Dynamics AX 2012 Manufacturing (Part 4-3)

Microsoft Dynamics AX 2012 Manufacturing – Lean Ninja IoT Scenario Part 4: Functionality/Make to Order

Microsoft Dynamics AX 2012 Manufacturing – Lean Ninja IoT Scenario Part 4-3: Functionality/Make to Order

 

Continuation from here: http://ax2012manufacturing.blogspot.com/2015/10/microsoft-dynamics-ax-2012_3.html

 

Addendum A: MRP

 

Please note that in this scenario in order to generate kanban for replenishing Near Side Line location from Warehouse bulk location based on Minimum on-hand requirement we used Kanban pegging event routine. In fact we could also use MRP to generate planned or firmed kanban for these purpose. The implication of doing this may be a delay if you run MRP infrequently, that's why for a quick turnaround it is preferred to run Kanban pegging event routine in a batch.  

 

As a part of Addendum A I'll still showcase how MRP can be used to generate kanban for replenishing Near Side Line location from Warehouse bulk location based on Minimum on-hand requirement.

 

So instead of running Pegging events processing we'll run MRP this time for Wheel2 item to limit the scope of MRP execution

 

MRP

 

 

Infolog

 

 

Now we'll look at Net requirements for Wheel2 item. There we can see how planned kanban has been generated to cover Minimum stock requirement for Wheel2 item

 

Net requirements

 

 

Net requirements (Side line location BULK-003)

 

 

Net requirements (Near Side line location BULK-002)

 

 

Net requirements (Near Side line location BULK-002) – Planned kanban 1

 

 

Net requirements (Near Side line location BULK-002) – Planned kanban 2

 

 

Net requirements (Warehouse location BULK-000)

 

 

Inventory transactions in this case will look like the following

 

Inventory transactions

 

 

Addendum B: Transfer

 

It was explained at the beginning why it was decided to use Manufacturing kanban to replenish Near Side Line location from Warehouse bulk location. The main reason was a necessity to implement wave kanban picking. In fact if we would not have to deal with wave kanban picking we could have used Withdrawal kanban instead. In Addendum B I'll showcase how we could set up Withdrawal kanban rule to replenish Near Side Line location from Warehouse bulk location.

 

This is how we will create Kanban rule and appropriate Transfer activity for production flow

 

Production flow: Activity = Replenish Near Side Line <- Bulk 2 (Welcome)   

 

 

Production flow: Activity = Replenish Near Side Line <- Bulk 2 (New activity)   

 

 

Production flow: Activity = Replenish Near Side Line <- Bulk 2 (Create transfer activity)   

 

 

Production flow: Activity = Replenish Near Side Line <- Bulk 2 (Assign transfer locations)   

 

 

Production flow: Activity = Replenish Near Side Line <- Bulk 2 (Assign activity time)   

 

 

Production flow: Activity = Replenish Near Side Line <- Bulk 2 (Wizard completed)   

 

 

Now we'll take a look at newly created activity

 

Production flow: Activity = Replenish Near Side Line <- Bulk 2

 

 

Production flow: Activity = Replenish Near Side Line <- Bulk 2

 

 

Then we'll create Withdrawal kanban rule as shown below

 

Kanban rule

 

 

Kanban rule - Events

 

 

Kanban rule – Production flow

 

 

Now I'll introduce enough on-hand for Wheel2 item in Warehouse bulk location (BULK-001), I'm not going to use WMS processes this time that's why on-hand in Warehouse location BULK-000 won't count

 

Inventory journal

 

 

And then I'll execute Kanban pegging event processing routine

 

Pegging events processing

 

 

Infolog

 

 

The following Withdrawal kanban has been created

 

Kanban

 

 

And inventory transactions at this point will look like the following

 

Inventory transactions (Wheel2)

 

 

This concludes the walkthrough!

 

Summary: In this walkthrough I illustrated how to establish an advanced Make to Order Lean Manufacturing scenario in Microsoft Dynamics AX 2012. We went through the process of setting up data, creation of initial demand, manufacturing process and Lean costing. In particular both warehouse management processes and lean manufacturing processes were used to enable this scenario. We also considered a high degree of variability, specifically, using different locations, handling different quantities and different products throughout the scenario. 

                               

Tags: Microsoft Dynamics AX 2012 R3, Lean Manufacturing, Pull, Kanbans, Kanban rules, Production flow, Warehouse Management, Hand-held devices.

 

Note: This document is intended for information purposes only, presented as it is with no warranties from the author. This document may be updated with more content to better outline the issues and describe the solutions.

 

Author: Alex Anikiev, PhD, MCP

 

Special thanks for collaboration in building this scenario goes to Lean Transformation Guru at MCAConnect, Phil Coy

Posted by Alex Anikievat 12:01 PM No comments:

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Labels: Hand-held devices, Kanban rules, Kanbans, Lean Manufacturing, Microsoft Dynamics AX 2012 R3, Production Flow, Pull, Warehouse Management

Microsoft Dynamics AX 2012 Manufacturing – Lean Ninja IoT Scenario Part 4: Functionality/Make to Order

Microsoft Dynamics AX 2012 Manufacturing – Lean Ninja IoT Scenario Part 4-2: Functionality/Make to Order

 

Continuation from here: http://ax2012manufacturing.blogspot.com/2015/10/microsoft-dynamics-ax-2012_9.html

 

Section: Creation

 

We'll begin with replenishment of Near Side Line location (BULK-002) from Warehouse bulk location (BULK-001). First we'll introduce a necessary on-hand in BULK-000 location as presented below

 

On-hand

 

 

Then we can run Kanban pegging event routine to generate necessary kanban

 

Kanban pegging event

 

 

Infolog

 

 

Please note that Manufacturing kanban has been generated to replenish Near Side Line location from Warehouse bulk location

 

Kanban rule

 

 

Kanban

 

 

At this point we are missing BOM structure for kanban, so we are going to assign BOM version manually to kanban using Assign alternative BOM version function

 

Assign alternative BOM version - Before 

 

 

Assign alternative BOM version - After

 

 

Now we'll look at kanban pegging tree

 

Kanban pegging tree

 

 

And also we'll take a look at inventory transactions

 

Inventory transactions

 

 

Please remember that we are using Manufacturing kanban for replenishment of Near Side Line location from Warehouse bulk location. And the next step will be to plan the entire pegging tree to plan kanban Process job, generate Kanban picking wave and Warehouse work

 

Plan entire pegging tree

 

 

Kanban pegging tree – Kanban jobs

 

 

 

Please note that Kanban Process job changes its status to Planned now

 

Inventory transactions

 

 

At this point we can also review Kanban wave

 

Kanban wave

 

 

and generated Warehouse work

 

Work

 

 

Please note that wave would not be created and items would be picked if I had on-hand in BULK-001 forWheel2

 

Now Warehouse worker will use hand-held device to execute Warehouse work

 

Login

 

 

Menu - Inventory

 

 

Menu – Inventory – Kanban picking

 

 

Kanban picking

 

 

Kanban picking

 

 

Kanban picking

 

 

Kanban picking

 

 

Kanban picking

 

 

Kanban picking work is now completed and we can take a look at inventory transactions

 

Inventory transactions

 

 

In a meantime we can also see Process kanban job planned on Schedule board and visible on Kanban board for Process jobs  

 

Kanban board – Schedule board

 

 

Kanban board – Schedule board

 

 

Kanban board - Process jobs

 

 

Kanban board - Process jobs

 

 

Kanban board - Process jobs (Details)

 

 

Kanban board - Process jobs (Picking list)

 

 

Kanban board - Process jobs

 

 

At this point we could complete kanban straight from Kanban board for process jobs, but instead of this we'll do kanban put away in WMS

 

Menu - Inventory

 

 

Kanban put away

 

 

Kanban put away

 

 

Kanban put away

 

 

Kanban put away

 

 

Now when kanban put away work is completed we can take a look at inventory transactions

 

Inventory transactions

 

 

Also we can observe completed kanban on Kanban board for Process jobs

 

Kanban board for Process jobs

 

 

After we completed Manufacturing kanban we have replenished Near Side Line location (BULK-002) from Warehouse bulk location (BULK-001). We can see how inventory on-hand was updated for Wheel2

 

On-hand

 

 

Before we proceed to the next step I want to also introduce additional on-hand for Body in the point of consumption, Line Side location (BULK-003)

 

Inventory journal

 

 

Next we'll place a new Sales order for AlexMotorcycle2

 

Sales order

 

 

Please note that AlexMotorcycle2 finished product is expected to be in a Finished good location (BULK-004). After we save Sales order the system based on Kanban rules in place will automatically create necessary kanbans. We can review created kanbans by opening Pegging tree form 

 

Pegging tree (Process kanban)

 

 

As you can see according to Kanban rules 2 Kanban jobs will have to be completed to produce AlexMotorcycle2, one for Transfer and another one for Process

 

Kanban (Process)

 

 

Pegging tree (Transfer kanban)

 

 

Kanban (Transfer)

 

 

This is how inventory transactions look like at this point 

 

Inventory transactions (Wheel2)

 

 

Inventory transactions (Body2)

 

 

Inventory transactions (AlexMotorcycle2)

 

 

Now I'll plan the entire pegging tree

 

Plan pegging tree

 

 

Please note that Kanban Process job has been Planned, and no Kanban picking wave was generated

 

Pegging tree – Kanban jobs

 

 

In a meantime we can review Transfer and Process jobs on Kanban board for Transfer jobs and Kanban board for Process jobs correspondingly

 

Kanban board for Transfer jobs

 

 

Kanban board for Transfer jobs

 

 

Kanban board for Transfer jobs - Details

 

 

Kanban board for Transfer jobs – Picking list

 

 

Kanban board for Transfer jobs - Pegging

 

 

Kanban schedule board

 

 

Kanban board for Process jobs

 

 

Kanban board for Process jobs

 

 

Kanban board for Process jobs - Details

 

 

Kanban board for Process jobs – Picking list

 

 

Kanban board for Process jobs - Pegging

 

 

You can also review Process job and Transfer job on the same screen as presented below

 

Kanban board for Process jobs

 

 

Now we can begin the execution of kanbans

 

Section: Execution

 

We'll begin with Starting Transfer job first

 

Transfer – Start

 

 

In case you want to do partial picking you can use Pick screen as presented below

 

Pick

 

 

Here's how inventory transactions look like after this step

 

Inventory transactions

 

 

Then we'll complete Transfer

 

Transfer – Complete

 

 

In case you want to do partial registration you can use Registration screen as presented below

 

Registration

 

 

Here's how inventory transactions look like after this step

 

Inventory transactions

 

 

As we complete Transfer now we have enough Wheels in its Part location for Workcell worker to execute Assembly process. We'll start Process kanban job now

 

Process job - Start

 

 

In case you want to do partial picking you can use Pick screen as presented below

 

Pick

 

 

Pick

 

 

Please note that according to Storage dimension group I had to specify Locations on both lines

And again we'll take a look at inventory transactions 

 

Inventory transactions (Wheel2)

 

 

Inventory transactions (Body2)

 

 

In case we need to complete partial quantity or specify Good/Error quantities you can use Complete job and error details screen as presented below

 

Process job – Complete with details

 

 

Process job

 

 

In case you need to update partial registration you can use Registration screen as presented below

 

Registration

 

 

Now we can take a look at inventory transactions again

 

Inventory transactions (AlexMotorcycle2)

 

 

Inventory transactions (Wheel2)

 

 

Inventory transactions (Body2)

 

 

Once we completed Manufacturing kanban we can see finished product is available in Finished goods location now

 

On-hand

 

 

And because we have produced the product we can now send it to the customer

 

Sales order – Packing slip and Invoice

 

 

Please note Location is specified on Sales order line per Storage dimension group requirement

 

After we updated Sales order physically and financially we can review inventory transactions

 

Inventory transactions (AlexMotorcycle2)

 

 

Inventory transactions (Body2)

 

 

Inventory transactions (Wheel2)

 

 

The very last step will be to run Lean costing routine to cost the production flow

 

Section: Costing

 

Cost the production flow

 

 

Prompt

 

 

Please note that no further registrations of kanban jobs will be possible after the date costing, but that's fine for the sake of this demo

 

Inventory transactions (AlexMotorcycle2)

 

 

Inventory transactions (Body2)

 

 

Inventory transactions (Wheel2)

 

 

To be continued here: http://ax2012manufacturing.blogspot.com/2015/10/microsoft-dynamics-ax-2012_70.html

                               

Tags: Microsoft Dynamics AX 2012 R3, Lean Manufacturing, Pull, Kanbans, Kanban rules, Production flow, Warehouse Management, Hand-held devices.

 

Note: This document is intended for information purposes only, presented as it is with no warranties from the author. This document may be updated with more content to better outline the issues and describe the solutions.