Overview: Component Picking
When you confirm picking, the system updates inventory. Confirmation changes the on hand, obligated, and committed quantities for the components picked.
These are a number of ways to pick components for manufacturing orders. This overview compares these methods so that you can select the one that is appropriate for your operation. You may use the same method for all items and orders or you may decide to use different methods for some items and orders.
This topic has these subtopics:
| Backflush Components at Receipt | |
Confirm Picking by Order
You can use the Picking Confirmation (MPK) program to confirm picking for each manufacturing order. Alternatively, you can use the Secured Picking (SMPK) program, if you do not want the operator to:
Reverse confirmation so that he can change the quantity picked after confirmation.
Delete a picking number.
Modify fields on the header.
Both programs require that components be obligated before you can create a shipment to the shop floor. Obligation assigns specific components and raw materials to the manufacturing order. There are several ways to obligate components:
If you selected Y for the MIM controlled items auto-obligate? option in the System Options Maintenance (XM) program (Manufacturing Options) for your manufacturing branch, the system obligates components for you when you click Obligate in the Manufacturing Order Maintenance (MIM) program.
If you selected M for the MIM controlled items auto-obligate? option, when you can click the Obligate button in the Manufacturing Order Maintenance (MIM) program you can select each component for the order. You would select this option if you want to pick specific lot or serial numbers or from certain warehouse/bin locations.
Alternatively, you can run the Manufacturing Order Auto Processing (MAP) program to obligate components and create shipments.
The system picks floor stock components when you receive the finished goods into inventory with the Receiver Maintenance (IRC) program.
Confirm Multiple Orders
The Manufacturing Order Picking Selection (MSS) program displays a list of open manufacturing orders. You can sort the list by priority, parent item, due date, or department for the first operation sequence. The listing identifies component shortages and whether the shortage is of a critical item on the bill of material.
You can click to select the orders that you are going to work on today. When you select an order, the program obligates the required components. When you click Process orders, the program confirms picking.
The advantage of Manufacturing Order Picking Selection is that you can see all orders and perform multiple functions at once.
The system picks floor stock components when you receive the finished goods into inventory with the Receiver Maintenance (IRC) program.
Pick Sets of Components
You may not be able to complete the quantity ordered in the current week but want to start work and pick components for the quantity that you can complete. Or you may not have space on the shop floor for all components needed for a large order. In that case you may want to pick the components required to build to a portion of the quantity ordered.
You can use the Picking Confirmation (MPK), Secured Picking (SMPK), or Manufacturing Order Picking Selection (MSS) program.
If you use Picking Confirmation or Secured Picking, click Partial and enter the quantity of components sets you want to pick. When you click Confirm, the program removes from inventory the quantity of components required to build this quantity of the parent item. When you are ready to pick additional components, the system creates another shipment for the remainder or another partial quantity.
If you use the Manufacturing Order Picking Selection program, select the manufacturing order, click Modify, and enter the quantity of component sets you want to pick. When you click Process orders, the program removes from inventory the quantity of components required to build this quantity of the parent item. When you are ready to pick additional components, the system creates another shipment for the remainder or another partial quantity.
Pick Selected Components
You may want to pick one or more components so that you can start work on a manufacturing order.
With the Manufacturing Order Maintenance (MIM) or Material Usage Maintenance (MUA) program, you can click the Pick button, which picks all the components that you obligated.
In the Picking Confirmation or Secured Picking program, click the Component button on the first screen to display the components of the order. Then click the Pick button, which picks all the components that you obligated.
With any of these programs, you can over-pick a component when necessary. You can also under-pick and then close the component. You can also select a substitute for a component if you do not have enough supply or want to use another component in place of the one on the bill of material.
Backflush Components by Operation Sequence
You may not need to create a pick list for your stockroom because you store components at the work center where they are used. Or you may have another reason to tie component picking to the completion of an operation sequence. See Overview: Component Backflushing.
This method requires that you select the Backflush components by operation seq? option in the Systems Maintenance Options (XM) program (Manufacturing Options) for your manufacturing branch. For each component, you indicate which sequence in the Operation seq no field in the BOM in either the Bill of Material Maintenance (MPS) or Configured Product Maintenance (MBM) program. You can also tie a component to a sequence for a specific manufacturing order with the Material Usage Maintenance (MUA) or Manufacturing Order Maintenance (MIM) program.
When you enter work in process information for operation sequences with the WIP Movement (WIPM) program, you enter employee hours worked and pieces completed in the Labor Entry (LLE) program, or you import data with the Labor Import (LEI) program, the system picks the components needed for that operation. In WIP Movement, you may enter data at significant pay points rather than for each operation sequence. WIP Movement backflushes completion data for operation sequences prior to the one you entered. If you are backflushing components, the program also picks them when you enter data for a subsequent operation sequence.
The system picks floor stock components when you receive the finished goods into inventory with the Receiver Maintenance (IRC) program.
Backflush Components at Receipt
If a parent item has no controlled components, you can have the Receiver Maintenance (IRC) program pick components when you receive the parent item. Select Y or A for the Process excess/short components? option in the System Options Maintenance (XM) program (Manufacturing Options) for your manufacturing branch. You must not obligate or pick any of the components for the order.
Receiver Maintenance (IRC) picks floor stock components when you receive the parent item.
Yield or By-Product Items
Yield items (i.e., by-products of the manufacturing process) are specified by a negative quantity per on bills of material. They are handled similarly to floor stock in that they are only processed during receiving.
Yield items are stocked when you receive the parent item.
Items that are controlled by lot or serial number cannot be yield items.
Yield items cannot be obligated in Material Usage Maintenance (MUA) and they are not picked during operation sequence backflush.
Fractional Quantities
Fractional quantities are rounded up to the next integer when a component is picked; the fractional overage is considered in subsequent picks.
Example:
A floor stock item's quantity per is .2; i.e., 1 of the floor stock item is enough to build 5 parent items. When 1 parent is received, 1 floor stock item is picked (i.e., backflushed). If 4 more parent items are received, the floor stock quantity picked does not change. If a 6th parent is received, the floor stock quantity picked increases to 2.
When the receipt of an item results in a fractional yield, the fraction cannot be stocked until it is a whole number.
Example:
An item's quantity per is -.2; i.e., at least 5 (up to 9) of the parent item must be received before 1 yield item is stocked.
One-Step Manufacturing
You can manufacture all or selected items in one step. When you release a one-step manufacturing order, the system obligates the components, creates a shipment, confirms picking, and prints shop paper all in one step without user intervention.
Select the One-step mfg? field in the parent item's record in the Branch Item Maintenance (IMB) program. You can create one-step manufacturing orders for controlled items. You cannot use one-step manufacturing for configured products, cascading orders, or bulk movement items.