November 9, 2018 admin

Pick & Pack – Production Orders

Hello, in this post we will explain how to Pick and Pack Production Orders using SAP Business One and CORE XRAY WMS. There are two ways in which this can be accomplished:

  1. Through the Production Module – where stock can be Issued for Production and Received from Production against the base document (the Production Order)
  2. Through the Pick and Pack Module – where stock has to be picked in order to be Issued for Production against a Pick List and then, from Packing one would create the Issue for Production document against the base documents (the Production Order and the Pick List)

Note: No matter if the used items are managed by batches, managed by serials or un-managed; if the warehouses are managed by bins or un-managed, the process will still be the same and the scanner will automatically adjust to your business setup. Without further ado, lets get down to the details regarding each mode of operating.

Through the Production Module

Issuing

Once a Production Order is released in SAP Business One (status: Released) it will become visible automatically on the handheld scanner in Issue for Production Function, IF the Production Order has at least one line item set to “Manual” issue method. If all line level items are set to “Backflush” then the Production Order is not displayed on the scanner (there is nothing to issue manually via scanning).

Using the handheld scanner, navigate onto page 2 where the Production Module is located and select Issue for Production.

In the Issue For Production Screen we would see the list of released Production Orders in SAP. The document number is displayed and what is being produced (code and name). Enter the production order number in the filter or double-tap on the row.

This will open the Production Order Lines – Items marked with Issue Method – Manual. In this case there’s only one such item on the line level – MYSERIALITEM001. Scanning the item barcode or double-tapping on the row will progress to the next screen where we’ll enter the line item details.

Because this item is serial managed (we can see this by looking at the “S” placed in front of “Loaded/Expanded” text in the black box at the top-right) the scanner will expect to scan the serial to be issued to production. Once we scanned it, pressing “Save” will return to the previous screen (items list) and we’ll be able to submit the data to the server to be added in SAP as an Issue for Production.

Here we can check if we loaded everything that is open (last two columns of the grid should match). Submit can be pressed now to create the document.

The scanner will let the user know the status of the server transaction and the Issue for Production number from SAP.

The production order’s first line has now been issued and is grayed out.

Looking at the Production Order’s Relationship Map we can see that we have a new linked document, the Issue for Production.

Basically, this is what we just added with the scanner in SAP Business One.

If the Serial Number Transactions Report is opened, we can see the serial we submitted with the scanner. The same happens for Batch Managed Items when issued for production, the serials are allocated against the document.

Receiving

At the end of production, when the final product is complete, the following scanner function needs to be used to record the Receipt from Production document: Production Module – Receipt from Production Function. The user would just have to confirm the produced quantity and hit “Submit”. A Receipt from Production document is added to SAP Business One and the scanner prompts for labels (if the newly produced item requires a label).

From the scanner, on the second page of the menu, select Receipt from Production (Production Module).

In the first screen we can see the production orders that can be receipted from production. Entering the production order number into the header field or double-tapping on the desired row determines the scanner to progress to the next screen.

The second screen shows the user the item code that should be receipted from production and the planned quantity in the “Open” column. Entering/scanning one of the issued components, the receipted item code, the receipted item’s barcode or double-tapping on the row will progress to the next screen where the users capture the item details.

The receipted item is managed by batches, the scanner will ask the batch to be entered. In this example, “20181109” was introduced as the batch number. But the value can obviously be in any format the business uses batches. Pressing “Save” in this screen would return to the previous one and we can Submit the entered details to the server.

We are now ready to submit the captured details to the server so that a Receipt from Production document is created in SAP. Press the green button.

In this example, the server has been configured to automatically close the Production Order in case the entire planned quantity is receipted from production. As a confirmation we also get the Receipt from Production number from SAP.

After closing the prompt, the scanner automatically asks the user if a label is required for the newly produced item. Pick the label size, the printer that should print the label, the number of copies and “Print”.

The receipt from production process using the scanner is now complete, let’s now check SAP. The Production Order is now closed.

The relationship map will now show all the documents that were involved in the process of issuing and receipting. Our Receipt from Production document submitted from the scanner (#145) also created an Issue for Production automatically for all the Backflush marked items part of the Production Order.

Our Receipt from Production document (#145) with the produced MYBATCHITEM001.

Looking at the Batch Number Transactions Report associated with the Receipt from Production document, we can see the data that was submitted from the scanner beautifully captured in SAP Business One.

Through the Pick and Pack Module

Another way of managing production is via the Pick and Pack Module. The process starts the same way, the Production Order has to be released in SAP Business One (status: Released). The additional step for better control over the stock to pick is to create a Pick List for the released Production Order. Once the Pick List is created and is released, it becomes visible on the handheld scanning devices under Pick Module. The warehouse user would then start picking the stock and, once picking is finished, would submit the transaction to the server (by pressing the Submit button). This operation will update the Pick List to “Picked” status. In real-life scenarios this is the moment when picked stock physically moves from the warehouse to the production area. Once it reached production and components are used, the warehouse user would go into Packing, select the pick list for the Production Order and press Submit. This is when the Issue for Production document is added to SAP.

Issuing

Let’s start with a similar Production Order, but this time we’ll progress it through production using Pick and Pack.

Using Pick and Pack Manager in SAP Business One, let’s now create a Pick List for this Production Order.

Going to select only the production order line item that has issue method “Manual”. In our case “MYSERIALITEM001” and “Release to Pick List”.

Our created and released pick list for the Production Order.

Using the scanner, we will now pick the production order items based on the created pick list. To do so, go to the scanner’s second screen and select Pick.

The first screen in Picking displays all the released pick lists that haven’t been picked yet (or fully picked). Entering/scanning the pick list number in the header field or double-tapping on the row will progress to the next screen where we’ll see the pick list lines.

The second screen displays the pick list lines – where to pick them from, what’s the item name and how many. The boxes section at the bottom allows the warehouse user to pick straight into a box. There’s always a starting box created automatically (box “1”) which is also the default box. “Print default” will print a box label that contains the box details (for which production order it is, mainly). In order to progress to the next screen – either scan the first item that needs to be picked, either press “Next!” (which opens the next available and unpicked line), either double-tap on the row.

The item details screen requires the user to enter the box number where he’s about to pick the item (or press enter to confirm the default one), then the bin he’s picking from (validated – needs to be the same bin as instructed by the scanner) and then the item that is picked. There’s a useful instruction area at the bottom in yellow that automatically changes as the user picks items.

After picking the item (serial “20181110”) the screen will look like the below. The instruction (yellow) automatically changed and the user is now able to Save and return to the previous screen. If, during picking, the instruction is to pick from a certain bin but the stock isn’t physically there, one can press “TO SF” (To Stock Finder) and search for it throughout the warehouse. Obviously, the search is done against the SAP stock recordings (checking the SAP database).

The progress bar underneath the Item header field is now full, indicating the pick list is 100% picked. We can now submit the details to SAP to update the pick list to “Picked”.

The prompt after the operation on the server finished informs the user all is well.

The scanner now returns to the list of pick lists. The pick list is now “Picked” in SAP, it is no longer “Released” so it won’t show up in the list.

Before moving into “Pack”, let’s check SAP. What we just did is update the Pick List from Released to Picked.

Now that the stock was picked and the pick list has been updated, we still need to create the Issue for Production document. This is done via the Packing function. So from the main menu page 2, click on “Pack”.

In this screen we see two lists, vertically aligned. The list on the top displays all the pick lists that were picked and are available for packing. All we have to do is select the pick list we want to pack and press “Add to Packing List (Below)”.

After pressing the button, the pick list row moves in the bottom list. We can now “Submit” so that the server uses the data associated with the pick list to create an Issue for Production.

Issue for Production created with only two scanner clicks. We receive back the SAP number associated with the recently added document.

The screen now becomes empty (after closing the confirmation pop-up). Everything was picked and packed.

In SAP, the Pick List is now closed.

The Production Order’s first line has now been issued and is grayed out.

When we packed the pick list from the scanner an Issue for Production document was posted in SAP and associated with the Production Order.

The below document was added in SAP against the Production Order.

And all the details are captured against the document (scanned serials or batches).

Receiving

This section of creating the Receipt from Production is the same as operating via the Production Module. At the end of production, when the final product is complete, the following scanner function needs to be used to record the Receipt from Production document: Production Module – Receipt from Production Function. The user would just have to confirm the produced quantity and hit “Submit”. A Receipt from Production document is added to SAP Business One and the scanner prompts for labels (if the newly produced item requires a label).

To record the Receipt from Production, from the main menu page 2 select “Receipt from Production” from the Production Module.

Users will now be able to record the receipts against the Production Order. This process is identical to the one described in “Through the Production Module” – “Receiving“.

Tagged: , , , ,