implementation warehouse enhancements philippe jacobsen sr. program manager application team august...
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ImplementationWarehouse Enhancements Philippe JacobsenSr. Program Manager Application Team
August 2012
Warehouse Enhancements
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
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.
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.
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
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
Integration to Manufacturing
Pick to Production Microsoft Dynamics NAV 2009 R2
• 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).
Location with Bin and Inventory Pick/Put-Away
Pick or Move to Production Microsoft Dynamics NAV 2013
• 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.
Location with bin and inventory pick/put-away
Pick or Move to Production Microsoft Dynamics NAV 2013
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.”
Location with bin and inventory pick and put away
Pick to ProductionMicrosoft Dynamics NAV 2009 R2
• 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
Location with WMS (directed put-away and pick)
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.
Output from Production Microsoft Dynamics NAV 2009
• Simplicity
Location with WMS (directed put-away and pick)
Output from Production Microsoft Dynamics NAV 2013
• Flexible• Combination of manual update and default setup
Location with WMS (directed put-away and pick)
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
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New Areas – Assembly and Service
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
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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.
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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.
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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.
Additional Improvements
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.
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Visibility Enhancements – New FactBox
FactBox for Warehouse Pick, Put-Away, etc ‒ Lot quantity per bin, using query
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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
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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
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Automated Data Capture System (ADCS)
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
Microsoft Dynamics NAV 2009 Implementation
User setup
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.
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
Setup ADCS users
Summary
Source document changes – Summary
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Location with Invt. Pick (Bin + Pick)
Source Documents for Inventory Pick:
• Released Sales Order
• Released Transfer Order
• Negative Quantity on Released Purchase Order
• Released Return Purchase Order
• Released Sales Order with Asmb. Order (ATO) [new]
Source Documents for Inventory Movement:
• Released Production Order/Comp. Lines [new]
• Released Asmb. Order/Asmb. Order Lines (ATS & ATO) [new]
Changes to source docs. for Warehouse
Source Documents for Warehouse Shipment:
• 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]
Documents acting as Warehouse Source Document:
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Location with WMS (Directed Put-away & Pick)
• Released Warehouse Shipment
• Released Production Order/Comp. Lines
• Released Assembly Order/ Assembly Order Lines (ATS & ATO) [new]
Summary of Each Location Type
Functionality Bin
Bin+ Pick/Put-a
Bin+ whse Ship/Rec.+ whse Pick/Put-a.
WMSDirected Put-a.& Pick
Refactoring, Quantity available to Pick Yes Yes
Inventory Movement and Internal Movement Yes Yes
Dedicated Bin Yes Yes
Default bin in production and outbound flowComp.Lines/RPO lines-MC-WC-Location Yes Yes Yes
Release-to-Ship Serv. O. Lines Yes
Integration with Assembly Order Yes Yes Yes Yes
Visualization of lot per bin FactBox using query Yes Yes
Refurbishment ADCS (Web Services, NAS on NST, user setup) Yes
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