line will be calculated according to the Quantity Per on the Product Structure for the selected lines. The quantities on all lines are only default values and can be manipulated as is needed.

The grid will display the following columns.

Select Checkbox;Delete Checkbox; Order Number for Firm; Released or Closed order lines; Line number for  Firm; Released or Closed order lines; Order Line Exists will inform the user if a line has been created. If the Line has not yet been created the column will bear the value NO. If the line has been created the Value Yes will be displayed. When the line has been closed, The value CLS will be displayed; Part Number; Part Description; Unit Of Measure; Scheduled Quantity; Actual Quantity or the Quantity that has been completed; Freeze Requirement, will allow the user to update the Order Quantity without updating the requirement Quantities. This is allowed because in many instances individual requirements are being adjusted in order to achieve the desired results in the Mixture. The result will also have an influence on the final yield quantity  of the order line which can be updated after it is known exactly how many of the product was made; Start Date; Completion Date; Stock On Hand, This value can be varied by selecting a store in the store Combo below the grid; Safety Stock; The later two columns will only be displayed if the Part only has been selected and no Firm; Released or Closed order lines are displayed in the grid. It is only displayed in order to assist the user in deciding how to manipulate the quantities in the grid if needed; Result Message will display any error messages or messages while processing lines in the grid.

hmtoggle_plus1Issue

When the user clicks this button the function Stores to Order Requirements will be Opened and the values of the selected row in the grid as will as the store selected in the Store Combo will be used to populate the fields on the function. The Stores to Order Requirement function will be Opened in the Mode All Unissued Requirements and if the user selects apply, the function will be performed in accordance with the user's normal rights and Security profiles. Please note that only 1 row can be processed at a time.

hmtoggle_plus1Location

The location will default from the the part Stock Location where a default location can be setup for a part. When the row is selected and a store has been selected the default location will be defaulted from the particular store. This value will be used to populate the function Production To Stores when the Receive Button is clicked below. When the issue button is clicked the value will not be used.

hmtoggle_plus1Lot Number

The Lot Number Combo will populate with distinct Lot Number,Part Number,Part Description,and Order Numbers from the Part Serial Number table where the part number is a component Part Number in the Product Structure table and the Part Source code is Manufactured.

Selecting a Lot Number will cross populate the Part Number field which in turn will populate the grid with the selected data as described with the  Part Number and Order number fields.

hmtoggle_plus1Mode

The user has the option to vary between two options i.e. MRP and Manual. When the mode MRP is selected the MRP Horizon frame will be active and the date will default to today's  date. This will control the planned orders to be populated in the grid.

When the Mode manual is selected the Manual frame will be enabled where default Start and Completion dates can be selected.

hmtoggle_plus1MRP Horizon Till

The MRP Horizon till will be defaulted to the current date and will control the populate of order lines in the grid by selecting the sum of all planned orders for final products with completion dates less than the selectd date.

hmtoggle_plus1Order Number

The Order Number Combo populates with Order Number, Order Line Status, Part Description, Part Number, Division Code and Lot Number from the Order Line,Part Master and Part Serial Number tables where the Order Line status is Firm, Released or Closed, the Part Master Source is Manufactured and the Order Type is Production. When a order is selected the grid will be populated with all firm, released or Closed order lines of the selected part order number. The lines on the same order number will normally be the lines associated with the part to be manufactured on line one as well as all the lines for parent items into which the part on line one is packed.

Tis mode is used when the user wants to maintain data on the selected order.

hmtoggle_plus0Part Number

The Part Number Combo will populate with Part Numbers and Descriptions from the Product Structure and Part Master tables where the parts is a Component Part and the Source of the part  is Manufactured.

When a part is selected here the grid will be populated with a suggested order line for the selected part number  where the proposed quantity is defaulted as zero.

The grid will also be populated with parent parts of the selected part where the parent part number is deemed a MPS class item. The MPS classes used in this functionality is as follows. The Component part number selected must have a MPS class code of X (Formula) on the part master and the Parent Part numbers must have a MPS Class Code of F (Final Product) on it's Part Master. The Parent component relationship can be one Component to Many Parents or Final Products.

When the Final Product lines are populated in the grid, the suggested order Quantity will be equal to the sum of the planned orders for the part with a completion date less than or equal to the MRP Horison till date.

hmtoggle_plus1Pick Status

The button labeled Pick Status will display the Pick Status for each existing order line row in the grid when selected. It can vary between Fully Picked, Nothing Picked Or Allocated, Partially Picked, or Not Applicable depending on the pick status of each row.

hmtoggle_plus1Planner

The combo will populate with active employees from the Employee Master Table where the Employee is identified as a Planner. The Employee selected here will be inserted as Planner on the Order Master when new orders are created.

hmtoggle_plus1Receive

When the user clicks the Receive Button, the function Production To Stores will be opened populated with the values of the selected line in the grid and the values of the Store and Location combos.The User can now proceed with the Production to Stores movement in the normal fashion and in accordance with the normal rights and security profiles associated with the function. Please note that only 1 row can be processed at a time.

hmtoggle_plus1Refresh

The button will refresh all the data in the grid as per the database when clicked. Data may have changed since the user last refreshed the screen.

hmtoggle_plus1Show Outstanding Order Lines

When this check box is selected, the grid will be populated with all outstanding planned order lines for parts not yet covered via released orders. The user can then by selecting the planned order lines add additional lines for the final products and increase the quantity of the part used as a component in the packing process.

hmtoggle_plus1Store

The combo Box for Store will allow the user to select a Store from Which he/she wishes to either Issue, or into Which he wishes to Receive Stock  or in order to Manipulate the quantity on hand in the grid showing users what is in stock of a particular part. The value selected here will be used in conjunction with the values in the selected grid row when the receive or Issue button is clicked to populate the values on either the Production To Stores or the Stores to Order Requirements functions.

hmtoggle_plus1Theoretical SG

The Theoretical SG will be displayed as reflected on the Part Unit Of Measure Conversion function Providing the Part Unit Of Measure is either a Liter or Kilogram and the alternate unit of measure is in either Kilogram or Liter. This is in order to be able to calculate the SG for the Order Line Part of the mixture. If either of the unit of measures does not conform to these rules a SG cannot be calculated and therefore the value will display 0.00