Advanced Materials Management.instructor

Epicor 9Advanced Materials Management

Instructor Manual

Disclaimer

Copyright © 2008 by Epicor Software Corporation. All rights reserved. Printed in the United Statesof America. No part of this publication may be reproduced in any form without the prior writtenconsent of Epicor Software Corporation. Epicor, Vantage, and Vista are registered trademarks ofEpicor Software Corporation. All other trademarks are property of their respective owners. Microsoftproduct screen shots reprinted with permission from Microsoft Corporation. Epicor SoftwareCorporation makes no representations or warranties with respect to the contents of this documentand specifically disclaims any implied warranties of merchantability, satisfactory quality or fitnessfor any particular purpose. The contents of this document are believed to be current and accurateas of its date of publication. Changes to this document between reprintings and other importantinformation about the software product are made or published in release notes, and you are urgedto obtain the current release notes for the software product. We welcome user comments and reservethe right to revise this publication and/or make improvements or changes to the products or programsdescribed in this publication at any time without notice. The usage of any Epicor Software shall bepursuant to an Epicor end user license agreement and the performance of any consulting servicesby Epicor personnel shall be pursuant to Epicor's standard services terms and conditions.

90521-900-9206-583

Contents

Advanced Materials Management................................................5Before You Begin.........................................................................6

Audience..................................................................................................6Prerequisites.............................................................................................6Setup.......................................................................................................7

Overview.....................................................................................9Application Setup Review..........................................................10

Company Configuration.............................................................................10Maintenance Programs..............................................................................11

Warehouse and Bin..........................................................................11Reason Code...................................................................................13Allocation Priority.............................................................................13User Security..................................................................................14Shop Employee................................................................................15Resource Group and Resource...........................................................17Part...............................................................................................19

Process.....................................................................................21Fulfillment Workbench..............................................................................21

Workshop - Enter a Sales Order.........................................................21Workshop - Mass Assign Shipping Warehouse/Bin.................................22Workshop - Allocate Material and Submit for Picking.............................22Workshop - Move Parts to Shipping....................................................23Workshop - Ship the Parts.................................................................23

Shop Floor Material Movement...................................................................24Workshop - Enter a Job.....................................................................24Workshop - Create a Purchase Order..................................................27Workshop - Receive Direct Job Material...............................................28Workshop - Start the Job..................................................................29Workshop - Investigate the Status of the AMM Job...............................32Workshop - Complete the Job............................................................32Workshop - Review the Job in the Job Tracker......................................35

QA Inspection Process..............................................................................35Workshop - Receive the Materials.......................................................35Workshop - Move the Material to Inspection........................................36Workshop - Inspect the Material.........................................................37Workshop - Move the Material to the Job.............................................37

Reports and Trackers................................................................38Reports...................................................................................................38Trackers..................................................................................................38

Conclusion................................................................................41

Advanced Materials Management | TOC | iii

Appendix...................................................................................42Icons......................................................................................................42Cost Types..............................................................................................42Backflush................................................................................................42Transaction Types.....................................................................................44

iv | Advanced Materials Management | TOC

Advanced Materials Management

This course is designed to take the student through the features and functionality of the AdvancedMaterials Management (AMM) module.

Hands-on workshops will guide you through this module.

Advanced Materials Management provides the ability to process move requests electronicallybetween inventory and shipping staging or receiving to an inventory location electronically. Italso provides allocation for finished parts in Work in Process (WIP) or Inventory.

Upon successful completion of this course, you will be able to:

• Understand the setup necessary for AMM.• Create sales order allocations using Fulfillment Workbench.• Receive incoming material.• Move finished products to inventory and purchase order receipts to inspection and to the

job.

Instructor Note

Introductions

• Introduce yourself to the group and have students introduce themselves to the group.• Review housekeeping items (location of restrooms, break/lunch arrangements, etc.).• Explain that the course is informal, however, cell phones should be shut off and IM

communication is only permitted during scheduled breaks and the lunch hour.• Stress importance of asking questions, stopping instructor when something is unclear,

and taking notes.

Expectations

• Review any expectations students submitted prior to class.• Ask students if they have any additional expectations and list them on the

flipchart/whiteboard.• Identify any expectations that are covered in another course or discuss them off-line.

Learning Roadblocks

• Ask students what roadblocks can get in the way of meeting the learning objectives andrecord these on the whiteboard/flipchart.

• Explain that both the facilitator and students must try to avoid learning roadblocks and totell each other when they arise.

• Ask students if they have questions about the learning roadblocks.

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Advanced Materials Management | Advanced Materials Management | 5

Before You Begin

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

AudienceSpecific audiences will benefit from this course.

• Shop Floor Manager• Job Planners• Buyers• Material Managers• Production Managers• Schedulers• Project Team Leaders

PrerequisitesBefore you begin this course, be sure you understand the prerequisite knowledge contained inother valuable courses.

• Navigation Course - This course introduces the navigational aspects of the system's userinterface. Designed for a “hands-on environment", general navigation principles and techniquesare available at each of the interface levels of system, module, and program within theapplication. Workshops focus on each of these levels and guide you through each navigationalprinciple introduced.

• System Flow Course - This course introduces a basic quote to cash scenario that includesthe process from the initial customer quote to final cash receipts and payment of supplierinvoices. This course emphasizes the series of processes that make up the quote to cashscenario by using a simple scenario to highlight various transactions. Your organization mayhave more complex processing routines than those described.

• Manufacturing Foundations Course - This course has been designed to introduce you tothe principal building blocks in establishing a strong manufacturing environment. This coursetells you about the necessary prerequisites involved with efficient production floorconfiguration.

• Manufacturing Execution System Course - This course discusses the ManufacturingExecution System (MES), an easy-to-use, online system that allows labor and inventorytransactions to be entered while work is done on the shop floor. Transaction entry is straightforward and rapid with the use of touch-screen, light-pen, or bar coding technology, inaddition to the traditional keyboard and mouse.

• Order Management Course - The course discusses the Order Management module andhow it facilitates the flow of manufactured items from inventory or jobs to the customer.Whether items are shipped from stock or from work in process, a shipping transaction isperformed. All shipping transactions are captured during invoicing in the Accounts Receivablemodule, creating financial transactions that ultimately post to the general ledger. Order entryand shipping are directly affected by the nature of the product and the process, specificallywhether the items are built-to-order or shipped from stock.

• Job Management Course - This course is designed to take the student through the featuresand functionality of the Job Management module. Job Management provides a comprehensive

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6 | Advanced Materials Management | Before You Begin

manufacturing control system designed for routing, scheduling, costing, and tracking ofcustom or repetitive parts produced for inventory or shipped to the customer from the plantfloor.

• Inventory Management Course - This course provides an overview of the inventoryprocess. It demonstrates the required steps required to update and maintain raw materials,WIP, and finished goods inventory quantities and costs.

• Purchase Management Course - This course focuses on activities that occur in theday-to-day life of Purchase Management. The process of Purchase Management includes thecreation and approval of purchase orders and requisitions, managing suppliers and theirprice lists, working with purchase order suggestions, and monitoring the purchase orderprocess using related reports and trackers. The advanced functionality in the SupplierRelationship Management and Purchase Contract modules also aids in managing purchaseorders.

SetupSetup is required before you begin this course.

• The Epicor 9 release must be installed and operational in a training environment.• The workshops contained in this course were written using the Education Database company.

To ensure successful results, you must complete all workshops logged into the same databaseand company. You may need to contact a manager for help to ensure the database is properlyinstalled.

• Determine if the database is installed on the client server ("networked-environment") orinstalled locally.

A networked-environment exists when one education database is installed on the client serverand all trainees are accessing that server at the same time. Some issues can arise duringapplication training within a networked-environment.

• Successive Self-Paced Training: Because some courses share the same datarequirements (part numbers, inventory transactions, and group IDs), a clean or restoredcopy of the data is required after each time a student completes a course. The educationdatabase can easily be restored at any time to provide fresh data for subsequent trainingsessions.

• Concurrent Self-Paced or Classroom Training: Sometimes more than one student istraining on the same course at the same time. If these multiple users have access to asingle installation of the same education data, any data that is created or updated duringthis training may affect on-going training efforts.

Instructor Note

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Advanced Materials Management | Before You Begin | 7

Instructor Note

The following setup is needed to instruct this course:

• Use the following settings for this course:

Default Epicor900Database

managerLogin

managerPassword

EPIC03 - Epicor USACompany

• Depending on what phase this course is taught (implementation, upgrade, refresher),some of the above setup may not be necessary. If teaching this session during theimplementation phase, you may wish to add codes applicable to the company's businesswhen demoing or ask students to add codes applicable to their company's business asthey complete the workshops.

It is highly recommended to review the account that will be used for training to verify allcodes and constants are appropriate based on the workshops and to familiarize yourselfwith the course.

• At times the Facilitator Notes suggest the instructor complete each workshop, and thenask students to complete the workshop. If a small number of students are in class, youmay prefer to do the workshops together.

• Open a system session to navigate to programs within the course. Use the Alt + Tab keysto navigate between the course and system session.

• Verify documentation (e.g., program and field help) execute on your PC and the student'sPC's.

• If training in a networked environment, please read the Networked Environment Guidelinesdocument prior to training. This document is available as a Shared Document on theEPICweb.

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8 | Advanced Materials Management | Before You Begin

Overview

AdvancedMaterial Management (AMM) enables manufacturers to produce electronic requestsfor materials, dispatch those materials, and track inventory movements of all inventory includingraw materials and work in process.

Using wireless terminals and bar coding technology, manufacturers are able to track inventoryin real-time. A manufacturer using the application now has complete control and visibility ofraw materials and work in process as it travels throughout the enterprise.

Review this list for information on key features in the Advanced Material Management (AMM)module.

1. Fulfilment Workbench

• Reserves specific parts in inventory for specific sales orders• Prioritizes orders to allocate stock to the highest priority customers first• Provides more efficient picking and shipping of sales orders

2. WIP Movement and Tracking

• Requests raw material or WIP to be moved in real-time• Monitors the movement of WIP• Obtains the current location of WIP• Drill-downs for serial or lot tracking numbers

3. Other Features

• A material queue is available of parts to deliver to resource groups or resources• Barcodes can be printed at various times to label containers in order to identify WIP and

inventory

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Advanced Materials Management | Overview | 9

Application Setup Review

This section reviews common company configuration factors and master file factors applicableto the AMM module.

Company ConfigurationCompany Configuration defines options for companies in Epicor 9. These options allow youto customize the application to best fit each company.

Menu Path: System Management ➤ Company Maintenance ➤ Company

Not all of the fields within the Company Maintenance (configuration) program will be discussedin this course; if interested in learning more about these fields, they are fully defined in theonline help system.

Instructor Note

Review pertinent fields in the Company Maintenance program that influence the AdvancedMaterials Management module.

All Modules Configuration

Select the Modules tab and display the All Modules sheet. The All Modules configurationsheet defines general system defaults.

There are many fields on this sheet that are important and that are covered in other courses.They are also fully explained in the online help. The section that is important to AMM is theDefault Warehouse section.

General

The general warehouse for the company is selected in this drop-down field. This will defaultinto each part record as it is entered, but it can be changed.

Receiving

The default receiving warehouse and bin is selected in this drop-down field. This will be whereall incoming shipments are placed when they are received.

Shipping

The default warehouse and bin that will be used when products are staged for production isselect in this drop-down field.

Inventory Module Configuration

Select the Modules tab, then the Materials tab and display the Inventory sheet.

There are many fields on this sheet that are important and that are covered in other courses.They are also fully explained in the online help. The fields that are to AMM are explained in thissection.

Print Bar Codes

Bar Codes can be printed in several modules. To be able to print barcodes, this checkbox mustbe enabled. Barcodes are of particular importance in the AMM module for printing labels.

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10 | Advanced Materials Management | Application Setup Review

Use Inventory Adjustment Reasons

Enable this checkbox if you require that reason codes be used when adjusting inventory balances.Inventory reason codes can have general ledger (GL) codes attached for accounting reasons.

Quality Assurance Module Configuration

Select the Modules tab, then the Production tab and display the QA sheet.

There are many fields on this sheet that are important, and that are covered in the QualityAssurance course and also fully explained in the online help. The field that is important toAMM is explained in this section.

Default Inspection Warehouse

This is the warehouse that will default into transactions that are being moved to QA forinspection.

Maintenance ProgramsThis section will cover maintenance programs necessary for the AMM module. In some instancesfields on a specific master file do not apply to AMM. Refer to the online help for additionalinformation on fields that are not reviewed in this course.

Instructor Note

Explain to students that this section will review specific master files and that several workshopswill be completed to cover their setup.

Warehouse and BinThe Warehouse Maintenance program is used to create new warehouses and link newwarehouse bins. The bins may also be created using the Warehouse Bin Maintenance program.

Menu Path: Material Management ➤ Inventory Management ➤ Setup ➤ Warehouse

Instructor Note

Navigate to the Warehouse program and review the following fields as you describe thembelow.

Warehouse

Warehouses and bins segregate materials so they can be readily found when needed. Reports,such as the Stock Status report, can be run by a warehouse. A warehouse can be a separatebuilding or a virtual warehouse anywhere on the plant floor.

Tip Examples of warehouses are:

• finished goods• raw materials• inspection• tooling

Warehouse

The Warehouse field is an ID for the warehouse. It can be up to eight characters in length.

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Advanced Materials Management | Application Setup Review | 11

Tip Examples of a warehouse ID are:

• RAW - for raw materials• FIN - for finished goods

Description

This is the full description for this warehouse.

GL Division

Use this drop-down field to select the default GL division for inventory transactions from thiswarehouse. If the division is not defined here, the system will default to the division for theplant.

Name, Address, City, State

These fields are for reporting and informational purposes.

Bins

Allows the user to define the bins associated with this warehouse. Bins can be added, editedor deleted from here.

Bin

A bins is a sub-division of a warehouse to further define where parts are stored.

Bin

The bin ID can be up to 10 characters in length.

Description

This is the full description for this bin.

Non Nettable

This checkbox indicates that the parts in this bin should not be included in the on-hand balance.

Tip Example:

An example of a non-nettable bin would be an inspection bin in the inspection warehouse.

Height, Width and Length

These fields are informational fields that can be used in reporting, or to determine if a bin islarge enough to hold a part which needs to be stored.

Setup of the Plant Floor Warehouse and Bins

Warehouses and bins can be established at the resource and/or resource group level for AMMtracking. There are several options in setting up warehouses and bins for WIP tracking:

1. The entire plant floor can be a warehouse with each resource group or each resource a binin the plant floor warehouse.

2. Each resource group can be assigned a warehouse with a bin.3. Each resource can be a warehouse with a bin.

Workshop - Set up the Plant Floor Warehouse and BinsNavigate to the Warehouse program

Menu Path: Material Management ➤ Inventory Management ➤ Setup ➤ Warehouse

1. Click New.

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2. Enter PLANT in the Warehouse field.3. Enter Plant Floor in the Description field.4. Click Save to save the new warehouse.5. From the Actions menu select Bins .6. Create the bins with the following information:

DescriptionBin

MachiningMACH

AssemblyASSY

Finished Goods StagingFG STAGE

7. After the creation of each new bin click Save .8. Exit the maintenance programs.

Reason CodeUse Reason Code Maintenance to assign standard explanations for a number of records -CRM events, labor scrap and rework, inventory adjustments, and RMA entries.

Menu Path: Production Management ➤ Job Management ➤ Setup ➤ Reason Code

To use reason codes, first select the appropriate options in your company configuration. Thenset up the codes in this program. You then will be able to select the reasons in Count DiscrepancyReason Code Entry,Labor Entry, Inventory Adjustment Entry, RMA Processing, RMA Dispositions,and Opportunity/Quote Entry.

Instructor Note

DEMO:

Navigate to the Reason Code program and review the reason codes that are in the Educationdatabase.

Allocation PriorityIf the Advanced Material Management (AMM) module is installed, this special maintenanceprogram becomes available. Allocation Priorities are used by the AMMmodule to automaticallyreserve an item’s on-hand quantity for specific customers. Customers that have a higherallocation priority code will have stock quantities allocated to their orders first.

Allocation Priority codes are assigned to customers after the codes have been established.

Instructor Note

Navigate to the Warehouse program and review the following fields as you describe thembelow.

Code

The Code field is a short ID for the code.

Description

This is the full description for this code.

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Priority

A priority is entered for the code in this field. This value indicates how many days before orafter the delivery date by which a customer with this allocation should be ranked.

Tip Examples of priority values:

• 4 indicates this customer's orders should arrive 4 days early• 0 indicates that there are no special considerations• -3 indicates that the customer that is assigned this priority will have their order slip

by three days

Workshop - Evaluate Allocation Priority Codes and then Assign one to a Customer

1. Evaluate the codesa) Navigate to the Allocation Priority program using the following menu path

b) Search for, and then select all of the Allocation Priority codes by clicking the Code button.c) Use the tree view to select each code to review their values.d) Exit the Allocation Priority program.

2. Assign a code to a customera) Navigate to the Customer program using the following menu path

b) Search for, and then select the Northern Machine (NM09) customer by clicking theCustomer button.

c) Choose a code in the Allocation Priority drop-down field.d) Save the information and exit the program.

User SecurityThe User Security program is where all users of the system are defined. Information such asID and name, as well as other vital details, are defined here. This program is maintained bythe system administrator.

Menu Path: System Management ➤ Security Maintenance ➤ User Security

The Employee field located on the Company Detail sheet is of particular importance to theAMM module. The name selected in this field will require that a security ID when logging in andout of the Manufacturing Execution System (MES).

There are many fields in User Security which are explained in other courses, as well as theonline help.

Instructor Note

DEMO:

Evaluate the security record for Zeke Graham to ensure that his ID is required when loggingin and out of MES.

1. Navigate to the User Security program.2. Enter ZEKE in the User ID field, and then press the Tab key to display this record's

information.3. Select the Company tab and display the Detail sheet.4. Verify that Zeke is selected in the Employee drop-down field. If not, select him in this

field.5. Click Save and exit the program.

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Shop EmployeeUse Shop Employee Maintenance to create the Shop Employee master file. Shop Employeesare the employees that perform work on the jobs, and are entered in Labor Entry.

There are many fields in this file that are covered in other courses and are also fully explainedin the online help. The fields that are of interest to the AMM module are explained in this section.

Instructor Note

Navigate to the Shop Employee program and review the following fields as you describe thembelow.

Production Information

The Production Information section stores important shop data about the employee.

Shift

The employee's shift is selected in this drop-down field.

Expense

The default expense code for this employee’s labor is selected in this drop-down field.

Department

The employee's home department is selected in this drop-down field.

Labor Rate

This is the dollar amount that will apply to labor transaction. If the Payroll module is installed,this field will be unavailable and the rate must be maintained in the Payroll module.

User ID

This option allows a shop employee to use the ID of another employee if they are not enteredinto security as a system user.

Status

The fields in this section indicate several attributes that an employee can be assigned to.

Status

Select active or inactive from this drop-down field.

Payroll Employee

Enable this checkbox if this is a payroll employee. This enables the Payroll module to accessthis employee.

Service Technician

Enable this checkbox if this employee is a service technician and the Field Service module isinstalled.

Material Handler

Enable this checkbox if this employee is a material handler. This provides access to materialhandling functions in the MES.

Shop Supervisor

Enable this checkbox if this employee is a shop supervisor.

Shipping/Receiving

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Enable this checkbox if this employee is a shipping and receiving person. This provides accessto the shipping and receiving functions in the MES.

Production Worker

Enable this checkbox if this employee is a production worker. This provides access to specificfunctions in the MES.

Production Worker

This section contains two check boxes that can further define the role of a production worker.

Request Material

Enable this checkbox if this employee is a production worker and he/she can request material.This provides access to request material functions in the MES.

Report Quantity

Enable this checkbox if this employee is a production worker and can report quantity.

Tip Example:

A resource with several workers in which only one person may be able to report quantityin a paint line.

Report Quantity

This section contains check boxes defining how operation quantities can be reported.

Override Job

Enable this checkbox to allow the user to override his/her current job and report quantity foranother job.

Report Scrap Quantity

Enable this checkbox if this employee is allowed to report scrap quantities.

Report Non-Conf Quantity

Enable this checkbox if this employee is allowed to report non-conformance quantities.

Employee Records to be Used in this Course

PasswordResource/ActivityIDNameRole

Moving material400Jerry LewisMaterial Handler

ZekeVM3600Zeke GrahamShop Worker 1

ASMB300Hank KetchumShop Worker 2

Shipping/receiving700Cory SnyderShipping Manager

100John J. LaborSupervisor

HenryPurchasingnoneHenry CrabtreePurchasing

IGadgetInspectornoneInspector GadgetInspector

Workshop - Evaluate and Modify Shop EmployeesNavigate to the Shop Employee program

Menu Path: Production Management ➤ Job Management ➤ Setup ➤ Shop Employee

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1. Select the Employees to update2. Search for, and then select each of the following employees and verify that the proper check

boxes have been enabled for them

Tip As mentioned in the Shop Employee section, Henry Crabtree will be used forpurchasing and Inspector Gadget for inspection; however, these two people are notshop employees.

ReportQuantity

RequestMaterial

ProductionWorker

ShippingandReceiving

ShopSupervisor

MaterialHandler

Name

Enable thischeckbox

Jerry Lewis

Enable thischeckbox

Enable thischeckbox

Enable thischeckbox

ZekeGraham

Enable thischeckbox

Enable thischeckbox

Enable thischeckbox

HankKetchum

Enable thischeckbox

Cory Snyder

Enable thischeckbox

Enable thischeckbox

Enable thischeckbox

Enable thischeckbox

Enable thischeckbox

Enable thischeckbox

John Labor

3. Save each record's updates, if necessary.4. Exit the program.

Resource Group and ResourceUse Resource Group Maintenance to setup resource groups and resources to be assignedto operations and to be used during Job Entry for scheduling purposes.

Note Each resource group must have at least one resource, which could be a person,place or object that is used during production.

Tip Resource group examples:

• A specific machine, such as a CNC machine.• A specific place in the plant, such as Shipping.• A tool to be used during production.• A person, such as an inspector.• Etc.

There are many fields in this file that are covered in other courses, such as the Job Managementand Engineering courses. They are also fully explained in the online help. The specific featuresof this program that are of interest to the AMM module are explained in this section.

Instructor Note

Navigate to the Resource Group maintenance program and point out its features as they aredescribed.

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Input Warehouse and In Bin

These fields indicate the location of where WIP material will be stored when it is moved to thisresource group.

Output Warehouse and Out Bin

These fields indicate where the WIP material will be moved when it leaves this resource group.

Auto Move

Enable this checkbox when it is allowed for WIP material to be automatically moved.

Tip If WIP material is automatically moved, the system will first look at the resourceand if a warehouse and bin are found, it will automatically move the WIP material to theresource. If no warehouse and bin are found, or if the resource fields are defaulted tothe resource group, the WIP material will be moved there.

Material Moves

The system can automatically move material from one WIP warehouse and bin to another WIPwarehouse and bin.

Tip Example of a move, using a job with the following operations:

Out BinIn BinOutputWarehouse

InputWarehouse

NameOperationNumber

CNCPlant FloorCNC10

CNCPlant Floor

ASMBPlant FloorASMB20

ASMBPlant Floor

In this example, when parts are reported completed at operation 10, a move requestwill be placed in the move queue for the material to be moved from the CNC bin to theASSY bin. If the user does not want a move request placed into the queue, but doeswant to see the WIP material moved, the Auto Move checkbox can be enabled toaccomplish this.

If the input bin of operation 20 is different from the output bin of operation 10, a moverequest will occur. If the input bin of operation 20 and the output bin of operation 10 arethe same, a move request will not occur.

Workshop - Evaluate and Modify Resource GroupsDuring this course, the VM3 and the Assembly Blue Crew resource groups will be used. In thisworkshop, we will evaluate them and determine how the AMM module will respond to thewarehouses that are set up.

Navigate to the Resource Group program

Menu Path: Production Management ➤ Job Management ➤ Setup ➤ Resource Group

Search for the first Resource Group to editNavigate to the Resource Group program

1. Search for, and then select all resource groups by clicking the search (binoculars) icon.

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2. Select the VM3 Vertical Mill 3x Matsuura resource group from the tree view to display itsdetail.

Edit the Warehouse and Bin information

1. Make sure the Location check box is checked and select the following for the warehouseand bin information

VM3Production FloorInput Warehouse:

INSIInspection AreaOutput Warehouse:

VM3Production FloorBackflush Warehouse:

2. Disable the Auto Move check box so that a move request will show up in the material movequeue.

3. Save the change.

Edit the Resource Warehouse and Bin information

1. Click the Resource sheet and highlight Resource VM - 3x Matsuura #1 in the Tree View.2. Select the following for the warehouse and bin information

VM3Production FloorInput Warehouse:


VM3Production FloorBackflush Warehouse:

3. Disable the Auto Move check box so that a move request will show up in the material movequeue.

4. Save the change.

Search for the second Resource Group to edit

Select the ASM Blue Crew resource group from the tree view to display its detail.

Edit the Warehouse and Bin information

1. Make sure the Location check box is checked and select the following for the warehouseand bin information

ASIManufacturing FloorInput Warehouse:


ASIManufacturing FloorBackflush Warehouse:

2. Make sure the Auto Move check box is disabled so that a move request will show up in thematerial move queue.

3. Click Save and exit the program.

PartThe Part file stores the default warehouse and bin for each part, as well as where any otherwarehouses and bins could be stored. The warehouse and bin information is located in theWarehouses sheet, below the Plants tab.

Key fields of interest to the AMM module are the Warehouse and Primary Bin fields.

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Instructor Note

Navigate to the Part program and review the Warehouse and Primary fields.

DEMO:

First, explain to students that during this course the Part Tracker will be used from time totime to evaluate the location of WIP parts. Then demonstrate the use of the Part Trackerto evaluate part warehouse and bin information - specifically the on-hand quantity:

Navigate to the Part Tracker program.

Menu Path: Production Management ➤ Job Management ➤ General Operations ➤Part Tracker

1. Select the On Hand sheet.2. Click the Search (binoculars) icon, filter by the Part Type of Manufactured, and select

all parts that have resulted from this search criterion.3. Select the part number - DCD-300-OR. from the drop down list in the tool bar.4. Select the Warehouse and Bins sheets to review the quantity on-hand.

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Process

This section will discuss sales order allocations using Fulfilment Workbench, Shop Floor MaterialMovements and the QA Inspection Process.

Fulfillment WorkbenchUse the Fulfillment Workbench window to either automatically or manually reserve materialquantities for an order release. This functionality is valuable when you want to satisfy demandmaterial quantities through jobs or stock in a sequence that matches allocation priorities assignedto your customers.

This section will lead you through the sales order allocation process using the FulfillmentWorkbench:

• Enter a sales order• Mass Assign a shipping warehouse and bin to multiple sales orders• Allocate the material and submit for picking• Move the parts to the shipping staging area• Ship the parts

Instructor Note

Complete the workshops found in this section with the students.

Workshop - Enter a Sales OrderThis workshop asks you to enter a sales order for the Dalton Manufacturing company. DaltonManufacturing has submitted their purchase order number 1429 for 5 of part numberDCD-300-OR (steel O rings) to be shipped 2 weeks from today.

Navigate to the Order Entry program

Menu Path: Sales Management ➤ Order Management ➤ General Operations ➤ OrderEntry

1. Click New and select New Order.2. Enter DALTON in the ID field and then press the Tab key to display its default information.3. Enter a date of two weeks from today in the Need By and Ship By fields.4. Enter the purchase order number 1429 in the PO field in the Header sheet.

Tip Notice that the Priority field has defaulted to a code of Normal Priority.

5. Click New and select New Line.6. Enter DCD-300-OR in the Part/Rev field and then press the Tab key to display its default

information.

Note the quantity on-hand and the quantity allocated.

7. Enter 5 in the Order Quantity field and then press the Tab key.

Notice that the cost has defaulted.

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Advanced Materials Management | Process | 21

8. Accept the defaults provided in the remaining fields.9. Click Save, write down the sales order, and exit the program.

Workshop - Mass Assign Shipping Warehouse/BinThe Fulfillment Workbench program can be used to mass assign a shipping warehouse andbin to multiple or all open sales orders that need to have a shipping location set. This functionalityis exceptionally useful to assign a single warehouse and bin to a large number of transactions.

Navigate to the Fulfillment Workbench program

Menu Path: Sales Management ➤ Order Management ➤ General Operations ➤Fulfillment Workbench

1. Display all open sales orders using the Search (binoculars) icon.2. Select Search, click Select All and click OK to pull in all the current open sales orders.3. Select the List sheet and click the Select checkbox for up to 15 open orders.

Tip Make sure that you select the sales order you created in the Enter a Sales Orderworkshop.

4. From the Actions menu select Mass Assign .

This process will assign a shipping warehouse and bin to all of the orders you have selected.

5. Choose a warehouse and bin from the drop down box and click OK.6. Click Save .7. Click the Order Fulfillment sheet and click the Total Weight column to sort the orders by

Total Weight.8. Highlight the order you created in the Enter a Sales Order workshop.9. Click the Supply sheet and notice that the warehouse and bin you selected is now listed in

the Submit for picking section.10. Remain in the Fulfillment Workbench program in preparation for the next workshop.

Workshop - Allocate Material and Submit for PickingThis workshops asks you to allocate material and submit for picking, one order at a time.

1. Click on the Order Fulfillment sheet and make sure that the order you created is highlighted.2. Click on the Supply sheet and enter 5 in the Reserved field.3. Enable the Pick check box and click Save.4. Click the Order Fulfillment sheet and click the Select checkbox on the Order line you

selected.5. From the Actions menu select the Select and Release for Picking option .6. Click OK when the pop-up message comes up.7. Select the Ship By Date option for the Pick Date Assignment option and then click OK.

Note You should get a message indicating that 1 Order release has been submittedfor picking.

8. Click No to this message so that the record will be sent to the Material Request Queue.9. Click Save.

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22 | Advanced Materials Management | Process

Workshop - Move Parts to Shipping

1. Double-click the MES icon located on your desktop.2. Enter Manager in the Login field.3. Enter Manager in the Password field.4. Enter 400 in the Employee field to log in as Jerry Lewis and press the Tab key to continue.5. Click OK to verify your shift.6. Click the Material Queue button.7. Select the order line that was processed in the previous workshop and then click the Select

button.

This will move the request to your queue.

8. Select the My Selections sheet.9. Highlight the line and click the Tags button to print a move tag.

Note A choice is available of how many tags to print. For example, one tag may beprinted for the entire group, or one tag per piece.

10. Preview the tags.11. Click Process to move this material from stock to the shipping dock.12. Review the following information

• The Type is STK-SHP , which indicates the parts are being moved from their stock locationto the shipping area.

Tip Refer to the Appendix Section - Transaction Types to see a complete listingof transaction types.

• The From location is the stock location where the parts are stored.• The To location is where they are being moved.

13. Click OK to finalize this transaction.14. Click the Logout button to leave the screen clear for the next employee to clock in or out,

or start or end an activity.

Workshop - Ship the Parts

1. Double-click the MES icon located on your desktop.2. Enter Manager in the Login field.3. Enter Manager in the Password field.4. Enter 700 in the Employee field to log in as Cory Snyder and press the Tab key to continue5. Click OK to verify your shift.6. Click the Shipping/Receiving sheet.7. Click the Customer Shipment button in the Shipping and Receiving sheet.8. From the Actions menu select Picked Orders

This will display all orders that have been allocated, picked and moved into the shippingstaging area.

9. Select the part that has been allocated and submitted for picking, and then click the CreatePacking Slip button

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Tip The header and lines can be modified, as needed.

10. Enable the Shipped checkbox to finalize this transaction.11. Click Save and exit MES.

Shop Floor Material MovementThis section describes how to complete the job process, all the way through to receiving theparts into inventory, using the functionality available in the AMM module.

• Enter a Job.• Create a PO.• Receive Direct Job Material.• Start the Job.• Investigate the Status of the AMM Job.• Complete the Job.

Instructor Note


Workshop - Enter a JobJobs are usually created by others in the organization, but for the purposes of this course, ajob will be set up that will cover various aspects of the AMM module. The job will use the resourcegroups and resources reviewed and modified in previous workshops.

Navigate to the Job Entry program

Menu Path: Production Management ➤ Job Management ➤ General Operations ➤ JobEntry

Job operations will be set up as follows:

Pieces per HourSetup TimeResource GroupDescriptionOperation

300.50VM3Mill Point to Point10

25N/AASMBAssemble perPrint

20

Material for this job will be:

BackflushStocked/Non-StockedQuantity perParent

RelatedOperation

DescriptionPartMaterial

NoStocked0.2510CRS Sheet.036” X 48”X 120”

CS-03610

YesStocked420Flat Washer516FW20

YesStocked420Nut516LN30

YesStocked420Bolt516x100B40

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NoNon-Stocked220Slide Standoff 1”

8400S-61150

The job will be issued for 100 pieces of part number H-4600 (Henwood Gear Case), and itwill be due 4 days from today.

1. Click the New icon and select New Job2. Enter AMM-XXX (where XXX are your initials) in the Job field.3. Enter H-4600 in the Part field.4. Select a date of two weeks from today in the Req By drop-down date field.5. Click the New icon, select New Demand Link and then select the Make To Stock option.6. Select the Make to Stock sub-sheet and display its Detail sheet.7. Enter 100 in the Quantity field.8. Select the Engineering tab and display its Operation Master sheet.9. Search for, and then select all operations by clicking the Operation button.10. Select the Mill Point to Point operation, then drag and drop it on the word Operations in

the tree view.

This positions this as operation number 10.

11. Expand the operation to view its details.12. Select the Assemble per Print operation, then drag and drop it on the word Operations

in the tree view.

This positions this as operation number 20.

13. Expand the operation to view its details.14. Select the Resource Groups sheet.15. Search for, and then select all resource groups by clicking the Resource Groups button.16. Select the VM3 Vertical Mill 3x Matsuura resource group, then drag and drop it on the

word Resources for the Mill Point to Point operation in the tree view.17. Select the ASMB Asm Blue Crew resource group, then drag and drop it on the word

Resources for the Assemble per Print operation in the tree view.18. Select the Mill Point to Point operation in the tree view.19. Enter 0.50 in the Hours field of the Setup Per Machine section.20. Enter 30 in the Prod Std field of the Production Per Machine section.21. Select the Assemble per Print operation in the tree view22. Enter 25 in the Prod Std field of the Production Per Machine e section.23. Select the Engineering tab and display the Parts sheet.24. Search for, and then select all parts by clicking the Part button.25. Drag and drop the following parts onto the operations that will consume them:

Related OperationDescriptionPart

10CRS Sheet .036” X 48” X 120CS-036

20Flat Washer516FW

20Nut516LN

20Bolt 20516x100B

20Slide Standoff 1"8400S-611

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Tip Each time that a material is added to an operation, it is also shown in a materiallisting at the bottom of the tree. This can be confusing; to eliminate the confusion,collapse the Materials list.

26. Select each material sequence associated with operation 10 and operation 20 and enter thefollowing provided values in each Qty/Parent field:

Qty/ParentDescriptionPartMaterial

0.25CRS Sheet .036” X48” X 120

CS-03610

4Flat Washer516FW20

4Nut516LN30

4Bolt 20516x100B40

2Slide Standoff 1"8400S-61150

27. Enable the Engineered and Released check boxes in the Job sheet.28. Navigate to the Actionsmenu, select Schedule and then select the Job Scheduling option

Add comments, if necessary.

29. Accept the default of Backward scheduling and then click OK.30. Save the job and exit the program.

Review the job using the Job TrackerThe Job Tracker will be used to evaluate the job it as it moves through the production process.

Navigate to the Job Tracker program.

Menu Path: Production Management ➤ Job Management ➤ General Operations ➤ JobTracker

1. Enter the job number created in the previous steps and then press the Tab key to displayits default information.

2. Using the tree view, select each of the operations and then select the Labor Transactionssheet.

3. Click Retrieve to retrieve any labor performed so far.4. Using the tree view, select each of the material requirements associated with these operations

and then select the Material Transactions sheet.5. Click Retrieve to retrieve any material transactions performed so far.

Note The 8400S-611 Slide Standoff 1" is a non-stock item and must be ordered andreceived from J.I.T Machining & Fabricating before the job operation requiring it canbe started.

6. Exit the Job Tracker program.

Review a part using the Part TrackerNavigate to the Part Tracker program

Menu Path: Production Management ➤ Job Management ➤ General Operations ➤ PartTracker

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1. Select the Parts sheet.2. Enter part number H-4600 in the Part field and then press the Tab key to display its default

information.3. Select the Part Locations tab and select theWIP sheet to view the current warehouse and

bin.

Tip There are no values in WIP at this point since the job has not been started.

4. Review the various sheets in this section.5. Exit the Part Tracker program.

Workshop - Create a Purchase OrderCreating purchase orders is not a part of the AMM process; however, the job that was createdin the previous workshop has a material requirement for an 8400-611 Slide Standoff 1” partthat must be ordered directly to the job.

Generate SuggestionsUse the Generate Purchasing Suggestions program to automatically create a list of suggestedpurchases based on time-phased information. You can then create actual purchase orders fromthese suggestions in the Purchase Order Entry program.

Navigate to the Generate Suggestions program.

Menu Path: Material Management ➤ Purchase Management ➤ General Operations ➤Generate Suggestions

1. Enter/select the following information in the listed fields to generate suggestions

RegenerativeProcessing Options

Leave blankCutoff Date

Accept the defaultSchedule

2. From the File menu select Process .

Instructor Note

If conducting a class on a network version of the same software application database,show the users how to run the Generate PO Suggestions program, but only have oneperson actually Generate PO Suggestions. This way, you do not have multiple users tryingto generate PO suggestions at the same time against the same software applicationdatabase. To make it fun, you can have a different person do it each time.

When the process is submitted, a message does not display to say the system has finishedprocessing. To know when the system is finished processing, check the System Monitor.

Make sure and explain what the System Monitor is so that the users know where to seethe process complete.

3. Exit the program.

New PO SuggestionsUse the New PO Suggestions program to process new purchase order suggestions generatedby the Generate Suggestions program.

Navigate to the New PO Suggestions program.

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Menu Path: Material Management ➤ Purchase Management ➤ General Operations ➤New PO Suggestions

1. Click the Search (binoculars) icon.2. Select Henry Crabtree in the Buyer drop-down field of the New Purchase Order

Suggestion Search window.3. Click Search.4. Click Select All and click OK.5. Double-click 8400s-611 in the tree view to display the details of the suggestion.6. Select the Material List sheet.7. Select the suggestion for the job created in the earlier workshop.8. Enable its Buy button.9. From the Actions menu select Generate to create the purchase order to finalize this

transaction.10. Click Yes in the dialog box to accept the confirmation.11. Exit the program.

Workshop - Receive Direct Job MaterialThe J. I. T. company truck just arrived at the dock and has the 8400S-611 Slide Standoffsordered for the AMM job. In this workshop, we will process this receipt using MES.

1. Double-click the MES icon located on your desktop.2. Enter Manager in the Login field.3. Enter Manager in the Password field.4. Enter 700 in the Employee field to log in as Cory Snyder and press the Tab key to continue.

Recall that Cory is the shipping/receiving person.

5. Click OK in the dialog box to verify your shift.

Note The only sheet available to Cory is the Shipping and Receiving sheet, as itwas defined in the Employee file.

6. Click the Shipping/Receiving sheet.7. Click the Receipt Entry button.8. From the File menu select New Receipt .9. Search for, and then select the correct PO by clicking the PO button.10. Enter 7990 in the Packing Slip field.11. Expand the tree view and double-click the line to display it.

Note The line will appear as received in full. If this was not the case, the supplierquantity could be changed to the amount received.

The material is being received into the Receiving area.

Note Please make sure that the Stock Location Warehouse and Bin RCVG2 arethe Receiving Area before saving the line.

12. Click Save and log out as Cory Snyder in the MES.

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Workshop - Start the Job

Select the Job to work onThis portion of the workshop covers a review of the work queue, selecting the job for work andrequesting material.

1. Select the job for work and perform setup on operation 10.2. Double-click the MES icon located on your desktop.3. Log in to MES4. Enter Manager in the Log in field.5. Enter Manager in the Password field.6. Enter 600 in the Employee field to log in as Zeke Graham and press the Tab key to

continue.Recall that Zeke is a shop worker.

7. Click OK in the dialog box asking to verify your shift.8. Select the Production sheet to display the production worker's options.9. Click the Work Queue button.

Tip The work queue contains a listing of all operations scheduled at each resourcegroup. This queue will inform the shop worker what operations should be performedand in what order they should be done, according to the schedule. The work queue isthe Priority Dispatch report online, along with additional information that can providea paperless shop floor.

10. Click Search to display the resource groups in theMachining Department (which is Zeke'shome department).

11. Select the VM3 resource group and click OK.12. Click the Staged Details tab to note that no material has been staged for this job operation.13. Click the Current Work tab and right-click the Job Number field.14. Choose the Job Tracker option and using the process from a previous workshop, view the

material to determine its status

Tip There are 490 sheets located in the racks bin in the Minneapolis warehouse. Thejob calls for 0.25 of a sheet; therefore, 100 sheets are needed. Zeke decides to requestmaterial for the operation and proceed with setup, because the material will be deliveredby the time setup is finished.

15. Click Get Request to request material.16. Enter the job number and press the Tab key to display the default information.

The job number and its corresponding information may default into this screen without typingin the job number.

17. Enter/select assembly number 0 in the Assembly field.18. Select operation number 10 in the Operation drop-down field.

Note Zeke can request the outstanding material, a specific number of pieces. or aquantity for a specific amount of time.

19. Click OK to process this request.20. Click the Select for Work button and then click the Setup button.

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21. Click OK to accept the dialog box message indicating that set up has not been completed,and then close this window.

22. Log out of the MES as Zeke Graham.

Move the materialThe material handler has been monitoring the material queue regularly throughout the day andmoving material as required. In fact, it may be mounted on his forklift and would be availableto him continually throughout the day. In this workshop, you will move the material requestedto the job.

1. Log in to MES2. Enter Manager in the Log in field.3. Enter Manager in the Password field.4. Enter 400 in the Employee field to log in as Jerry Lewis and press the Tab key to continue.5. Select the Material sheet, then the Material Queue button to display the move requests.

Recall that Jerry is the material handler.

6. Click OK in the dialog box to verify your shift.7. Select the entry for part number CS-036 and then click the Tag button

Note The user has the option of printing one tag for this move, a tag for eachcontainer, or a tag for each part.

8. Accept the defaults provided.9. Preview the tag that will follow these parts.

Note The 8400S-611 part that was received in the previous workshop is also listedin the queue to be moved.

10. Click Process to process this move.11. Fill in the From and To Warehouse and Bin location information, if needed and click OK.

Note The top part of the sheet shows the current location and the bottom portionshows the location where the parts will be moved. These locations can be changed, ifnecessary.

12. Click Search to locate a bin for the inspection area, and click OK.13. Log out of the MES as Jerry Lewis.

Complete setup and start production for operation 10Zeke has completed setup, and in this portion of the workshop he will report completion, checkthe staged details for material and start production.

1. Enter 600 in the Employee field to log in as Zeke Graham and press the Tab key tocontinue.

Recall that Zeke is a shop worker.

2. Click the End Activity button to enter information about the setup.3. Accept the default of 0 in the Current field (as no parts were produced during this setup).4. Enter 100 in the Setup % Complete field to finalize setup.5. Click OK to complete this transaction.

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6. Click the Work Queue button using the process in the previous workshop, select the AMMjob and click the Staged Details sheet to note the material has now been staged.

7. Select this job for production.8. Remain logged in as Zeke.

Report a partial quantity complete for operation 10Throughout the day, a completed quantity can be reported so that the parts can move alongto the next resource group, and work can begin on the next operation. In this portion of theworkshop, 50 parts will be reported complete.

Quantity can be reported in two ways:

• The Report Quantity button allows the shop worker to remain on the job and move thecompleted quantity forward.

• The End Activity button can be used if the operation is complete, or the shop worker isleaving at the end of the shift.

In this portion of the workshop, the Report Quantity option will be used.

1. Click the Report Quantity button.2. Enter 50 in the Current field.3. Accept the default of the enabled Move checkbox.4. Click the Print Tags button and preview the tags that can be attached to the parts.5. Click OK to finalize the transaction.6. Log out of the MES as Zeke Graham.

Move complete WIP parts from operation 10 to operation 20The material handler has been monitoring the material queue regularly and notices the newentries that have occurred since the beginning of his shift. In this workshop, the parts completedon operation 10 and the parts in receiving will be moved to operation 20.

1. Log in to MES.2. Enter Manager in the Log in field.3. Enter Manager in the Password field.4. Enter 400 in the Employee field to log in as Jerry Lewis and press the Tab key to continue.


5. Click OK in the dialog box to verify your shift.6. Select the Material sheet, then the Material Queue button to display the move requests.7. Select the parts completed on operation 10, print tags if necessary, and click the Process

button to move them.8. Fill in the From and To Warehouse and Bin location information if needed and click OK.9. Select the H-4600 parts, print tags if necessary, and click Process to move them.10. Fill in the From and To Warehouse and Bin location information if needed and click OK.11. Select the 8400S-611 parts, print tags if necessary, and click Process to move them.12. Fill in the From and To Warehouse and Bin location information if needed and click OK.13. Review the part H-4600 in the Part Tracker using the steps outlined in a previous workshop.14. Select the WIP sheet to view the activity.15. Log out of the MES as Jerry Lewis.

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Workshop - Investigate the Status of the AMM JobOccasionally, the shop supervisor does not need to log in to review the current status of a job.In this workshop Manual Labor will log in to review the AMM job.

1. Enter Manager in the Login field.2. Enter Manager in the Password field.3. Enter 100 in the Employee field to log in as John J. Labor and press the Tab key to

continue.

Recall that John is the shop supervisor.

4. Click OK in the dialog box to verify your shift.5. Click the Job Tracker button.6. Enter the AMM job number and then press the Tab key to display it.7. Expand the operations and materials in the tree view.8. Select each of the materials that are associated with the operations in the tree view, then

select the Job Details sheet, then the Materials sheet, and the Material Transactionssheet and then click Retrieve to retrieve any material transactions.

9. Select each of the operations in the tree view, then select the Job Details sheet, then theOperations sheet, and the Labor Transactions sheet and then click the Retrieve buttonto retrieve any labor performed so far.

10. Back in the MES Menu, under the Supervisor sheet, click the Shop Tracker button andthen select the Active Transaction sheet to view active transactions and enter informationin the following fields

Machining DepartmentDepartment

VM3Resource Group

AMM-XXX (where XXX are your initials)Job

11. Refresh the information and note that the assembly, operation and employee defaults.

This shows that Zeke is actively producing parts on operation 10.

12. Exit the Job Tracker program.13. Log out as John Labor in the MES.

Workshop - Complete the Job

Begin production on operation 20Production can begin on operation 20 now that finished parts have been moved from operation10. The material ordered directly to the job was received and moved to the Assemble perPrint resource group in the previous workshop.

The hardware that is needed for this operation is backflushed material and will be automaticallyissued from stock when a quantity is reported. Backflush material does not appear on thematerial queue as it is usually considered floor stock and may be stored in a warehouse bin atthe resource or resource group.

1. Log in to MES2. Enter Manager in the Log in field.3. Enter Manager in the Password field.

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4. Enter 300 in the Employee field to log in as Hank Ketchum and press the Tab key tocontinue.Recall that Hank is a shop worker.

5. Click OK in the dialog box to verify your shift.6. Click the Start Production Activity button.7. Enter the job number in the Job Number field and then press the Tab key to display the

default information.8. Enter 0 in the Assembly field.9. Enter 20 in the Operation field.10. Click OK to begin production.11. Log out of the MES as Hank Ketchum.

Complete operation 10The final pieces have been finished on the first operation, number 10. This portion of theworkshop asks you to record production for that operation.

1. Log in to MES2. Enter Manager in the Login field.3. Enter Manager in the Password field.4. Enter 600 in the Employee field to log in as Zeke Graham and press the Tab key to

continue.5. Click OK in the dialog box to verify your shift.6. Select the operation being reported in the grid and then click the End Activity button

The number of pieces already reported should default into the Current field and the RequestMove check box should be automatically enabled. If not, add the amount of the quantity inthe Current field.

7. Click OK to finalize the transaction.8. Click Yes to accept the dialog box indicating that these pieces have been produced in a short

amount of time.9. Clock out of the MES program as Zeke Graham.

Move WIP parts from operation 10 to operation 20Jerry Lewis - the material handler - is watching the material queue and notes that 50 pieceshave been reported and need to be moved to the next operation.

1. Log in to MES.2. Enter Manager in the Login field.3. Enter Manager in the Password field.4. Enter 400 in the Employee field to log in as Jerry Lewis and press the Tab key to continue.


5. Click OK in the dialog box to verify your shift.6. Select the Material sheet, then the Material Queue button to display the move requests.7. Maximize the tree view and select the parts completed on operation 10, then print tags if

necessary, and then click Process to move them.8. Fill in the From and To Warehouse and Bin location information if needed and click OK .

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Note The top part of the sheet shows the current location and the bottom portionshows the location where the parts will be moved. These locations can be changed, ifnecessary

9. Log out as Jerry Lewis in the MES.10. Review the part H-4600 in the Part Tracker using the steps outlined in a previous workshop.11. Select the WIP sheet to view the activity.

Complete operation 20Assembly work has been progressing and the completed parts are now ready to be reported.

1. Log in to MES .2. Enter Manager in the Login field.3. Enter Manager in the Password field.4. Enter 300 in the Employee field to log in as Hank Ketchum and press the Tab key to

continue.5. Select the operation being reported in the grid and then click the End Activity button.6. Enter 100 in the Current field.

Note Notice that the Move checkbox has been enabled

7. Click OK to complete this transaction.8. Click Yes to accept the dialog box indicating that these pieces have been produced in a short

amount of time.9. Exit the Part Tracker.10. Review the part H-4600 in the Part Tracker using the steps outlined in the previous

workshop.11. Clock out as Hank Ketchum in the MES.

Move completed parts to inventoryNow that all the parts have been reported as complete, they must be moved into the properinventory location. Jerry Lewis - the material handler - continues to monitor the material queueand notes that 100 pieces have been reported and need to be moved to inventory.

1. Log in to MES.2. Enter Manager in the Login field.3. Enter Manager in the Password field.4. Enter 400 in the Employee field to log in as Jerry Lewis and press the Tab key to continue.5. Click OK in the dialog box to verify your shift.6. Select the Material sheet, then the Material Queue button to display the move requests.7. Maximize the tree view and select the H-4600 parts completed, then print tags if necessary,

and then click Process to move them.

The part that is being manufactured is lot controlled and the system defaults the lot numberinto the Lot field.

8. Fill in the From and To Warehouse and Bin location information if needed and click OK.9. Review the part H-4600 in the Part Tracker using the steps outlined in the previous

workshop.

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10. Select the WIP sheet to view the activity.11. Exit the Part Tracker program.12. Log out and exit the MES.

Workshop - Review the Job in the Job Tracker

Navigate to the Job Tracker program

Menu Path: Production Management ➤ Job Management ➤ General Operations ➤ JobTracker

1. Select the Job Number to Review.2. Enter the job number in the Job field and then press the Tab key to display its default

information.

Tip Notice that each operation and material requirement has a green checkmarkindicating that the operations have been completed and the material has been issued.

3. Select each of the operations in the tree view, then select the Job Details sheet, then theOperations sheet, and the Labor Transactions sheet and then click Retrieve to retrieveany labor performed so far.

4. Select each of the materials that are associated with the operations in the tree view, thenselect the Job Details sheet, then the Materials sheet, and the Material Transactionssheet and then click Retrieve to retrieve any material transactions.

Note Notice the backflushed items have been issued and coded as issued by backflush

5. Exit the Job Tracker program.

QA Inspection ProcessUse this program to inspect the non-conformance entries made for defective assemblies andmaterials. You can also inspect purchase order receipts and customer returns.

This section will lead you through the Quality Assurance Inspection Process.

• Receive the Materials• Move the Material to Inspection• Inspect the Material• Move the Material to the Job

Instructor Note


Workshop - Receive the MaterialsThe 240 sheets of part number BS-CR-RD-150 ordered on PO 132 from Sampson Steel hasarrived at the dock and must be received.

1. Log in to MES.2. Enter Manager in the Login field.3. Enter Manager in the Password field.

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4. Enter 700 in the Employee field to log in as Cory Snyder and press the Tab key to continue.

Recall that Cory is the shipping/receiving person.

5. Click OK in the dialog box to verify your shift.6. Access the Receipt Entry program.7. Choose the Shipping/Receiving sheet and select the Receipt Entry button.8. From the File menu select New Receipt .9. Enter 132 in the PO field and then press the Tab key to launch its default information.10. Enter 4832 in the Packing Slip field.

At the bottom portion of the sheet, the pending receipts lines are shown.

11. Expand the tree view and then double-click the line to display its information.

The line will appear as received in full. If this was not the case, the supplier quantity couldbe changed to the amount received.

The material is now being received into the Inspection Area.

12. Click Save and log out as Cory Snyder in MES.

Workshop - Move the Material to InspectionThe material handler is monitoring the material queue regularly throughout the day, and movingmaterial as required. This workshop asks you to move the material to inspection.

1. Log in to MES.

Note If you are already logged into the MES program, you can skip this step.

2. Enter Manager in the Login field.3. Enter Manager in the Password field.4. Select an Employee.5. Enter 400 in the Employee field to log in as Jerry Lewis and press the Tab key to continue.


6. Click OK in the dialog box to verify your shift.7. Select the Material Queue button on the Material sheet to display all move requests.8. Maximize the tree view and select the entry for part number BS-CR-RD-150 and then click

the Tag button.

The user has the option of printing one tag for this move, a tag for each container or a tagfor each part.

9. Accept all of the defaults provided and preview the tag.10. Click Process to process this move.

Notice that the top part of the sheet shows the current location, and the bottom portionshows the location where the parts will be moved. These locations can be changed, ifnecessary.

11. Select Inspection Area for the To Location Warehouse and INSI for the To Location Binand click OK.

12. Save the information and log out as Jerry Lewis in MES.

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Workshop - Inspect the MaterialJohn Labor is not usually an inspector, but during a shift when no inspector is on duty, he isauthorized to inspect using Inspector Gadget's name.

1. Log in to MES.2. Enter Manager in the Login field.3. Enter Manager in the Password field.4. Enter 100 in the Employee field to log in as John J. Labor and press the Tab key to

continue.

Recall that John is the shop supervisor.

5. Click OK in the dialog box to verify your shift.6. Select the Supervisor sheet to display the supervisor options.7. Click the Inspection Processing button and then click the Search icon to display the

inspection queue.8. Select the PO receipt for the BS-CR-RD-150 material and click OK .9. Double-click the PO line in the tree view to initiate the inspection process.10. Select Inspector Gadget in the Inspection drop-down field.11. Enter 240 sheets in the Passed Quantity field and then press the Tab key to display the

balance of the information.12. Make sure the Request Move check box is enabled and checked.13. Print material tags, if needed.14. Click Save and Log out as John J. Labor in MES.

Workshop - Move the Material to the JobThe material handler continues to monitor the material queue regularly throughout the day,and moves material as required. This workshop asks you to move the material inspected in theprevious workshop to the job.

1. Log in to MES.2. Enter Manager in the Login field.3. Enter Manager in the Password field.4. Enter 400 in the Employee field to log in as Jerry Lewis and press the Tab key to continue.


5. Click OK in the dialog box to verify your shift.6. Select the Material Queue button to display all move requests.7. Maximize the tree view and select the entry for part number BS-CR-RD-150 and then click

the Tag button.The user has the option of printing one tag for this move, a tag for each container or a tagfor each part.

8. Accept all of the defaults provided and preview the tag.9. Click Process to process this move.10. Click Save and log out as Jerry Lewis in MES.11. Exit MES.

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Reports and Trackers

This section focuses on reports and trackers related to the AMM module.

Reports

Instructor Note

Navigate to the each of the reports listed in this section as they are described.

Scheduled Shipments

Menu Path: Sales Management➤ Order Management➤ Reports ➤ Scheduled ShipmentsThe Scheduled Shipments Report lists all the outstanding order releases. It displays themin order by Due Date, Order Number, Order Line, and Order Release.

Job Pick List

Menu Path: Production Management ➤ Job Management ➤ Reports ➤ Job Pick ListUse the Job Pick List to list material requirements for jobs selected. Both inventory andpurchased materials can be included. Inventory materials are listed in a format useful forentering issue quantities directly on the report.

Sales Order Pick List

Menu Path: Sales Management ➤ Order Management ➤ Reports ➤ Sales Order PickListThe Sales Order Pick List displays open sales order releases that are due within the daterange you select.

TrackersTrackers are read-only menu options that reflect transactions as they occur.

Each tracker may contain both sheets from the primary entry program and supplemental sheetsthat are unique to the tracker. Information on primary sheets and fields is included in the helpfor the entry program. Supplemental sheet information is included in the help for the specifictracker.

Tip Before you use any Tracker, you should review the Tracker Overview topic to learnabout its general program functionality. The overview topic explains the Tracker interface,as well as how to best search for specific records. The topic also contains definitions ofconcepts and terms.

Instructor Note

Navigate to the each of the trackers listed in this section as they are described.

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Job Tracker

This tracker is a display-only version of the primary entry program. Use the tracker to reviewcurrent information about a selected record. You cannot add or edit records in a tracker.

For example, use the Job Tracker to review information about a job, such as demand links,operations, and materials.

Part TrackerThe Part Tracker enables you to get current information on parts in the database. This includesinformation such as revisions, on-hand quantities, costs, locations, inspection, and planningdata.

You can pull multiple part records into the Part Tracker via the Part Search feature, but theTracker can only display one part at a time. You cannot add or edit records in a Tracker.

Additional information is available through the Actions menu of the Part Tracker, including:

• Approved Suppliers

• Forecast

• Configurator

• Where Used

• Master Production Schedule

• Price List

• Attachments

• Memos

• Change Logs

Customer Shipment Tracker

This tracker is a display-only version of the primary entry program. Use the tracker to reviewcurrent information about a selected record. You cannot add or edit records in a tracker.

Miscellaneous Shipment Tracker

The Miscellaneous Shipment Tracker provides a listing of all miscellaneous shipments thathave been made.

Shop Tracker

Use the Shop Tracker to review current information about shop activity. This includesinformation on resources, labor activity, and shop warnings.

Receipt Tracker

The Receipt Tracker is helpful in reviewing purchase order receipts to resolve receiving issues.

Lot Tracker

The Lot Tracker displays information about lot-tracked part records.

This includes information such as lot numbers, on-hand quantities, and transactions. You cannotadd or edit records in this Tracker.

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Serial Number Tracker

The Serial Number Tracker is used to investigate the location of a specific serial numberedpart that can be on-hand, as well as where a serial number part can be used.

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40 | Advanced Materials Management | Reports and Trackers

Conclusion

Congratulations! You have completed the Advanced Materials Management course.

Please take a moment to let Epicor know how to serve you better by completing a courseevaluation at http://www.keysurvey.com/survey/191084/2e21/. Your feedback provides theguidelines for the future direction of Epicor education.

Instructor Note

Ask students the following:

• Have the objectives for this course been met?• Have the expectations for this course been met?• What questions do you have?

Refer students to other courses for those questions that cannot be answered in this course.

Ask students to complete the evaluation.

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Advanced Materials Management | Conclusion | 41

Appendix

This section contains information that will be useful during this course, as well as when youbegin using the system in your organization. Information includes icons that are used in thejob tree, costing issues, as well as backflush information.

Icons

Cost TypesThere are four different cost types for inventory valuation and are used whenever an item unitcost is required in a transaction, such as an issue to manufacturing.

The cost type is initially set in the Company (configuration) Maintenance program and usuallyshould not be changed without consulting with the Financial Department. The cost type for eachitem can be different, for instance, finished goods can be at a standard cost, while raw materialcan be at average.

A part's cost type can be changed only when the balance falls below zero. The actual cost ofthe item can be changed at any time using the Cost Adjustment menu option.

Average

This cost type is the weighted average cost of an item in inventory. The costs are updatedautomatically when items are received to inventory.

Last

The Last cost type infers that the last receipt to inventory updates the unit cost.

Standard

All issues from, and receipts to, inventory are performed at the same cost. Any purchasing ormanufacturing variances from this cost are captured by the appropriate General Ledger (GL)accounts.

Lot

This cost type is for items that are lot tracked. This gives the ability to segregate the unit costsby purchased or manufactured lot. The overall inventory value for a specific item is the averageof all lots.

BackflushBackflush refers to the automatic issuing of material. This can occur as the material is neededfor specific labor operations on the plant floor, or as part of the job closing process.

Backflushing can occur at two different points:

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1. When a quantity is reported against an operation and all the prerequisites are met (seebelow).

2. At job completion, when unissued material needs to be backflushed.

Backflushing at the Point of Quantity Reporting

Backflushing is a process where the system actually issues materials on your behalf. Backflushingis very dependant on labor reporting. When labor is reported against a related operation, materialis then added as detail to the operation.

Prerequisites

• The part must be coded as backflush.• The part must have a primary warehouse and a primary bin.• The material requirement must be attached to a job operation.• The operation must have a labor quantity reported against it.• Labor entry must be accurate and timely.• Serial number controlled, lot controlled or dimensionally controlled inventory cannot be

backflushed.

Advantages

• Eliminates the need to manually issue material to each job operation where the material isneeded. Backflush happens automatically - eliminating manual efforts.

• Takes the scrap factor into account when computing the quantity used. The quantity requiredplus the scrap factor is backflushed when quantities are eliminating manual efforts to calculatescrap.

Common Mistakes

ResultSituation

This will cause errors in removing material frominventory.

Changing the Backflush flag on a material whiletransactions are in process.

This will cause the material to be issued twice.Issuing material and then enabling theBackflush flag on a part.

The user will not know the extent of the manualeffort that will be required to issue these partsto jobs.

Changing the Backflush flag on a part withoutrunning a Where Used report to determine theimpact on other assemblies.

The material called for on the job will bedecreased while the substitute part is not

Using substitute materials without telling thesystem about the substitution.

decreased, causing inventory to be incorrecton both parts.

Inventory will be reduced by the amount ofpieces reported while no parts were actuallyconsumed.

Running rework and not reporting it as rework.

Parts are shown in inventory when they havealready been consumed.

Labor reporting is not timely.

Backflushing at Job Completion or Closing

Backflushing at job completion or job closing is an unconditional backflush. The material doesnot need to be attached to an operation and does not need to have the Backflush checkboxenabled on the part Plant sheet for these parts to backflush.

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Job completion is a task performed when all of the parts on a job have been produced and theoperations have been completed. Job completion should not be confused with job closing. Jobcompletion removes the job from manufacturing and places it in a queue for the Accountingdepartment as a candidate for closing. The Accounting department closes a job once all thecosts have been received and recorded.

Job completion performs two important tasks:

• Any unused capacity on the job will be removed. The job disappears from the job schedulingboard.

• Any unused material will be removed. Any inventory or purchasing requirements willdisappear.

Important Thoughts to Keep in Mind When Using this Procedure

• Were these parts actually used on this job? Perhaps they were not needed.• Has a cycle count been performed and the inventory corrected since they were pulled from

stock and today's date?

Assumptions

There is an unstated assumption regarding backflushing that assumes the amount of materialused will equal the standard quantity called for on the job. This assumption is a result of theactual process the backflush follows. The system relieves inventory for the quantity per calledfor on the operation.

Warning messages appear before the backflush process begins. The users are asked if theywant to run the backflush process. They are also warned if the complete quantity value is lessthan the planned production quantity. If you choose to continue the backflush process, thematerial issue quantity calculations will be based on the complete quantity. Once you backflusha job, all material records are considered issued complete. The process cannot be reversed,so the user should verify whether or not they are ready to run this process on the current job.

Tip If you do the backflush in error, you need to adjust all inventory, and job quantities,and costs to correct the mistake.

Transaction TypesTransaction types classify part transactions. The following transaction types and their descriptionsare used to identify each type of transaction on a display window or printed report. This is veryhelpful when researching a part in the Part tracker or when running the Material TransactionDetail report.

Adjustments

• ADJ-MTL - Adjustment to job cost material.• ADJ-SUB - Adjustment to job cost subcontract.• ADJ-PUR - Adjustment to purchase cost variance.• ADJ-CST - Adjustment to stock cost.• ADJ-QTY - Adjustment to stock quantity.

Discrepant Material Reporting

• DMR-MTL - DMR to job material.• DMR-REJ - DMR to reject.• DMR-SUB - DMR to subcontract.

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• STK-DMR - Stock to DMR.• SUB-DMR - Subcontract to DMR.• DMR-STK - DMR to stock.

Inspection Processing

• ASM-INS - Assembly to inspection.• INS-ASM - Inspection to assembly.• INS-DMR - Inspection to DMR.• INS-MTL - Inspection to job material.• INS-STK - Inspection to stock.• INS-REJ - Inspection to reject.• INS-SUB - Inspection to subcontract.• STK-INS - Stock to inspection.• SUB-INS - Subcontract to inspection.

Manufacturing

• MFG-WIP - Manufacturing receipt to job.• MFG-PLT - Manufacturing receipt to plant.• MFG-STK - Manufacturing receipt to stock.• MFG-VAR - Manufacturing variance.• MTL-DMR - Job material to DMR.• MTL-INS - Job material to inspection.

Plant

• PLT-ASM - Plant to assembly.• PLT-MTL - Plant to job material.• PLT-STK - Plant to stock.

Purchasing

• PUR-INS - Purchase receipt to inspection.• PUR-MTL - Purchase receipt to job material.• PUR-STK - Purchase receipt to stock.• PUR-SUB - Purchase receipt to subcontract.• PUR-UNK - Purchase receipt to unknown.

Return Material Processing

• RMA-INS - RMA receipt to inspection.

Salvage Material Processing

• SVG-STK - Salvage material receipt to stock.

Shipments

• MFG-CUS - Shipment of manufacturing job to customer.• MFG-VEN - Shipment of manufacturing job to supplier.• KIT-CUS - Shipment of a kit component to customer.• STK-CUS - Shipment of stock to customer.

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Stock Transactions

• STK-ASM - Stock to job assembly.• STK-KIT - Stock to kit component.• STK-MTL - Stock to job material.• STK-PLT - Stock to plant.• STK-SRV - Stock to service.• STK-STK - Stock to stock transfer.• STK-UNK - Stock to unknown.

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