Planned

Assemblies - Bulk Upload

We have many assemblies per month - a bulk upload feature would be MASSIVELY of benefit.


Currently we input each assembly one by one manually, we have a few hundred a month.


We know what we need to build the month before, based on sales figures and stock levels. We then create and authorise assemblies, which tells us how much available stock we have. We then order from this figure in DEAR.


We then upload via csv assembly SKU's and quantities to a choice of draft or authorised.


Then when the day comes to manufacture those lines, we pick off the assemblies that are required from the list of authorised assemblies, pick them (only then should DEAR request an expiry date), and complete them.


Expiry dates can't be expected to be entered before you've authorised or even picked your stock - we don't know what the expiry dates of the components are before we've picked them, thus we cannot set the expiry of the FG until components have been picked. 


THEN...


DEAR would auto-populate an expiry date based on the earliest expiring product (it already does this when picking components). This can then be overridden if required.


An alert set for a min expiring dates for components would be hugely beneficial too, then it would flag up if something with poor dates are used (which would cause problems down the line if the user forgot to check).



(Currently we create a manual assembly, try to authorise it. "Expiry date is required"...ok lets put a year from now, then authorise it, pick it, sort by expiry dates. Then if we remember, we reset the FG expiry date to the first expiring component. Or we remove that product, and replace it with another better date component, set the FG expiry date, allocate stock and away we go.) It sounds simplistic but that's the process. Theres loads of room for error.


thanks!


1 person likes this idea
  • Thank you for valuable suggestions.


    Please let me suggest possible implementation details and confirm if my understanding is correct:


    1. We will add a special import function for assemblies. It will allow to import csv file with fields "Location, SKU, Quantity, RequiredByDate". Only products with BOM can be included in the list. For each line in the file, new assembly with authorised order state will be created, with loaded order from BOM.

    2. Expiry date validation will be changed to only trigger on assembly completion.

    3. Products with BOM and FEFO costing methods should have a new setting "Minimum Days till Expiry" in days. When trying to complete assembly with the product when completion date + "Minimum Days till Expiry" is less than selected Expiry date, the confirmation should be shown to confirm the completion.

    4. If expiry date is not set for FEFO assembly product on completion, this date should be auto-filled with minimum expiry date of picked components.

  • Hi Marvin - many thanks for your reply - super glad to see this is planned.


    In reply: 

     

     1. We will add a special import function for assemblies. It will allow to import csv file with fields "Location, SKU, Quantity, RequiredByDate". Only products with BOM can be included in the list. For each line in the file, new assembly with authorised order state will be created, with loaded order from BOM. - Correct. Please add ‘Order Notes’ to the import csv also. The user can use this to say ‘May 2019 Production’ for example to distinguish it from other batches which can be seen on the summary screen, and is searchable.

     

     

     2. Expiry date validation will be changed to only trigger on assembly completion. I feel this could be triggered when you hit the 'allocate' button to allocate components at the pick stage.

     

    3. Products with BOM and FEFO costing methods should have a new setting "Minimum Days till Expiry" in days. When trying to complete assembly with the product when completion date + "Minimum Days till Expiry" is less than selected Expiry date, the confirmation should be shown to confirm the completion. Or as the component allocation happens, and the date is set, it should bring up a warning at that stage before OK'ing it to move to WIP stage.


    4. If expiry date is not set for FEFO assembly product on completion, this date should be auto-filled with minimum expiry date of picked components. Yes, see point 3.


    I'll be adding more detail shortly which may be useful to the production planning

  •  Further info if required:

     

    I imagine a FG process to be synonymous to a sale process, whereby you would have a draft assembly (sales order), then a new picking state (sale picking), work in progress (sale packing) and completion (shipping). I feel the FG could do with one more state, namely a picking state after draft and before WIP where you could print a pick list and have all the components picked and ready to be worked on. 

     

     

    This may not be the industry standard for light-scale manufacturing, but this is how we do it:

    1. Sales dept will work out sales figures for production for a period.

    2. Production dept inputs each individual batch into DEAR and authorises them, or a magical csv bulk upload

    3. Once batches are authorised, the components are then allocated, which also means any components not on hand will be backordered.

    4. Then the ordering dept goes to the 'Reorder Backordered' page and it'll pick up all the figures with negative availability values. This is then ordered.

     

    Production commences: 

     

    5. Production picks up lines that are low in stock, searches for those products, notices the authorised batches with applicable notes (May 2019 Production, for example). A batch is selected from this list.

    6. Once in this batch Assembly Order, the user will proceed to print a pick list (this is where a ‘picking’ status would be beneficial). A pick list is produced from the original Assembly order, but with expiry dates(earliest expiring first), if applicable. The production is now in ‘Picking’ status.

    7. Warehouse picks the stock and notifies Production of any discrepancies in stocks, damaged, shortages, etc. that would halt the production of that batch. The components are then scanned into the pick screen or auto-filled from the Assembly Order. At this scan stage, just like a sale order, the scanned components must match the Assembly Order or it will bring up an error.

    8. If there are discrepancies, Production would ‘undo’ the pick and alter the component type/batch total qty/use different dated components, etc. At this stage when the ‘undo’ is selected, it should only undo the pick “allocation”, not the entire pick page (so the components still remain visible in the pick screen, and individual components can be changed, instead of having to re-scan all components in again).

    9. Once the ‘Allocate’ has been hit, expiry date is automatically set (can be manually changed), and the assembly enters the ‘Work in Progress’ stage, product labels are printed which contains the expiry date, and Warehouse manufactures to completion.

  • Currently DEAR seems to sort assemblies by default in Date or Assembly# order.


    If the above was put into place, the user may enter the assemblies 1/2 months ahead of time, in which the date would be automatically set.


    But then when working on the assembly, the date still remains the same, unless the user remembers to change it. This just makes it a little difficult as some assemblies may be way down the list even though they are Work in Progress.


    It would be good to have the option or even default to sort by last modified, so at least all the current assemblies will be together.


    A date of completion could also be automatically set when the complete button is selected.

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