Production Guide

Production Guide

The process chain of the production consists the following steps:

creating a production order
releasing the production order
picking for the production
starting the production
moving the components to the production line
producing
finishing the production

1. Configuration settings for the production

Before starting the production process, adjust the following configuration settings:

1.1. Quality status
Define the default status for the produced items. At the company level of the Organizational Structure go to the Production tab. Select the quality status from the dropdown menu. For more information about the quality status see: 5.1.9. Quality status

1.2. Production line settings
Adjust the settings of the production lines. For more information about the production line settings see: 5.2.3. Production line settings

1.3. Production controller
Customize the settings of the production in the production controller. For more information about the production controller see: 5.1.3.48. Production controller

1.4. Picking for production
Customize the settings of the picking in the Picking for production controller. For more information about the controller see: 5.1.3.47. Picking for production controller

1.5. Batch number of the product
When producing items managed by batches, specify the settings of the batch number.
On the Batchnumber production company controller, select an extension to define the batch number format. Adjust the batch number settings on the controller. For more information about the batch number controller see: 5.1.3.4. Batchnumber production company

1.6. Best before date for the product
The best before date settings can be specified for items with best before dates.
Adjust the calculation formula of the best before date on the 3.2.3.29. Expiry definition UDT. Link the expiry definition to the item in the Produmex Production tab on the 3.1. Produmex Production Tab.
Adjust the settings of the best before date modification on the Best before for production generator. For more information about the generator see: 5.1.3.6. Best before for production generator

1.7. Item settings
Adjust the settings of the product and the materials in the Produmex Production tab of the Item Master Data. For more information see: 3.1.3. Produmex Item Master Data Tabs

1.8. Scale configuration
It is possible to integrate a scale to the production process. For more information see:8. How to setup/ integrate a scale with Produmex

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2. Create a production order

Create a production order in SAP B1. For more information about the Produmex extensions on the ’Bill of Materials’ and ’Production Order’ screens see: 3.3. Production When a production order is created, both the SAP and Produmex status of the order is ‘Planned’.

3. Release the production order

Production orders can be released in the office environment only. The order release can be performed on the production order or on the production manager.

3.1. Production order

3.1.1. Assign the production line on the production order

Please note that the production line can only be assigned or changed on the production order if the SAP status of the order is ‘Planned’.

Select a production line from the dropdown menu next to the ‘Warehouse’ field. Only the active production lines located in the product’s warehouse are listed.

3.1.2. Release the order

Change the SAP status of the order from ‘Planned’ to ‘Released’ then press the ‘Update’ button. The Produmex status of the order will remain ‘Planned’ until the production is started. As long as the Produmex status is ‘Planned’, the SAP status of a released order can be changed to ‘Planned’ or to ‘Closed’.

3.2. Production manager

Open the ‘Production manager’ from the Produmex Production menu. For more information about the Production manager screens see: Production manager screens

Press the ‘Production orders’ button to open the ‘Production order’ screen.
On the Production order screen select the production line from the dropdown menu.

Select a production order from the list. The following production orders will be listed:

Production orders without an assigned production line. These production orders will be listed under every production line. The ‘Production line’ field is empty.
Production orders assigned to the selected production line.

To release the order click on the ‘Release order’ button. The status of the order will be changed from ‘Planned’ to ‘Released’. The ‘Release order’ button is only active when the status of the selected line is ‘Planned’.
After a production order without an assigned production line has been released, the production still can be started at any free production line.

4. Start the production order

Production orders can be started in the office environment or on the shopfloor.
When using the ‘Receipt from Production’ flow, it is possible to start multiple production orders on one production line, except if the ‘Only 1 started production order allowed’ option is set to true for the production line. For more information see: 5.2.3. Production line settings
When using the ‘Production’ flow, only one started production order is allowed on the production line.

4.1. Office

In the office environment the production order can be started on the production order or on the Production Manager.

Production order
Click on the ’Start’ button to start the production order. The button is only active is the following verifies:

The status of the production order is released.
The production order has an assigned production line.

A ‘Start production’ window will open up. Click on the ’Cancel’ button to close the form.

Production manager
Open the Production Manager and click on the ’Production orders’ button. Select the production line from the dropdown menu. Select the production order and click on the ‘Start production order’ button. The button is only active when the status of the selected order is ‘Released’.

A ‘Start production’ window will open up. To go back to the previous screen, click on ‘Cancel’.

4.1.1. Assign a tank

When there is a component that has to be lined up, assign a tank to the component on the ‘Start production’ screen before starting the production order.
Select a component from the ‘Lined up tanks’ section. Then select a location listed under ‘Tanks’. Only locations that verify for the following are listed:

the location is lined up
the location is added to the production line as a lined up location
there is stock of the component available on the location

Press the ‘Assign tank’ button. After a lined up location has been assigned to the component, the code of the location is displayed in the ‘Tank’ field.
When the ‘Auto line up selection’ option is enabled on the Item Master Data of the component, the system will automatically line up the location for the component.

4.1.2. Batch number and best before date

When the produced item is managed by batches and/or has a best before date, based on the settings, the batch number and the best before date can be changed on this screen. For more information about the batch number and best before date settings for production see: 1.5. Batch number of the product, 1.6. Best before date for the product. Enter the batch number(s) and/or select the best before date from the calendar.

4.1.3. Start the production order

After the lined up locations have been assigned and the batch number(s) and best before date have been defined, click on the ‘Start production’ button to start the production.
After the production order has been started, the status will be changed from ‘Released’ to ‘Started’ and the order will be assigned to the production line where it was started. On the production order the Produmex order will be changed to ‘Started’. The SAP status will remain ‘Released’.
The ‘Production line details’ button is only active when a production order with the status ‘Started’ is selected. It opens up the ‘Production details’ screen.

4.1.4. Change tank

It is possible to change the assigned lined up location after the production has been started. On the ‘Production detail’ screen select a component from ‘Ingredients (lined up)’ list. Then select a lined up location from the ‘Tanks’ list. Click on the ‘Change tank’ button. This button is only active if the selected lined up location is not assigned to the component.
A ‘Production – swap tank’ window will open up.
Add the quantity or weight remaining in the previous tank to the respective field.

4.2. Shopfloor

Production orders can be started also on the shopfloor. When using the default settings, the production order can be started only in the ‘Production’, Disassembly’ and ‘Disassembly – weight’ flows. When the ‘Allow starting production order on production receipt flow?’ option is enabled on the Production controller, the production order can be started also in the ‘Receipt from Production’ flow.

For the detailed description about starting production orders on the shopfloor see:

Receipt from production flow:8.1.2. Select a production order
Production flow: 8.2.4. Start production
Disassembly flows:8.3.4. Start production

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5. Production picking

In the picking step collect the needed components for the production. Based on the Production line settings, the destination of the picking can be the input location or the pick to location.

Produmex offers two flows for picking the components of a production. The ‘Picking for production’ flows uses the production order as an input. Because the picking is performed without a picklist, the stock to be picked is not locked in the inventory. The picked quantity can exceed the planned quantity in the production order.

The ‘Picklist for production’ flow uses a pick list generated from the production order as an input. The system will lock the stock when creating the proposal and the pick list. Pick lists can only be generated from a production order when the ‘Create proposal for picking’ option is set to true in the Picking for production controller. The picked quantity cannot exceed the proposed quantity in the pick list.

5.1. Picking for production

Press the ‘Picking for production’ button. On the next screen select a task.
Press the ‘Normal picking for production’ button to pick for the production.
Press the ‘Unpick’ button to remove previously picked stock from the pick/input location.

When the ‘Allow continuous picking for production’ option is enabled on the Picking for production controller, an additional ’Continuous picking for production’ button is displayed on the screen. When performing the picking with this flow, the system will allow to pick production order lines whose full quantity has been picked.

Picking for production flow

Normal picking for production
Select moveable location
Select a product to pick
Select alternate stock
Identify SSCC/ pick location
Identify SSCC/ pick location
Identify SSCC/ pick location
Identify product
Select destination location

5.1.1. Normal picking for production

5.1.1.1. Select production order

Select a production order to pick from the list. Only production orders with an assigned production line and ‘Released’ or ‘Started’ status are displayed in the list. Proceed with the right arrow button. The following information is shown on the list:

The production order number. Started production orders are indicated with an icon.
The order type. It is possible to pick for ‘Standard’, ‘Special’ and ‘Disassembly’ type of production orders too with this flow. ‘Standard’ and ‘Special’ production orders are indicated with an icon and ‘Disassembly’ production orders are indicated with an icon.
The code, description and barcode of the item to produce.
The destination location of the picking. Depending on the Production line settings, the input or the pick to location of the production line is assigned to the production order.
The due date of the production order.
The batch number of the product.

5.1.1.2. Select moveable location

Press the ‘No moveable location’ button or select a moveable location from a list to move the picked items with a moveable location. The steps for picking with or without a moveable location are identical except for the cancellation. When picking onto a moveable location, the list of the already picked items cannot be cleared.

5.1.1.3. Select a product to pick

Select a production order line to pick from the list. Proceed with the right arrow button. The following information is shown on the list:

The code, description and barcode of the item to pick.
The quantity that still needs to be picked. It is calculated by: {Already picked quantity - Planned quantity}. When picking with the ‘Normal picking for production’ flow, the production order lines whose full quantity has been picked are not displayed on the list. When picking with the ’Continuous picking for production’ flow, those order lines are displayed too.
The available quantity on the input location of the assigned production line.
Optional components are indicated with an icon.
Lined up and time registry components are not listed.

5.1.1.4. Identify SSCC/ pick location

Identify the SSCC or location to pick from. The system sorts the proposed stock based on the option selected as ‘Picking order by’ in the Picking for production controller. The details of the first proposed stock will be displayed on the bottom of the screen.
When the proposed stock to pick has a linked SSCC, the ‘Scan an SSCC’ screen is displayed. On the bottom of the screen the pick location and the SSCC is shown. Scan the SSCC.
In case of the scanned SSCC was linked to a single item or batch pallet, the system asks whether to move the full pallet or not. Press the ‘Yes’ button to move the full logistic unit. Press ‘No’ to move only a partial unit.
To pick only a partial pallet, press the ‘Pick partial logistic unit’ button. On the next screen scan the SSCC. When moving only a partial logistic unit, identify the products to move.

When the proposed stock to pick has no linked SSCC, identify the pick location. Scan the location or select it from the list after pressing the ‘Select location’ button. Only the location that is displayed on the bottom of the screen can be scanned or selected.

5.1.1.5. Select alternate stock

To pick from another SSCC or location, press the ‘Alternate stock’ button and select a production line from the list and proceed with the right arrow button. The following information is shown on the list:

Pick location
Quantity to pick
Code, description, barcode of the item to pick
Batch number
Best before date
SSCC if the displayed stock is full pallet

On the next screen scan the SSCC or the pick location.

5.1.1.6. Identify product

Identify the product to pick. In case a full logistic unit is moved, the system automatically skips the following screens.
Scan the product or select it from a list after pressing the ‘Select a product’ button. Only items stored on the selected logistic unit or pick location are displayed on the list.

Select the batch from the list. The following information is shown on the list:

Batch number
Second batch number
Best before date
Quality status

When there is only one batch on the location or the logistic unit for the item, then the system automatically proceeds with that batch.

Enter the quantity to pick. The picked quantity can exceed the quantity in the production order, but is limited by the available quantity on the logistic unit or pick location. For more information about quantity entering methods see: 4.3.4. Screens for entering additional information

5.1.1.7. Select destination location

After the product has been identified, scan the destination location or select it after pressing the ‘Select location’ button. Only the default location can be selected as the destination location. The default location is the input location of the production line. When a pick to location is set for the production line, it is the default location.
To continue the picking, press the ‘Continue picking’ button. The system will go back to the ‘Select product to pick’ screen. The button is only displayed when there are still components to pick.
When all the components have been picked, and the destination location has been identified, the system shows the ‘There are no more items to pick’ message.
After the picked items have been moved to the destination location, the system generates a ‘Move’ document in the Produmex office module to register the movement.
When the Picking for production: (After picking 401) print event is set in the Organizational Structure, the system asks whether to print the picklist for production. Press the ‘Yes’ button to print the pick list.

5.1.1.8. Cancellation

To cancel the picking, press the left arrow button. When nothing was picked, the system will go back to the ‘Select a task’ screen.
In case of picking onto a moveable location, the system will ask for identifying the destination location for the already picked products.
In case of picking without a moveable location, the system will ask for confirmation. To cancel the process, press ‘Yes’. The list of the picked items will be cleared. To proceed with the already picked items press ‘No’.

5.1.1. Unpick

Unpick flow

Select production order
Identify SSCC
Identify product
Select destination location

5.1.2.1. Select a production order

Select a production order from the list. Every production order with at least one picked component is displayed in the list, regardless of the flow the picking was performed.

5.1.2.2. Identify SSCC

Scan the SSCC. To select the SSCC from a list, press the ‘No SSCC’ button. Only SSCC’s stored on the pick location of the assigned production line can be scanned or selected.
When there is no SSCC present, press the ‘No SSCC’ button. On the next screen press again the ‘No SSCC’ button.

After an SSCC was identified, scan the GS1 label or press the ’Done’ button to proceed with the unpicking.

5.1.2.3. Identify product

When unpicking only a partial logistic unit, identify the product. Scan the product or select it from a list after pressing the ‘Select a product’ button. Every item that can be found on the pick to or input location will be listed, but only items linked to the production order can be scanned or selected.
When the item is managed by batches and there are more than one batch on the logistic unit or pick location, select the batch as well.

After a product has been identified, the system goes back to the ‘Scan an SSCC’ screen. An extra ‘Book move’ button is displayed. Press this button to finish the unpicking.

5.1.2.4. Identify destination location

After the ‘Book move’ button was pressed, identify the destination location.

A default location is displayed on the screen.

When the location suggestion is enabled for the warehouse, the Default location is the first suggested location calculated based on the logic described in Location suggestions.

Note: When we use the suggested location functionality in the reception flow (receiving items to a location instead of a dock) and the system cannot find a suitable location for the item, it automatically receives the item to the dock.

When the location suggestion is not enabled for the warehouse, the Default location is the standard location set for the given warehouse on the Produmex Inventory tab of the Item Master Data of the item. If the items to move have different standard location set for the warehouse, no default location is displayed.

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Scan an SSCC to unpick the product to that SSCC. If the scanned SSCC is not in stock, identify the destination location on the next screen.

Scan a location to unpick the products to that location or press the ‘Select other location’ to select it from a list.

Press the ‘New SSCC’ button to unpick to a new SSCC. On the next screen scan a location or select it from a list after pressing the ‘Select other location’ button.

After the unpicked items have been moved to the selected location, the system generates a ‘Move’ document in the Produmex office module to register the movement.

After a component was unpicked, it can be picked again with the ‘Normal picking for production’ flow.

5.1.2.5. Cancellation

To cancel the unpicking, press the left arrow button. When there are already unpicked products the system will ask whether to process with the unpick or not. Press the ‘Process unpick’ button to book the unpick. Press the ‘Cancel unpick’ button to clear the list of unpicked products.

5.2. Picklist for production

NOTE: in the Beas integration procedure, picklists are created by WMS in the warehouse that is defined in the WO BoM (in case of available inventory) even if a Beas Reservation exists for another warehouse in the actual Work Order.

5.2.1. Office

Before picking with the Picklist for production flow, create a pick list in the office environment.
On the production order click on the ‘Create pick list proposal’ button. The button is only displayed if the ‘Create proposal for picking’ option is set to true in the Picking for production controller. A pick list proposal will be generated and the stock to be picked will be locked. It is only possible to create a pick list proposal for a production order with an assigned production line.
It is also possible to create pick lists for production via the Pick list proposal manager.
Then click on the ‘Gen. pick list’ button on the pick list proposal window to create the pick list. It is only possible to generate a pick list for released production orders.

Production picking flow

Pick list for production
Select a pick list
Select an item
Identify moveable location
Identify the SSCC or pick location
Select batch
Other tasks
Enter quantity
Picked pallet

5.2.2. Shopfloor

5.2.2.1. Initiate the flow

To initiate the flow, press the ‘Pick list for production’ button on the scanner.

5.2.2.2. Select a pick list

Select a pick list from the list. Only active pick lists for a production order will be displayed. The following information is shown on the list:

Production order number
Destination location of the picking. Depending on the settings of the production line, the destination location is the input location or the pick to location of the production line.

5.2.2.3. Select an item

Select a pick list line to pick. Press the right arrow button to proceed.

5.2.2.4. Identify moveable location

Press the ‘No moveable location’ button to pick the components directly to the destination location. During this flow it is not recommended to pick onto a moveable location.

5.2.2.5. Identify the SSCC or pick location

Scan the SSCC or the pick location. To select the pick location from a list, press the ‘Select location’ button.

Pick location
Quantity to pick from the item
Item to pick
Storage logistic unit
Total quantity of the pick list

5.2.2.6. Select batch

When the item is managed by batches and there are more than one batch on the logistic unit or pick location, select the batch as well. Only the batch defined in the pick list can be selected.

5.2.2.7. Other tasks

Press the ‘Other task’ button to reach the following tasks:

Alternate stock
Skip item

Press the ‘Alternate stock’ button to select alternate stock. On the next screen select the alternate stock from the list. After the alternate stock has been selected, identify it as described above.
Press the ‘Skip item’ button to skip the item. The system will go back to the ‘Items still to pick’ screen. (5.2.2.3.)

5.2.2.8. Enter quantity

After the SSCC or pick location was identified, enter the quantity to pick. The picked quantity cannot exceed the quantity in the pick list.

5.2.2.9. Picked pallet

After the quantity has been added, the locking is removed for the product. The product is moved to the destination location. The movement is registered in the Produmex office module in a ‘Move’ document. Proceed with the next line of the pick list. After every component has been picked, the system displays information about the picked pallet.

Name of the production line
SSCC of the new logistic unit

Note:

NEW If the full quantity of the selected item is picked and the 204 - Picking: after item is picked print event is set for the pick list type on the Print Events tab of the Organizational Structure, the system asks if you want to print a label. To proceed with the printing click OK.
When the ‘Picking for production: new LU full event (201)’ print event is set in the Organizational Structure, the print event is triggered and the logistic label is printed. The default report for this print event is the DefaultLogisticsLabel.rpt.

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6. Component weighing production

When the ‘Prod. Order start condition’ is set to ‘Component weighed’ for a component in the Bill of Materials , weigh the component before moving it to the production line.
Please note: This step is only for items where the weight is the primary uom.

Products picked to the Pick to location of the production line can be weighed. When the production line has no pick to location set, the components picked to the input location can be weighted.

6.1. Initiate the flow

Press the ’Component weighing production’ button on the touchscreen.

6.2. Select a production line

Select a production line from the list. Only active production lines will be listed.

6.3. Select a production order

Select a production order from the list. Only released production orders that are not assigned to another production line will be displayed on the list. When there is a started production order on the production line, the system will proceed with that order automatically.
The following information is displayed on the list:

Type of the production order indicated with an icon. Please note that Disassembly type production orders are not supported in this flow.
Code, description and barcode of the item to produce.
Number and due date of the production order.

6.4. Select item to weigh

On the next screen every not lined up material from the production order will be listed.
Different batches will be displayed in separate lines.
The available quantity is the quantity of the batch on the location. The completed quantity is the weighted quantity. The planned quantity is the quantity in the production order line.
The quantity will be displayed in black when the components are not yet weighted but there are enough available stock for the weighing. The quantity will be displayed in red when there are no available stock to weigh. The quantity will be displayed in green when the weighing is completed.
Select a batch and press the right arrow button to weigh the products from that batch.

6.5. Weigh product

Weigh the products. It is also possible to enter the weight manually.
The To-do quantity is the quantity that still needs to be weighed. It is calculated by {Planned quantity-Completed quantity}.
There are two indicator bars displayed on the screen. The to-do quantity is marked on both bars. When the quantity tolerance is greater than zero, the quantity tolerance range is also displayed on the indicator bars.
The weighed quantity is displayed in green on the indicator bars when the quantity is in range. The weighed quantity is displayed in yellow on the indicator bars when the quantity does not reach the minimum range of the to-do quantity. The weighed quantity is displayed in red on the indicator bars when the weighed quantity exceeds the maximum range of the to-do quantity.
Press the ‘<Tare>’ button to tare the scale.
Press the ‘<Zero>’ button to zero the scale.

6.6. Select SSCC

Select the target SSCC for the weighed products. Press the ‘<new>’ button to move the weighed components to a new logistic unit or select an SSCC from the list and press it.

6.7. Finish weighing

Press the ‘Complete weighing’ button to register the weighing of quantities within the quantity range. When the Warehouse: new LU has been created (700) print event is set in the Organizational Structure, the system triggers prints the label. The default report for this print event is the ’DefaultLogisticsLabel.rpt’.
Press the ‘Partial (ask label)’ button to register the weighing of quantities less than the minimum quantity range. Based on the settings in the Production controller, the system might ask whether to print the label when the print event is set in the Organizational Structure.

The weighed products will be moved to the input location automatically.
Press the ‘Return unweighed items’ button to move the unweighed items to the rest location. The system will ask for confirmation. Press the ‘Move’ button to move the unweighted items. Press the ‘Cancel’ button to cancel the movement.

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7. Move Components to the Production Line

You have the following options to move the picked components to the production line:

(1) If you produce with the Receipt from Production flow, the picked components can be moved to the production line with the Move to Production Line flow (see section 7.1 below).

(2) If you produce with the Production flow, you can use the Move to Production Line flow (see section 7.1 below) or you can move the components on the terminal (see 8.2.8. Move the components to the production line).

Note:

When the Auto move all linked items to BOM? setting is enabled on the Production controller, the system automatically moves the components from the input location to the production line after selecting the production order in the Receipt from Production flow or Production flow.

With default settings, components can only be moved from the input location to the production line. If the Allow to move stock to prod. line from rest location? setting is enabled on the Production controller, the components can also be moved from the rest location to the production line.

7.1. Move to Production Line flow

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Start the flow
Select a production line
Select a production order
Select an item to move
Identify the SSCC to move
Identify the SSCC to move
Identify the SSCC to move
Identify the SSCC to move
Identify the SSCC to move
Identify the SSCC to move
Identify the SSCC to move

7.1.1. Start the flow

Tap the Move to production line button on the scanner.

7.1.2. Select a production line

Select the production line on the Select a production line screen and tap the right arrow.

When there is no started production order on the selected line, the system displays the No started production order found message. Tap OK and the system goes back to the Select a production line screen.

7.1.3. Select a production order

If there is more than one started production order, the system displays the Select a production order to pick for screen.
Select a production order, tap the right arrow and the system displays the Production information screen.
If there is one started production order, the Select a production order to pick for screen is skipped and the Production information screen is displayed.
The Production information screen displays the following information:

Production order number
Planned quantity
The code, the description and the barcode of the item to produce
The due date of the production order
Remarks for the production order

Tap OK.

7.1.4. Select an item to move

After identifying the production order, the system lists the components from the production order on the Items to move screen. Only those components are listed that are available on the input location.

Note: Time registry items are not displayed on the list.

Next to the item code the system displays the quantity to be moved. Negative quantity means that the quantity on the production line exceeds the planned quantity.

Select an item and tap the right arrow button.

7.1.5. Identify the SSCC to move

On the Identify the SSCC to move screen you have the following options:

a) scan the SSCC to move (see section (a) below),
b) move a partial logistic unit (see section (b) below),
c) go back to the Select a production line screen by tapping the Stop button or the left arrow.

a) Scan the SSCC to move.

Note: Only SSCCs meeting the following conditions can be moved:

there are items linked to the production order on the logistic unit,
the logistic unit is stored on the input location of the production line.

When the SSCC is scanned and the logistic unit is moved to the production line, the system displays the Logistic unit/items are moved message. Tap OK.

The movement is registered in the Produmex office module in a Move document.

If there are other items to move, the system displays the Identify the SSCC to move screen.

If there is no more item to move, the flow is finished, and the system displays the Select a production line screen.

b) Move a partial logistic unit.

Tap the Partial logistic unit button.
On the Scan a product screen scan the product or tap the Select a product button and select the product from the displayed list.
Enter the number of items on the Enter the quantity screen and tap the right arrow.

Note: The moved quantity cannot exceed the available quantity on the input location, but it can exceed the planned quantity of the component on the production order.

The components are moved to the production line and the movement is registered in the Produmex office module in a Move document.

If there are other items to move, the system goes back to the Identify the SSCC to move screen.

If there is no more item to move, the flow is finished, and the system displays the Select a production line screen.

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8. Production

Produmex supports each of the three SAP B1 production order types.
Based on the significant differences between the ‘Disassembly’ type and the other two types of production orders, Produmex offers disassembly flows in addition to the production flows.
To perform ‘Standard’ and ‘Special’ type of production orders, the system offers two different production flows:

Receipt from production
The flow can be performed either on fixed terminals or on scanners. With default settings the production cannot be started on the thin client. After the production the calculated consumed quantity will be locked. Perform the material confirmation, component issues and the closing of the production order in the Production manager.

Production
The flow can only be executed on fixed terminals. The production can be started on the terminal. The consumed quantities can be modified on the terminal. After the consumed quantity has been confirmed the components are issued and an ’Issue for production’ document is created in SAP B1. In this flow, it is also possible to close the production order on the terminal.

When the ‘Main Touch Production Flow Script’ is set as the workflow for the touchscreen, the Production flow automatically starts on the touchscreen after logging in.

To perform ‘Disassembly’ type production orders, Produmex also has two disassembly flows. The main difference between the two flows is in the way of defining the disassembled quantities.

Disassembly
Enter the disassembled quantity one by one for each component.

Disassembly - weight
Add the disassembled quantities on a collective screen. It is possible to add the quantity by weighing with the linked scale.

It is also possible to perform ‘Disassembly’ type of production orders in the ‘Production’ or ‘Receipt from production flows’.

To initiate the flow, press the ’Receipt from Production’ button on the terminal or on the scanner.

1. Select a production order

Select a production order from the list and press the right arrow button to proceed.
When using the default settings, only the production orders with ‘Started’ status are displayed in the list.
When the ‘Allow starting production order on receipt flow’ option is set to true on the Production controller, the released production orders with an assigned production line are displayed on the list too. The system will automatically change the status to ‘Started’ when proceeding with these orders.

On the scanner, ‘Started’ orders are indicated with an icon. ‘Standard’ and ‘Special’ type flows are indicated with the icon. ‘Disassembly’ productions are indicated with the icon.
After the production order has been selected, the system checks whether there are enough stock on the production line to produce. When there is not enough stock to produce, an error message is shown.

2. Select a task

If there is a by-product line on the production order, the Select task screen opens. This screen is automatically skipped if the production order does not contain by-products.

To produce the main product, press the ’Produce’ button.

To produce by-product(s), press the ’Produce by-products’ button. On the next screen select a by-product to produce from the list. Every by-product from the production order is listed.

The steps of main product and by-product production are similar. The differences are described at each given step.

3. Identify batch

Depending on the batch number settings for production the system might ask to enter the batchnumber, if the product is managed by batches.
Depending on the best before date settings for production, the system might ask to enter the best before date, if the product has a best before date.

When the product has batch attributes, the system asks for adding those attributes too.

4. Select logistic carrier and identify the SSCC

Then select the logistic carrier from the list. Every logistic carrier that has stock on the ‘Stor. Loc. logistic carriers’ location for the warehouse is listed.

To produce without a logistic carrier press the ‘Other tasks’ button. On the next screen select a task:

Press the ‘No logistic carrier’ button to produce onto a new SSCC.
Press the ‘Produce on existing SSCC’ button to produce onto an existing SSCC. On the next screen scan the target SSCC.

The system automatically proceeds to the Select a task screen and skips the Select a logistic carrier screen if there is no available logistic carrier on the ‘Stor. Loc. logistic carriers’ location or if the company does not use logistic carriers. In this case the ‘New SSCC’ button is displayed instead of the ‘No logistic carrier’ button. Press this button to produce onto a new SSCC. No logistic carrier will be linked to the produced item.

The system also proceeds automatically if the product has a ‘Default log. car. production’ set on the Produmex Production tab of the Item Master Data. In this case a ‘Proceed’ button is displayed instead of the ‘No logistic carrier’ button. Press this button to create a new SSCC with a linked logistic carrier.

5. Enter the quantity produced

After the SSCC has been defined, add the produced quantity. By default the planned quantity is displayed, but it is possible to produce different quantities.
The maximum of the produced quantity for the main product is calculated based on the following values:

base quantity of the components from the production order
the quantity tolerance of components set in the production order
the available quantity on the production line

Note: lined up components and time registration items are not taken into account when calculating the maximum quantity.

The calculation of the maximum quantity occurs in three steps:

First the system calculates the maximum producible quantity for each material based on only that material.
Maximum quantity = Quantity on the production line/ (base quantity *(1-quantity tolerance))
Then the system selects the lowest value from the maximum producible quantities. To define the maximum quantity, the system rounds down that value to the decimal places specified for the uom in the Item Master Data of the product.

The produced quantity for by-products is not limited by the available quantity of the materials on the production line.

5.1. Enter the weight

In case of producing a catch weight item, enter the produced weight too. The maximum weight is calculated from the produced quantity, the default weight and the weight tolerance defined in the Item Master Data of the product.

If the Weight Capture needed during Production setting is enabled on Item Master Data > Produmex tab > Production tab, the system displays the Enter the weight screen during the flow. In this case the product / by-product must be weighed with a scale.

Prerequisites: You must define a scale for the production line or the output location of the production line in the Organizational Structure.
The setting applies to items that are not managed by serial numbers.
If the item is a catch weight item, you can weigh the item after the first quantity has been added.

5.2. Items managed by serial numbers

When the item to produce is managed by Produmex or ‘On release only’ type serial numbers, it is possible to add the quantity by scanning the serial numbers or by entering the quantity.
When the item to produce is managed by ‘On every transaction’ type serial numbers, the quantity can only be added by scanning the serial numbers.
For more information about quantity entering methods see: Screens for entering additional information.

6. Production

After the quantity has been added, the product is produced and the system moves the product to the output location. The quality status of the received product is the quality status set as the Quality status production on the Production tab of the Organizational Structure.

When the product is produced, the system locks the consumed stock. The locked quantity is calculated from the produced quantity and the base quantity of the component. Materials are not locked for by-products.

Documents:

When producing by-products, the system creates a receipt for production document for the by-product and no other documents.
When producing the main product, the system creates a receipt for production document for the main product and issue for production documents for material items which are on lined up location with direct consumption setting.

7. Print event

If set in the Organizational Structure, the ‘Production: logistic unit produced event (400)’ print event is triggered and the Production label is printed. The default report of the print event is DefaultProductionLabel.rpt.

8. Item produced

On the screen the ‘The item is produced’ message is displayed. Press ‘Ok’ to go back to the ‘Select a production order’ screen. When the ‘Proceed with current production order after entering quantity on prod. receipt flow?’ option is set to true in the Production controller, the system automatically proceeds with the current production order.

If the production order is not closed, it is possible to produce more than the planned quantity.

Close the production in the Production Manager.

If the Automatically close production orders on completion? (Y/N) setting is enabled on the production controller, the production order is automatically closed when the planned quantity for the main product has been reached. The Issue for Production documents are booked with the planned quantities and the components are issued.

2017/06/12 12:28 · csuhaa

Production flow

1. Initiate the flow

To initiate the production flow, press the ‘Production’ button on the terminal.

2. Select production line

Select the production line where the production will take place. Press the right arrow button to proceed. Every active production line is displayed on the list.

3. Select production order

Select a production order from a list.

The screen lists production orders with type standard and special. For production orders with type disassembly use the Disassembly Flow.
Released production orders that are assigned to the selected production line or that are not assigned to any line yet are displayed on the list.

When there is a started production order on the line, the system automatically proceeds with that order.

4. Start production

After the production order has been selected, the system will display the details of the production:

The code and description of the item to produce.
The due date of the production order and the attached remarks.
The type of the production indicated with an icon.
The planned quantity.
Production order number.

To start the production, press the ‘Start production’ button. When no production line was assigned to the order, it can be started at any production line. After the order has been started on a production line the system automatically assigns that line to the production order.

5. Identify batch

Depending on the batch number settings for production the system might ask to enter the batch number, if the product is managed by batches. If both the product and the by-product(s) are managed by batches, the batch number of the by-product(s) is the same as the batch number of the product.

Depending on the best before date settings for production, the system might ask to enter the best before date, if the product has a best before date. If the product and the by-product(s) have a best before date, the best before date of the by-product(s) is the same as the best before date of the product.

When the product has batch attributes, the system asks for adding those attributes too.

6. Select lined up location

When there are no components that has to be lined up, the system skips this screen.
When there is a component that has to be lined up in the production order, select the lined up location from the list. Different lined up component are displayed on separate screens. A location is listed if the following is verified:

The ‘Can be lined up’ option is enabled for the location
The location is added to the production line as a lined up location
A component that has to be lined up is stored on the location

When there is only one location that verifies these criteria, the system automatically proceeds with that location.
This screen can also be reached by pressing the ‘Change lined up locations’ button on production cockpit.

7. Production cockpit

The next screen is the Production cockpit.

Code, description and barcode of the item to produce
The planned quantity
The number of the production order
The due date of the production order
The remarks added to the production order
The type of the production order indicated with an icon
The list of components that still have to be moved to the production line. The item code, description and barcode of the components and the needed quantity are displayed.
The following components are not listed:
- lined up components
- time registration components
- optional components
Produce button (see 8.2.9.Produce)
Produce by-products button (see 8.2.10. Produce by-products)
Change lined up locations button (see: 8.2.6. Select lined up location)
Add items to use button (see 8.2.8. Move components to production line)
Print product label button (see 8.2.12.Print label)
End production order button (see 8.2.13. End production)
Clock button. Click the button to register time registration items (see 10. Time registration).

8. Move components to production line

The components can be moved either on the scanner or on the terminal. Use the ‘Move to production line’ flow to perform the move on the scanner.
Only stock from the production line’s input location can be moved to the production line. When the ‘Allow to move stock to prod. line from rest location’ option is set to true in the Production controller, stock from the rest location can be moved to the production line too.

Press the ‘Add items to use’ button to perform the move on the touchscreen.
There are three possible ways to move the materials to the production line.

To move only one item, press the ‘Move an item‘ button. Identify the product to move.
First scan the linked SSCC. When the product has no linked SSCC, press the ‘No SSCC’ button. On the next screen scan the product to move or select it from the list after pressing the ‘Select a product’ button. Every item on the input location is listed and can be moved.
After the product has been identified, add the quantity. The moved quantity cannot exceed the quantity stored on the input location.
To move the entire stock of the components, press the ‘Move all items linked to the production order’ button. The system will move the entire stock of the items linked to the production order, regardless of the planned quantity.
To move everything from the input location press the ‘Move all items’ button. The system will move the entire stock from the input location, regardless of the planned quantity or the item.

When the ‘Hide all item buttons’ option is enabled in the Production controller, the system automatically proceeds with the ‘Move an item’ task after the ‘Add items to use’ button have been pressed.
When the ‘Auto move all linked items to BOM’ option is enabled in the Production controller, this step can be skipped as the components were automatically moved to the production line after initiating the flow.
After the components have been moved to the production line, the system registers the movement in a ‘Move’ document in the Produmex office module.

When there are no items displayed on the ‘Items still to pick’ list, it means that all the required not lined up materials are already on the production line and are available for the production.

9. Produce

To produce the items, press the ‘Produce’ button.

After the ‘Produce’ button has been pressed, identify the SSCC to produce on. For the detailed description see: 8.1.4. Identify the SSCC
When the item to produce has batch attributes, the system will ask for adding those attributes too after the SSCC has been identified.
On the next screen enter the produced quantity.

10. Produce by-products

To produce by-products, press the ‘Produce by-products’ button. On the next screen select a by-product from the list. Every by-product from the production order is listed.

Then select the logistic carrier from the list. Every logistic carrier that has stock on the ‘Stor. Loc. logistic carriers’ location for the warehouse is listed.

To produce without a logistic carrier press the ‘Other tasks’ button. On the next screen select a task:

Press the ‘No SSCC’ button to produce without a logistic unit.
Press the ‘No logistic carrier’ button to produce onto a new SSCC.
Press the ‘Produce on existing SSCC’ button to produce onto an existing SSCC. On the next screen scan the target SSCC.

The system also proceeds automatically if the product/by-product has a ‘Default log. car. production’ set on the Produmex Production tab of the Item Master Data. In this case a ‘Proceed’ button is displayed instead of the ‘No logistic carrier’ button. Press this button to create a new SSCC with a linked logistic carrier.

On the next screen enter the quantity to produce. The quantity to produce is not limited by quantity of materials available on the production line. Displayed information:

Production order number
Item code and description
Batch number of the main product/by-product
Best before date of the main product/by-product
Open quantity for the main product

After the by-product is produced, the system returns to the Production Cockpit.

In SAP Business One, the receipt from production document is created and the by-product is taken into stock on the output location of the production line.

11. Enter the weight

Prerequisites: You must define a scale for the production line in the Organizational Structure.
The setting applies to items that are not managed by serial numbers.
If the item is a catch weight item, you can weigh the item after the first quantity has been added.

12. Receive product

After the quantity has been added, the product is produced. The system moves the product to the output line and books a ‘Receipt from Production’ document.
The system issues the lined up materials and books an ‘Issue for production’ document for those components. The issued quantity is calculated as the product of the base quantity of the component and the produced quantity.

Note: If the Direct Consumption of Goods setting (Organizational Structure > Silo > General tab) is disabled, the raw materials are not consumed when closing the production order in the Production Flow. To close the production order the Production Manager must be used.

13. Print label

If set in the Organizational Structure, the ‘Production: logistic unit produced event (400)’ print event is triggered and the Production label is printed. Default report for the print event: DefaultProductionLabel.rpt

There is another way to print the label. On the main production screen press the ‘Print product label’ button. On the next screen add the produced quantity. The system automatically skips this screen, if there is already produced quantity. On the next screen add the number of labels to print.

14. End production

After the product was produced, the production can be continued, stopped or put on hold. This screen can also be reached by pressing the ‘End production order’ button on cockpit.

To go back to the production lines without finishing the production, press the ‘Back to production lines’ button. The Produmex status of the production order will remain ‘Started’.
To go back to the production cockpit, press the left arrow button.
To put the production on hold, press the ‘Put on hold’ button. Issue for Production documents will be booked for the consumed quantities and the components will be issued but the production order will remain open.
To stop the production press the ‘Stop production’ button. Issue for Production documents will be booked for the consumed quantities and the components will be issued and the production order will be closed.
After pressing the ‘Stop production’ or the ‘Put on hold’ buttons, confirm the consumed quantities for the components.

15. Confirm the quantity to consume

The consumed quantity can be modified and confirmed on individual screens for each material. The consumed quantity of lined up materials cannot be modified or confirmed on the touchscreen. The consumed quantity of the time registration components can be added in the next step or after pressing the ‘Clock’ button on the Toolbar.
When the ‘Use waste?’ option is enabled in the Production controller, the waste quantities can be added as well.
When the ‘Skip consumption screen on flow for linked components?’ option is enabled in the Production controller, consumption screens for components that have been prepared (eg. weighted) will be skipped.

The stock on the input location is listed on the screen. The different batches are displayed in separate lines. Products stored on different SSCC’s are also displayed in separate lines.

The ‘Item to consume’ is the item code and description of the component.
The ‘Quantity to consume’ is the product of the produced quantity and the base quantity of the component.
The ‘Difference qty to use’ is the difference of the ‘Quantity to consume’ and the ‘# Used’ quantity.
The batch number, the second batch number and the best before date of the batch.
The ‘# On line’ quantity is the quantity of the stock that was moved to the production line.
The ‘#Used’ quantity is the quantity that was consumed for the production.
The ‘#Rest’ quantity is the quantity remaining on the production line.
The ‘#Waste’ quantity is the quantity of the waste.

The default ‘# Used’ quantity is calculated based on the following logic:

If the available quantity is greater than or equal to the quantity to consume:
Default #Used quantity = Quantity to consume.
If the available quantity is less than the quantity to consume but within the quantity range:
Default #Used quantity = Available quantity.

When the ‘Auto fill consumed quantity from prepared quantity on stop production?’ option is set to true in the Production controller, the default ‘#Used’ quantity for prepared components (eg. weighted) is the prepared quantity, if it is within the quantity range.
The ‘# Rest’ quantity is the quantity of the stock remaining on the production line. It is calculated by {‘#On line’ quantity - ‘# Used’ quantity}.
The # Used (9) and the # Rest (10) quantity of the selected batch can be modified in the respective input field. After the modification press the ‘Update’ button.
Please note: The ‘# Used quantity’ must be within the quantity range defined by the produced quantity and the components base quantity and quantity tolerance. Because the sum of the ‘# Used’ and ‘# Rest’ quantity must be equal to the on line quantity, when modifying either one of them, the other one is automatically updated.
In case of using waste, the # On line quantity is equal to with the sum of the # Used, # Rest and # Waste quantity. When modifying the used or the rest quantity, the system updates the waste (12) quantity automatically. The # waste field cannot be modified manually on the touchscreen.
When confirming the consumed quantity of a serial numbered item, add the serial numbers of the consumed products too. After the consumed quantity has been added, the system ask the method of entering the serial numbers. Select a method then on the next screen scan the serial numbers.

In case of a catch weight component, the default weights are displayed too.

The weight to consume. It is calculated from quantity to consume and the weight defined in the Item Master Data.
The On line, Used, Rest and Waste weight of the batch. By default it is calculated from the weight of the batch available on the production line and the quantity to consume.
The On line, Used, Rest and Waste weight of the item. By default it is calculated from the weight of the item available on the production line and the quantity to consume.
The used weight of the selected batch can be modified in this field.
The rest weight of the selected batch can be modified in this field.
The waste weight of the selected batch is displayed in this field.

Press the right arrow button to proceed to the next component.

16. Time registration

When the production order contains time registration components, define the consumed quantity for those components as well. For more information about time registration see: 10. Time registration

17. Issue components

Once the material consumption is confirmed, the used quantities are issued and the remaining stock is moved to the rest location of the production line. The movement is registered in a Move document in the Produmex office module.

Documents:

When producing by-products, the system creates a receipt for production document for the by-product and no other documents.
When producing the main product, the system creates a receipt for production document for the main product and issue for production documents for material items which are on lined up location with direct consumption setting.
Time registration items are also issued in a separate issue for production document.

18. Production order status

When stopping the production order, the Produmex and the SAP status of the production order will be changed to ‘Closed’.
When putting the production on hold, the Produmex status on the production order will be changed to ‘On hold’, but the SAP status of the production order will remain ‘Released’. The production can be continued after a restart on the production line. The production can only be restarted on the production line where it was performed previously. It is not possible to start an ‘On hold’ production in the Production Manager.

2022/06/27 09:08