Open Forum

Expand all | Collapse all

Automated Manufacturing

  • 1.  Automated Manufacturing

    Posted Jan 08, 2019 05:46 PM
    I just want some opinions.

    If I'm using NAV 2017 and wanted to make the manufacturing process completely automated, what would I have to have in place and turned on?  I know this is a vast subject, but I'm curious if NAV will do this without additional applications.



    ------------------------------
    Xan
    Katy TX
    ------------------------------


  • 2.  RE: Automated Manufacturing

    Posted Jan 09, 2019 07:28 AM
    Edited by Mary Ellen Simmons Jan 09, 2019 09:02 AM



  • 3.  RE: Automated Manufacturing

    TOP CONTRIBUTOR
    Posted Jan 09, 2019 09:05 AM
    ​The first thing to understand is what you mean by "completely automated". Here are some possible definitions:
    • As soon as demand is present automatically create the production order and start production
    • Deliver production orders to work stations on the floor/device where the operators can run production
    • Deliver production orders to a Manufacturing Execution System (MES) that manages and/or runs the machines, then reports back to NAV hours, consumption and outputIs this real-time or batch updated


    Out of the box NAV will allow you to scheduled and create production orders. Any integration with the shopfloor is outside of base NAV. There are add-ons to streamline the deployment of production orders to the floor.

    ------------------------------
    Andrew Good
    President
    Liberty Grove Software
    Oakbrook Terrace IL
    ------------------------------



  • 4.  RE: Automated Manufacturing

    Posted Jan 09, 2019 12:49 PM
    Hello Andrew,

    I believe we met at the conference in Toronto a few weeks ago!

    Not to take away from the original poster's question, but I have just posted in the forum regarding "Deliver production orders to work stations on the floor/device where the operators can run production". If you have a moment could you read over the issue we are having. Subject "automatic (electronic) order processing".

    Thank-you.

    ------------------------------
    Michael Kery
    Macgregors Meat & Seafood
    ------------------------------



  • 5.  RE: Automated Manufacturing

    Posted Jan 09, 2019 09:17 AM
    Thanks so much for the reply.  Would InSightWorks considered a MES?  That is being used for time clock management.

    ------------------------------
    Xan
    Katy TX
    ------------------------------



  • 6.  RE: Automated Manufacturing

    SILVER CONTRIBUTOR
    Posted Jan 09, 2019 09:45 AM
    Hi Jan,

    It would help a lot if you can describe what you manufacture and what you mean by completely automated.

    InsightWorks will allow you to collect data from the shop floor, but it is not "complete automated" - it requires the interaction of the workers on the shop floor with the software.

    Are you meaning to collect information from the production equipment rather than having it keyed in?

    More information would be really helpful.

    ------------------------------
    Robert Jolliffe MCSE, MCS - NAV Manufacturing Expert
    President
    Sabre Limited
    Cambridge
    robert@sabrelimited.com
    www.sabrelimited.com
    ------------------------------



  • 7.  RE: Automated Manufacturing

    Posted Jan 09, 2019 10:58 AM
    Sorry for the vagueness.  This company is a manufacturing company for the energy industry, that might get 1-2 orders per day, and converted to NAV 2017 in 2017 from M1.  Every order is custom with it's own BOM.  They are not using NAV "Jobs" so they are not using "Tasks".  The only 'add on' is InSightWorks TCM for their time collection, which is linked to NAV 2017.  When an order is sold the quote is turned into a Sales Order and the BOM is loaded up.  They are not using the Planning Worksheet, yet, they are creating released production orders (not planned), and tracking the RPO with legs (RPO # + 1, 2, 3 etc) with manual flushing.  They want to automate the MRP.  ​

    ------------------------------
    Xan
    Katy TX
    ------------------------------



  • 8.  RE: Automated Manufacturing

    SILVER CONTRIBUTOR
    Posted Jan 09, 2019 11:38 AM
    Hi Xan,

    Thanks for the extra information.  This is more helpful.

    When you say "Legs" you are referring to sub-assemblies that are pegged to the main production order I assume (that's a term I've only heard of related to Visual ERP)?

    The "Legs" idea in NAV is done by creating the Production Order from the Sales Order through Order Planning.  That will bypass MRP for the purposes of sub-assembly manufacturing.

    The Planning Worksheet is the MRP module in NAV.  There is a fairly significant setup required at the item level usually - and it takes a fair amount of testing and trial and error to make sure things are working well.  I believe I have a blog post on setting up MRP somewhere (it might not be up on the interwebs yet) but it breaks down to this:

    1. Pick a single product group (maybe from one vendor) and setup that product for MRP and get it working the way you like by adjusting the planning settings and running it for a while to see how it works.
    2. Expand and add a few more product groups usually with different planning methods
    3. Roll up all your products that you want to MRP Plan
    4. Don't use MRP for everything.  Not everything in your system needs to use MRP (simple Kanban/2Bin processes are often much better).

    Hope that helps.

    -Rob






    ------------------------------
    Robert Jolliffe MCSE, MCS - NAV Manufacturing Expert
    President
    Sabre Limited
    Cambridge
    robert@sabrelimited.com
    www.sabrelimited.com
    ------------------------------



  • 9.  RE: Automated Manufacturing

    Posted Jan 10, 2019 10:26 PM
    Hi Robert;
    Thanks so much for the heads up.

    I know what you are talking about regarding the Production Order "legs" being created from Sales Order → Planning; and how this is bypassing the sub-assemblies on the MRP/ Planning Worksheet.  Are they also causing the Requisition Worksheet to be incomplete?  How do I fix this?

    Your response has been very helpful.  It's good to know I'm not going crazy.

    ------------------------------
    Xan
    Katy TX
    ------------------------------



  • 10.  RE: Automated Manufacturing

    TOP CONTRIBUTOR
    Posted Jan 10, 2019 08:22 AM
    Xan,

    It sounds like you are trying to use NAV's Manufacturing module for a custom project based business.  This will have its own challenges, but is still feasible.  The first thing to know is that the MRP engine is reliant upon data (dates, item setup, BOMs, etc.).  In order to get a suggestion you need to tell the system how it is supposed to analyze the data, and this is done by getting the setup data and planning parameters entered.

    The second challenge is going to be timing.  If these are custom BOMs, there will be a delay in planning/purchasing until engineering releases the BOM.  This issue compounds itself if the sub-assemblies ("legs") are also custom.  Once the Production Orders are in the system, with valid BOM data, the MRP engine should be able to start making suggestions on what to buy, how much, and when.

    I would strongly encourage you engage your partner for some training on the various Reordering Policies available on an Item Record.  If you have multiple locations, you will also want to understand the relationship of the Stockkeeping Units (SKUs) in NAV.  Once you have a grasp on these features of NAV, you'll want to do what Robert outlined regarding the roll-out of the data and test, test, test until you are getting the suggestions you expect.

    P.S.  In testing, you should only run the Planning Worksheet when you know what you expect to see.  You can't troubleshoot an issue if you don't know whether it is an issue.

    ------------------------------
    Ben Baxter
    Consultant
    Accent Software, Inc.
    Carmel IN
    ------------------------------



  • 11.  RE: Automated Manufacturing

    Posted Jan 10, 2019 10:39 PM
    Hi Ben;

    Thank you so much for your input.

    I understand everything you are saying, which is good for me to know, cause I can follow you.

    You are correct.  There is insult on injury because the "Legs" (sub assemblies) are custom as well.   Everyone is working on dates, Item Cards, BOMS, shop calendars, routings, work centers, ect., to get all data in good shape.  What do I do about these "legs".  Will routing links fix this?

    You don't know how much I appreciate all the help from everyone.


    ------------------------------
    Xan
    Katy TX
    ------------------------------



  • 12.  RE: Automated Manufacturing

    TOP CONTRIBUTOR
    Posted Jan 14, 2019 08:08 AM
    Having the "legs" as custom Items isn't an issue as much as it is a time sink.  It means the BOMs and potentially Routes needs adjusted each time.  Your best bet is to get as much of the standard requirements outlined in your master record, then have the customization of each happen once the Production Order is created.  To simplify your process you can set both the parent and sub-assemblies with a Manufacturing Policy of Make-to-Order.  This will allow the MPS/MRP engine create a single Production Order with multiple lines, each line representing the sub-assemblies for the Parent.  This way you have one (1) Production Order to manage.

    If you have sub-assemblies that are not custom, you will want to consider the other MFG Policies and Reorder Policies for those Items.

    Routing Links will allow you to attach the Items to specific Routing Steps, which adjusts the requirement date of the component.  It also allows greater control over the timing of the consumption of components in a backward/forward flush environment.  It does not make custom sub-assemblies any harder/easier to handle.

    ------------------------------
    Ben Baxter
    Consultant
    Accent Software, Inc.
    Carmel IN
    ------------------------------



  • 13.  RE: Automated Manufacturing

    Posted Jan 14, 2019 12:50 PM
    Ben;
    I get what you are saying.  The company was not set up in the beginning with all the sub-assemblies attached to the top level Item, so, they need to sort through that.  Also, there are numerous Items that are purchased and then sent to another Vendor for a process (paint, heat treat, components added, etc.) before the item is received.  I'm trying to incorporate a "Drop Shipment" procedure onto these items.  Because they have SKUs, it's difficult, so, should I set up a "Transfer" location for "Vendor"?
    Thanks so much.

    ------------------------------
    Xan
    Katy TX
    ------------------------------



  • 14.  RE: Automated Manufacturing

    TOP CONTRIBUTOR
    Posted Jan 15, 2019 08:36 AM
    Getting into the specifics of your process flow is something you should discuss with your Partner.  NAV is a very flexible product, and the best workflow for your organization is something your partner will best be able to help you with.

    ------------------------------
    Ben Baxter
    Consultant
    Accent Software, Inc.
    Carmel IN
    ------------------------------