Lot Blending

Outcome

• For Silo items and corresponding locations:

  Only one item (single item number) that is set up as being stored in a silo with first-in-first-out (FIFO) consumption will be allowed in any silo location at any given time. Items stored in silos are not blended (mixed). Rather, the system uses existing logic to segregate lots within the silo. Each lot retains dimensional and demographic data such as status, allocations, attributes, etc. Lots are relieved from the silo using FIFO logic.

• For Full Mix items and corresponding locations:

  Only one item (single item number) that is set up as being stored in a full tank will be allowed in any Full Mix location at any given time.

  Note: Multiple bulk items cannot be mixed or blended using the system functions. You must use manufacturing orders to blend multiple items to produce a new item.
  • When you put-away or transfer lots of full mix items to a full mix tank that is not occupied by another lot of the same item, the item data such as status, allocations, action dates, etc. are retained.
  • When you put-away or transfer lots of full mix items to a tank that is occupied by the same lot of the same item, then the item data, including status, allocations, action dates, etc., are retained. The quantity of the item in the 'To' location is increased to include the quantity transferred or put-away.
  • When you put-away or transfer lots of full mix items to a full mix tank (which is the 'From' lot) that is occupied by a different lot of the same item (the 'To' lot), the two lots are blended unless:
    • either lot is on a Picking List. Therefore, blending is not allowed.

      or

    • allocatable lots are attempted to be blended with non-allocatable lots. This is not permitted.

  Items designated as 'Full Mix' are required to use an automatic lot numbering method. Therefore, the resulting blended lot is identified by a new, system-generated lot number. These are the dimensional and demographic data for the new, blended lot:

  • Status
    • IF the status of either the 'From' lot or the 'To' lot = '3-Rejected' THEN the status of the new, blended, lot = '3-Rejected'
    • IF the status of either the 'From' lot or the 'To' lot = '1-Under Inspection' THEN the status of the new, blended, lot = '1-Under Inspection'
    • ELSE the status of the new lot = '2-Approved'
  • Dates
    • Expiration date: earliest of the 2 blended lots
    • Follow-up date: earliest of the 2 blended lots
    • Harvested date: earliest of the 2 blended lots
    • Earliest sales date: earliest of the 2 blended lots
    • Priority date: earliest of the 2 blended lots
  • Allocatable
    • IF both the 'From' and 'To' lots are allocatable, THEN the new lot is allocatable ELSE, the lot is not allocatable
  • Allocations
    • IF either the 'From' or 'To' lots have system-generated allocations, THEN the new lot will show the same allocations
    • Manual allocations are not retained and must be entered by the user.
  • Allocated Quantity
    • Allocated quantity of the new, blended lot will equal the total allocated quantity of the 'From' and 'To' lots.
  • Catch Weight
    • Catch weight (if used for the item) of the new, blended lot will equal the total approved catch weight of the 'From' and 'To' lots.
  • On Hand Quantity
    • On Hand quantity of the new, blended lot will equal the total on hand quantity of the 'From' and 'To' lots.
  • Approved Quantity
    • Approved quantity of the new, blended, lot will equal the total approved quantity of the 'From' and 'To' lots.
  • Potency
    • Potency of the new, blended lot must be entered by the user.
  • Attributes
    • Attributes (if used for the item) will not be preserved for a blended lot. Attributes for the new, blended lot must be entered by the user.

Lot blending is a concept used when handling bulk items in tanks and/or silos. Because food safety is more important than ever, the system supports a solid lot blending process that is industry-specific in Food & Beverage, as well as the Chemicals industry. Blending ensures a secure proper proactive control of logistics flows and provides follow-up and traceability within the supply chain.

To gain traceability, a Location Characteristic may be attached to stock locations and to the item master. In contrast to Location Type, Location Characteristic has a limited number of options describing the nature of the location, providing the ability to add logic to the behavior of an item in the location.

Two important tables are used for lot blending. They are MILOMA (Lot Master File) and MIWLAL (Location Action Log).

The lot characteristic (TANK) defined for the item is stored in the MITMAS table (item master).

The lot characteristic (WHLC) defined for the location is stored in the MILOMA table (lot master).

The MIWLAL table (Location Action log) displays the history for related transactions (with a transaction type of '99-Blending').

Before you start

• The Location Characteristic conditions in Lot/Serial Number Settings must be fulfilled.
• The Location Characteristic conditions outlined in the document Create Location in Warehouse must be defined and must match the corresponding item's location characteristic.
• Basic item setup must be completed.
• Basic data for inventory management must be set.

Completing the basic item setup

1. Open 'Item. Open' (MMS001).

2. On panel G, select a Lot characteristic of '0-No special characteristics', '1-Bulk', '2-Silo with FIFO consumption' or '3-Full Mix Tank'.

   Note: After the value is set, it cannot be changed until the quantity on hand of the item is zero (for all balance identities, all locations, all warehouses).

3. If you select a Lot characteristic of '2-Silo with FIFO consumption', you must define the item's Lot control method on panel E as anything other than '0-Not used'.

4. If you select a Lot characteristic of '3-Full Mix Tank', the item must:

   • Have a Lot control method of '1-Lot control used but not defined in lot master' or '3-Lot control used and must be entered in lot master'.

     AND

   • Use a Lot numbering method (defined on panel E of MMS001) of '1-Automatically use YYMM plus a 6-position long sequence number', '2-Automatically use YY plus an 8-position long sequence number', '3-Automatically use a 7-position long sequence number', or '6-Automatically use YYMMDD plus a 4-position long sequence number'.

Setting the basic data for inventory management

1. Open 'Stock Location. Open' (MMS010).

2. On panel E, select a Location characteristic value of '0-No special characteristics', '1-Bulk', '2-Silo with FIFO consumption' or '3-Full Mix Tank'.

   Note: After the value is set, it cannot be changed until the quantity on hand in the location is zero.

3. If you select a Location characteristic of 2 or 3:

   • Multi-storage must be set to '3-Same item'

     AND

   • Container management must be set to '0-Not selected'.

4. Open 'Item. Connect Warehouse' (MMS002).

5. On panel G, the default location for the item must have the same Location characteristic as the item. Otherwise, an error message, saying "Item can only be stored in location with corresponding Location characteristic," will be presented.

6. If the item has a Location characteristic of 2 or 3, the Container Management setting on panel G must be set to '0-Not used' and this value cannot be changed.

7. Open 'Item. Connect Facility' (MMS003).

8. On panel E, you cannot set up items with the Location characteristic value of 3 to use dynamic or actual costing. Therefore, the Inventory accounting method field cannot be set to '3-Dynamic' or '4-Actual'.

9. Open 'Number Series. Open' (CRS165) to view each series that supports blending:

   • Series B5 A for Lot blending
   • Series B6 A for Tank cleaning

10. On 'Stock Transaction Type. Open' (CRS205), you may assign a Transaction type of '99-Blending'.

Follow these steps

Blending lots

1. Launch 'Blending Lot. Open' (MWS155).

2. On panel A, specify the Warehouse, Item Number, Location (From Location), Lot Number, To Location, Quantity (to transfer), and Catch Weight (if used for the item).

3. On panel E, you can select a Status for the new lot and enter additional details. The system displays details of the last recorded movement on the New lot no, (Total) New qty, and (Total) Allocated qty fields.

4. Click Next to perform the transfer. A new item-lot number is created for the blend.

   Note: 'Blending Lot' (MWS155) replaces 'Movement. Change Loc - Item' (MMS175) and 'Movement. Change Loc - Balance ID' (MMS177) for items with a location characteristic of '3 - Full Mix Tank'.

5. Open 'Tank cleaning' (MWS156) to set all Balance Identities in a selected location to '0' by generating a Transaction Type = '91-Scrap transaction'.

   Note: This function is restricted to locations with a Location characteristic of '2-Silo with FIFO consumption' or '3-Full Mix Tank'.

6. On panel B, enter or select the Warehouse and the Location within the warehouse to be cleaned.

7. Click Next and the system displays all lots found in the location as well as the last cleaning date/time.

8. Specify a Remark and a Trans Reason code, if desired.

9. From the Actions menu, select Clean Tank Update. The system displays the message: 'WARNING - the location balance will be '0' after cleaning.'

10. Again, select Clean Tank Update from the Actions menu.

11. Click Next to clean the tank. The screen refreshes and shows that no lot balances occupy the location.

12. Open 'Location Activity Log. Open' (MWS157) to view the history for blended transactions.

13. On panel A, specify a Warehouse and Location.

    Note: Optionally, you may specify a transaction date and time, item number and lot number to filter the result set.

14. Click Next and the system will display all records from MIWLAL (Location Action Log) that match the input criteria.

15. Open 'Lot. Trace' (MMS140) and select the Transaction Type of '99-Blending' to trace blended items.