Work in Progress
Due to SYSPRO’s strong position in manufacturing companies it stands to reason that DATASCOPE WMS has advanced functionality for factory environments. Some 40% of all DATASCOPE WMS sites are manufacturing plants.
From food blending companies to paper mills and chemical plants that software has a proved track record. The following functionality is covered in DATASCOPE WMS:
The Job release function in DATASCOPE WMS is a highly intelligent solution that has a wide range of advanced functionality. This function in essence allocates the jobs material requirements and releases a picking slip or slips to have the material picked.
Stock allocation and availability
This feature is a major improvement for many factories experiencing raw material stock outs. In such plants, the planning department often release the picking slips from SYSPRO without realizing that thereis not sufficient stock to cover all pick slips. Now DATASCOPE WMS will stop the planning department from flooding the warehouse with picks that cannot be completed.
There are currently 8 different reservation strategies built into the software for jobs along with the ability to write a site specific custom rule. These dictate which stock should be reserved first with priority given to qualities such as TrackID age (FIFO/LIFO) and lot expiry dates.
Multi warehouse picking
Any picking slip released in DATASCOPE WMS is tracked through the warehouse through different statuses. Each status change is recorded along with each transaction and user.
The system can be configured to split the picking slips up by warehouse. This allows a site to release a job for picking and get multiple picking slips (one per warehouse). This is particularly useful when products from different warehouses are staged into the production process.
Bulk and Pick Face picking
This is an interesting feature. The DATASCOPE WMS can be configured to pick full bags or cartons from a bulk warehouse and then pick all part bags or cartons from a pick face warehouse. Here the SYSPRO BOM is linked to the pick face warehouse and DATASCOPE WMS is setup with pick face bins for each component in the pick face warehouse which are linked to the bulk warehouse as a source warehouse . When the job is release the software will allocate full bags from eth bulk warehouse and then then allocate the remainders for the pick face warehouse. It then automatically updates the SYSPRO job materials allocations to match this.
Stock code replace
A replace function exists to allow a user to replace a product on the job if there is insufficient stock available of the required component material. This can be done on the fly in the releasing screen and can be controlled to only allow alternate stock codes to replace components whilst also converting by a factor This updates the SYSPRO material allocation on the job as the pick is released.
Kit Issue Components
The software understands and manages any product flagged in SYSPRO as a kit issue item on the bill of material. These items can be seen on the release screen and can be printed onto any pick slip documentation but no material reservation is performed for them and the pick on the scanner will not call for them. Kit issue flagged components can be issued on job receipt, allowing the user to select the bin and/or lot that is being issued.
Job Stock Code Replace
This function is used to globally replace a component with a substitute component on all jobs that are not yet confirmed in SYSPRO. This is very useful when a large batch of jobs have been released and we find that we cannot use a particular component. Instead of cancelling all the jobs we can replace the stock code with a substantiate stock code and update all jobs waiting to go into production.
This function also allows for an adjustment to the component usage. So, if this component was a food product or a chemical, the software could replace one component with another but with a different usage ratio.
WMS Job Creation
This program allows a user to easily open multiple jobs for a single stock code. So rather than raising one job for ten thousand products we can use this program to quickly raise 10 jobs each of one thousand components.
Most factories like to print product or carton labels for each job they release to the factory floor. This program fulfills that need. Putting a small job label on each carton as it is manufactured helps to track that carton and speeds up the job receiving process.
The job picking module offers a full solution for tracking each job picking slips through the warehouses. There are two main ways to pick for jobs in DATASCOPE WMS. These are:
Pick Slip /Scanner
In most factories, a typical pick slip is released. This may be a single pick slip for each job or it may be split up by warehouse or we may have a bulk picking slips and a pick face picking slip.
The release of the picking slip can trigger a printed document or a barcoded label or not print out at all.
Pick slips are then allocated to pickers from a DATASCOPE WMS allocation screen or if a printed label or sheet is in place a picker can assign a pick slip to his name.
The picking process drives the picker through the warehouse to pick all items required for the order. Once all product has been picked for this order the picker will confirm that pick and move onto the next one.
The software allows the picker to select alternate pallets and or lots if the settings are flagged accordingly. Tolerance settings can also be set to allow a picker to slightly over or under pick components.
The mass based picking module is designed for manufacturers in the food, chemical or pharma industries. Here the software is loaded onto PC’s that are linked to weigh scales in the factory. The DATASCOPE WMS pick is then managed on the scales.
Each weigh station can be linked to a large and small load cell. Large bags are weighed into the software and posted to the job. Once the requirement is reduced to a small value the small scale is used to measure the final pick of that component. Alternatively the large and smaller requirements are split by the software into bulk and fine pick warehouses in which case they can be picked simultaneously. As each component is weighed it is issued to the job.
The software can also print a bag label for each transaction posted to the job. These labels are placed onto the bags of product. The label shows the Job number, parent stock code, component stock code, lot number and quantity picked. This helps to ensure that the components do not get mixed after picking.
The job returns function has been designed to integrate to a weigh scale or to operate on its own. The module can be used to return product that was previously issued to a job card. An example of an environment that could use the job return with scale integration is in a factory where large rolls of product are issued to a job, used and then some balance returned to stock.
The software allows for a simple scan of the job number and the original TrackID. The product is placed on the scale and the transaction is posted. The software validates that the TrackID did in fact go to the selected job.
This module performs a mass check of product picked for a job. This is used in mass sensitive job picking environments after the pick is complete to check the cumulative mass.
The Job receipt screen is available on both the PC and scanner screens. This screen is used to process the job receipts of manufactured product.
The scanner screen is used mainly as a simple scanned receipt of each pallet as it is collected by a forklift driver. The transaction can be posted easily while on the forklift. Typically, a pallet label (TrackID) is printed to a local printer or to a mobile hip printer carried by the operator.
The PC version of the Job Receipt screen is typically used in fixed location transaction points such as on a palletizing conveyor. The screen can be customized using scripting to simplify the inputs.
WIP costing and job closure checks can be applied to this screen, along with the ability to provide a TrackID number or be allocated 1 automatically.
As mentioned above this screen also handles the kit issue of any kit issue flagged components on the job and optionally allows lot and bin selection. Issuing of labor is also optional.
Product and sample labels can also be triggered on job receipt, along with a quality inspection (either single stage or 2 stage). Moreover, DATASCOPE allows for the receipt of a reject/rework product when performing the job receipt. This assists sites in correctly capturing the correctly quality of product coming off the job.
This module performs a simply inventory backflush transaction and automatically prints TrackIDs for the created item.
The job issue module resides on the PC and mobile devise. This program allows a user to simply selected a product on the factory floor and issue it to a job. The software will validate that the component being issued is in fact on the job as a material allocation. If not, the software will stop the transaction or if the user as the correct permissions, this program will add the material allocation in SYSPRO and perform the issue. This is very useful in situations where substitute products need to be manually issued to a job or where a stock code equal to the parent stock code needs to be issued to the job (this is a requirement is many manufacturing plants)