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1.  Over-Picking for Production

Posted 9 days ago

For those in manufacturing, how do you address over-picking for production?

Base NAV will only let you generate a pick for the quantity of items on a BOM. Sometimes it is common with low cost components that you need a few extra. The amount of overage you need is not always known and cannot be accurately listed on the BOM. How do others deal with this?

Second, what if you have items that are always used that you just keep in the production area at all times? I am aware of the Open-Shop floor bin. Unfortunately, that does not work for me as we use manual flushing. Even if I leave material in the "To Production" bin, when the next order comes up NAV will always suggest to pick fresh material and not use what is already in the TO bin.

I have seen on another site reference by a couple of people that they made modifications to overcome similar types of issues, but they do not elaborate on how they went about it.

https://community.dynamics.com/nav/f/34/t/151300

I would like to know for those on this board what you have done to address these types of issues.



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Jeffrey Mantz
Zefon International
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2.  RE: Over-Picking for Production

Posted 7 days ago
We have similar issues where simple fixed percentages of extras don't work. A prod order may require 10 units for setup regardless of the overall qty to be produced.
You can assign additional quantities at specific machine centre's which is part of our solution but I am interested to see what other responses you receive.
As for your components stored at lineside, is there a reason to not put them on either forward or backward flush?

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814Guy McKenzie
SPS (Eu) Ltd
Blackpool
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3.  RE: Over-Picking for Production

Posted 7 days ago
​Jeffrey-

You are asking more than one question here and to get started we will need to know if you are using warehouse picking in your process and if you have implemented bin management.

To pull extra for your production order you can manipulate the scrap quantity.  This simply modifies NAV's recommended quantity to pull, not what is consumed by the production order.  This is especially useful since you use manual flushing.  You will only consume what you use.

One idea for the producing staging location would be to make that a bin.

Best of luck.

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Jason Nicolaou
Solutions Architect
Socius
Dublin OH
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4.  RE: Over-Picking for Production

Posted 7 days ago
We have the same issue. We draw rod into wire. The rod used never matches the order quantity. Therefore, we had our partner Sikich customize our inventory picks so that it allows us to create the pick and then when we tell the system we are done, it goes and adjusts all related quantities. There are a lot of nice features such as specialized prompts and a running total at the bottom of the page.

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Gregory Alford
ERP Manager
Tri Star Metals LLC
Carol Stream IL
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5.  RE: Over-Picking for Production

Posted 7 days ago
Hey there,

In addition to the other comments.  I wanted to point out that you mention this occurs with 'low cost components'.  I'm assuming that means nuts, bolts, consumables and other small items?

If so, I would suggest you challenge what items you have setup for inventory tracking in NAV.  Low cost items are typically more trouble and cost to track in inventory than it is worth.  I recommend you consider using a Kanban Inventory system for the low cost items.

If the sum of low cost items and consumables is, say, 10% of the cost of the production item than you can set that as an overhead amount that will get rolled into the finished good at output.

These small and low cost items can also be managed as Vendor Managed Inventory where the vendor does inventory counts and replenishes automatically based upon certain min/max values that you all agree on.

Hope this helps,
Victor

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Victor Diercksen
Director of Business Technology
PermaPlate Company, Inc.
Salt Lake City UT
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6.  RE: Over-Picking for Production

Posted 6 days ago
​We manually consume and output whicher allows us to over-pick and return to stock (negative consumption).

To avoid having inventory disappear and re-appear, you can move inventory to a production line bin for your pick process, manually consume actual quantities real-time, and move inventory back to raw material stock when it is not consumed.

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Lewis Rosenberg
IT Manager
Mars Fishcare
Chalfont PA



NAVUG Board of Advisors, Programming
NAVUG Programming Committee
NAVUG Membership Committee
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7.  RE: Over-Picking for Production

Posted 6 days ago
To give more detail, our location is setup with bin mandatory, require pick, require put, require shipment, require receive. Basically everything except directed. ALL items are lot control, both components and finished. Manual flushing seems the way to go (for us) due to the lot control. Manual flushing also allows us to over consume any components that were needed (but you have to find a way to pick those items). For shipping and receiving the location setup works fine. It would seem ideal in our case to remove the pick requirement for production only if that was possible.

I realize we can create another location and remove the pick requirement. That just seems to increase the complexity quite a bit by adding the location just for this.

Lewis, what you are doing is basically ideal for me. My location has require pick though so it will not let me consume unless I pick. Is your location set to require pick?


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Jeffrey Mantz
Zefon International
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8.  RE: Over-Picking for Production

Posted 6 days ago
​Jefffrey,

We have a finished goods location which is directed putaway and pick.

We also have a raw material location which is not directed putaway and pick, but it is bin controlled.

We have stockkeeping units set up that allow us to post production output to the finished goods location while consuming component inventory from the raw material location.




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Lewis Rosenberg
IT Manager
Mars Fishcare
Chalfont PA



NAVUG Board of Advisors, Programming
NAVUG Programming Committee
NAVUG Membership Committee
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