Configuring the application to manage production orders

Various areas of the application need to be configured correctly to properly manage production orders within Infor WMS. There are additional System Settings that support integration with a specific ERP. These directly relate to production order processing.

Warehouse > WMS > Administration > System Settings

  • AUTOMATICALLYCONSOLIDATEORDERS - Run speed pick consolidation on eligible items when a new wave is created.

    Turn on this setting to enable the system to automatically assign speed pick locations to eligible items when a wave is created. If this setting is off, you can still consolidate eligible items by manually creating a wave.

  • DISALLOWDUPLICATEIDSONRFRCPT - Prevent receiving duplicate license plates on an RF receipt.

    Turn off this setting if the ERP directs receiving using the ProcessReceiveDelivery BOD and multiple receipts to the same LPN are required. Multiple receipts for the same LPN may be required as finished goods are received off the Production Line.

  • REQUIRESIGNALTOCLOSEPRODUCTION - Require ASN Production Status to be "Closed" before closing the Production Order.

    Turn on this setting to require the system to not allow the "Finalize Close" process to initiate unless the ERP has sent a SyncProductionReceiver status ="Closed" message. The "Closed" message signal it is ready to begin receiving messages generated from Infor WMS when closing Production Orders.

  • TOLERANCEPCTPRODCOUNT - Tolerance percent allowed above pallet size on production cycle counts.

    This value is used to validate the quantity being entered by the operator during the cycle count is the approximate quantity expected on the pallet. The value is a percentage of the pallet quantity as defined on the pack for the item. For example, if the specified value is 10, the operator could enter a quantity ten percent higher than the normal pallet for the item. If the standard pallet size is 150, the count cannot exceed 165 (10% of 150 is 15).

Warehouse > WMS > Configuration > Item > Outbound tab

  • Round Quantity on Backflush (Default = ON)

    Turn on this flag to round the quantity shipped of component items up to the next whole number during the backflush process. If this is off, the backflush process can result in decimal quantities being shipped. The use of this flag depends on the type of component used. Items tracked by volume or weight are typically tracked with decimal quantities so this flag will be Off.

  • Allow Consolidated Picking (Default = OFF)

    Indicates if the item should be considered for consolidated picking when the item is included on a wave. The check box must be selected for production order items to be correctly assigned to Speed Pick locations during the wave consolidation process.

  • Automatically Assign Consolidation Location

    Indicates if the system should attempt to assign the speed line location without user interaction when consolidation is performed on the wave prior to allocation.

  • Force UOM Replenishment Quantity

    Indicates if pick location replenishments are only issued to users in the Default Minimum Replenishment UOM for Consolidation identified for the item.

  • Minimum Wave Quantity

    For considered of consolidation on a wave, the total quantity ordered for all orders included on the wave must be greater than or equal to value specified in this field. The specified value acts as a filter to prevent items from being assigned to speed pick locations if the order quantity is below a threshold. For production order processing, a value must be set so that the item is always included. Decimals, such as .00001, are allowed.

  • Location Minimum for Consolidated Picking

    When consolidation is completed, this setting is used as the minimum quantity in the speed line location. The speed line location is used to control the replenishment into the production line staging location. This value is used as the Minimum Capacity on the Assign Locations tab of the item configuration.

  • Location Maximum for Consolidated Picking

    When consolidation is completed, this setting is used as the maximum quantity in the speed line location. The speed location is used to control the replenishment into the production line staging location. This value is used as the Maximum Capacity on the Assign Locations tab of the item configuration.

  • UOM used for Location Min/Max Settings

    This selection assists in viewing the minimum and maximum settings described above. The drop-down menu lists the UOMs available for the item. Select the value from the list that you want to use to view the Minimum and Maximum fields. Note that the database always stores the values in the master units. For example, if you want to specify the number of pallets for min/max consideration, set the value to the PL unit of measure.

  • Default Replenishment UOM for Consolidation

    This selection determines the unit of measure used during replenishment. This value is the Minimum Replenishment UOM on the Assign Locations tab of the item after consolidation is complete.

  • Allocation Strategy

    Items that are going to be backflushed need to use a firm allocation strategy for the speed pick to be overallocated. Production order items that are not backflushed must use a soft allocation strategy. A soft allocation strategy provides the flexibility needed during picking to deplete inventory.

Warehouse > WMS > Configuration > Location

There are four types of locations available for use in production flows. For production order management, there can be up to three locations for each production/manufacturing line being used. The Location Type and Backflush Indicator are used by the application to properly manage the inventory and process flow for these locations. Two types of locations support the Backflush Inventory from Speed Pick flag turned off, but only one of these two types can be used in association with a production line at one time for the same component item.

  • Type = Outbound Staging (STAGED): This is the production line. The host may send this field as the Stage location on the order header.
  • Type = Production Cycle Count. This selection allows for the definition of a Cycle Counting Location for each production line. Parallel to assigning a speed line location to a Production Staging Location, this field allows assigning a valid cycle count location to a production line when many Production Cycle Count Locations exist (one for each production line or many lines to one using the default CCPROD location).
  • Type = Speed Line and Backflush = ON: This is the speed line (consolidation) location for component items on the order lines that have been defined to use backflush logic. These items have the Backflush Indicator turned On for the order line. Because this location is used for backflush items, the Lose ID flag must be On. Note that if backflushing is not used in the operation, you do not need to create this type of location.
  • Type = Speed Line and Backflush = OFF: This is the speed line (consolidation) location for component items on the order lines that are configured to be shipped by a user to record actual consumption of the material. These items have the Backflush Indicator turned Off for the order line. Because this location is used for actual consumption items, the Lose ID flag must be Off. Note that if backflushing is used for all items, you do not need to create this type of location.
  • Type = Speed Line and Backflush = OFF: This is the speed line (consolidation) location for component items on the order lines that are configured to be shipped by the ERP to record actual consumption of the material. These items have the Backflush Indicator turned Off for the order line. Because this location has consumption directed by the ERP, the Lose ID flag must be On. Note that if backflushing is used for all items, you do not need to create this type of location.

When multiple variations of speed pick locations are assigned within a facility to multiple production lines, use and troubleshooting are facilitated by adding an alpha identifier to the location for speed of type identification (B=Backflush, A=ActualConsumption, DS=DirectShip type location). When Actual Consumption and/or Direct Ship type locations are used together in a facility, Production Staging must be used to define production line setup.

These fields on the location are key to system performance with production orders:

  • Production Line Staging Location for Consolidated Picking

    This field is only enabled for Production Cycle Count and Speed Line type locations. The value entered must be a valid location with the type of Outbound Staging (STAGED). This is used in consolidation to link speed pick locations to a production line number. The product used in the production order is replenished to the correct staging area for the order.

  • Backflush Inventory from Speed Pick

    This field must be checked to use backflush logic for production orders. The flag is used to correctly link the type of product being consolidated to the correct speed location. If this selection is checked, the Lose ID selection must also be checked. Order lines that have the Backflush Indicator turned on consolidate into the speed pick location flagged for backflush. Order lines that do not have the Backflush Indicator turned on consolidate into the speed pick location that also does not have the backflush flag turned on.

Additional locations used to facilitate the Production Process include:

  • Pick and Drop Location

    This location is used in the replenishment process to drop inventory for a To Location in an intermediate location before reaching the final location. This process is typically used where the inventory warehouse and production facility are separated. The ID for this location is used in the Inbound Staging Location field on the Detail tab of the Zone screen where the production line(s) are located.

  • Auto Ship Location

    This location is used as the To Location to automatically ship inventory picked to that location. The location streamlines the process of shipping inventory from the speed pick location. This location requires the location type Outbound Staging and requires the flag Automatically Ship Picked Product to be turned on. This location does not have to be defined for each production line but does provide improved flows.

Warehouse > WMS > Configuration > Zone

Zone settings control the replenishment method, and the pick and drop location used for the zone.

These fields within a zone configuration support production processing:

  • Detail Tab

    The Inbound Staging Location field on the Detail tab of the edit zone screen must have a Pick and Drop location specified if Cherry Pick Multi LPN Replenishment is used.

  • Replenishment Method Tab

    The Replenishment method for the production lines configured within a zone can use regular replenishment or cherry pick replenishment. You can configure this setting based on the desired replenishment method. Additionally, you can select the Ignore Inbound and Outbound Stage Locations for this From Zone field on the Replenishment Method tab for the zones requiring that the pick and drop location configured for the zone is not used.

Warehouse > WMS > Configuration > Trading Partner > Owner

Production Order closing can be manually executed via RF as described in Closing the production order. To expedite closing, an ERP can direct closing the Production Order in Infor WMS with minimal intervention by users in the facility shop floor area. This is especially useful when multiple Production Orders are defined to create the same end item continuously, with no requirement to change out material between orders. The Production Process section (comprised of the three fields defined below) on the Processing tab within the Owner screen is only used to streamline closing. This functionality is referred to as "Auto Close" for Production Orders. The owner settings at the warehouse level support logic that streamlines closing Production Orders.

The fields on the Processing tab within the Owner screen that support production processing are:

  • Automatically Finalize Production Order

    When the check box is selected, Infor WMS uses the SyncProductionReceiver status = Closed, sent by the ERP, to trigger unallocating any allocated inventory, setting the shipments for the Production Order to 0 (zero) open quantity, setting the status to Shipped Complete, and setting the ASN to Closed. The REQUIRESIGNALTOCLOSEPRODUCTION System Setting is not required for Auto Close to execute and does not impact the auto close logic if the field is selected. Note, though, that when selected, the RF user cannot utilize the "Initialize Close" or "Finalize Close" functions in RF. A warning message is displayed when the RF user attempts to select one of the functions.

  • Create Moves From Production Staging for Counts

    When the check box is selected, after the identified Production Order is closed, Production Move tasks are generated to move all component inventory used by the Production Order from the production line to a centralized location. In addition, Production Cycle Count tasks are generated for cycle counting when the inventory is placed in the centralized location. Once it is moved away from the production line, the component inventory is no longer identified with the Production Order and any adjustments resulting from the count do not contain a Document Reference. (A Document Reference points to the Production Order when manually closing and counting component inventory on the production line.) Used when component item changeover requirements must be expedited, this field also allows inventory from multiple lines to be placed in this location for counting and eventual putaway. (See Production Staging configuration section below for information on limiting moves by item). These tasks are limited to one each per production line, per item. If the tasks already exist for the production line, this restriction keeps redundant tasks from being created.

  • Cycle Count Location for Production Inventory

    The default location for Production Cycle Count is CCPROD with a Location Hold type of Other. Location selection is required when the Create Moves From Production Staging for Counts check box (defined above) is selected.

These settings impact all production lines in the warehouse, but can be controlled in part by the ERP not sending the SyncProductionReceiver status = Closed. When production line changeover is required and the new end item is used again, it is possible to halt movement of material away from the line using the Production Staging settings.

Warehouse > WMS > Configuration > Production Staging

Initially designed to allow production lines to share speed pick locations, this configuration parallels the fields found on the Item Outbound tab but includes additional control. Production Staging handles multiple production/manufacturing lines and scenarios. When items require different min/max quantity settings per Speed Pick location, the Production Staging configuration screen is used to identify the unique setting for each speed pick location by associated production line. Infor WMS logic determines consolidation location and min/max quantities by searching the production staging table first.

The following logic is followed when entries exist in the Production Staging screen:

  • If the item/stage location combination from the shipment matches what is configured in Production Staging it will be used for consolidation requirements.
  • If a particular item/stage location is configured in Production Staging but the speed pick is not assigned, Infor WMS logic performs a lookup of the speed pick associated with the Stage location on the shipment and uses the Item Outbound tab for data, acting as the backstop for consolidation.
  • If two production lines use the same speed line location, the location is shared between production lines. Consolidation occurs for each line in this location.
  • If the item/stage location does not exist on the Production Staging screen, the Item Outbound tab configuration is used for consolidation requirements, acting as the backstop for consolidation.

Here are sample production staging configurations with location types and usage:

Owner Item Production Line Speed Line Backflush LoseID Use/Location Type
AE1 SKU23 PRODLINE1 PL1DS No Yes

Directed Ship (Used when ERP/Host directs decrementing inventory)

Or Or
AE1 SKU23 PRODLINE1 PL1A No No Actual Use (used when Infor WMS directs decrementing inventory)
AE1 SKU44 PRODLINE1 PL1B Yes Yes Backflush
AE1 SKU44 PRDLN2 PL1B Yes Yes Shared/Backflush
AE1 SKU77 PRODLINE1 Backstop

Most fields on the Production Staging screen can be viewed from List View Preferences. When Actual Consumption and/or Direct Ship type locations are used together in a facility, Production Staging must be used to define production line setup.

To facilitate control of Production Moves, the Production Stage includes this additional setting to restrict movement of items away from the production line:

  • Move Task to Count Location is Not Created

    When this check box is selected, Infor WMS does not generate a Production Move or Production Cycle Count task for the identified item. This allows universal items, used on many end items, to remain stocked on the production line consistently.

Warehouse > WMS > Configuration > Productivity > User

In addition to the normally used RF permission, these are used within the scope of the Production Process:

  • Production Move

    When the Owner is configured to move inventory away from the production line on closing a Production Order, the user can use this RF task to move the inventory.

  • Production Cycle Count

    When the Owner is configured to move inventory away from the production line on closing a Production Order, the user can use this RF task to count inventory in the Production Cycle Count location any time after the inventory is moved.

  • Cherry Pick Multi

    When the zone is configured to support Cherry Pick Replenishment, the user replenishing the Production Line can be assigned Cherry Pick Multi (CM Task) permission to allow picking multiple LPNs for multiple locations on the shop floor.