Walkthrough: Use Bulk Picks in Production
This walkthrough demonstrates how to generate a bulk pick for production orders. Bulk picks are used when you want to pick enough items to fulfill more than one production order.
Bulk picking can be used when one item is required for different production orders. Instead of picking the item separately for each production order, bulk picking calculates the following:
Quantity of the items that are required for all of the selected production orders.
The one or more bins from which the items are to be picked.
When creating a bulk pick, you have the option of breaking the bulk item before moving the item, or moving the full quantity without breaking the item.
Function Background
When a location is set up that does not require non-directed consumption picks, bulk picks can be used to pick the ingredients for multiple production orders. Using the Inventory Movement page, the bulk pick calculates the total amount of ingredients that are required for the selected production orders. After the inventory movement is registered, the items are moved to the bin that has been defined for the To-Production Bin Code for the location.
When using bulk picks with a production order, the process is as follows:
Note
To follow this process, on the location's Location Card page, on the Warehouse FastTab, Require Non-directed Consumption Pick must be turned off.
Story
The JF company manufactures and sells YOGIES chocolates from its SEATTLE location. The W100420 ORGANIC MINI PRETZEL and the W100120 FAT FREE MINI PRETZEL share a couple of the same ingredients: R100840 YEAST and R100750 STANDARD ROCK SURFACE SALT.
A released production order was created for 100 pounds of the ORGANIC MINI PRETZEL item. The production order components require 102 pounds of FLOUR, 0.1 pounds of YEAST, and 8.16 pounds of SALT.
A released production order was also created for 150 pounds of the YOGIES FAT FREE MINI PRETZEL item. The production order components require, 153 pounds of WHEAT FLOUR, 0.15 pounds of YEAST, and 12.24 pounds of SALT.
Both productions orders require R100840 YEAST and R100750 SALT, which ends up being a total of 0.25 pounds of YEAST, and 20.4 pounds of SALT.
Instead of moving each item individually to the INBOUND bin, the Inventory Movement page is used to create a bulk pick, which will pick enough YEAST and SALT to fulfill both of the production orders.
Because SALT is purchased in bags but consumed in pounds, a bag must be broken to consume the quantity required for the production order. When creating the bulk picks, two scenarios are possible:
Break the bulk item, and then move the item.
Move the full break bulk item.
After the bulk pick is created and the movement is registered, the items are moved to the INBOUND bin, which is the To-Production Bin Code for the SEATTLE location.
Prerequisites
Production orders are defined.
Sufficient inventory exists in the bins at the selected location. If there is not enough inventory to fulfill the production orders, then only the available inventory will be listed for the bulk pick. For example, if the production orders called for 660kgs of flour, but only 500kgs were in inventory, then the bulk pick will only show 500kgs.
The To-Production bin of the location does not already have enough inventory to fulfill the production orders. If enough inventory exists in the To-Production bin, the item will not be added to the bulk pick.
On the Location Card page for the location, Allow Breakbulk is turned on.
If Allow Breakbulk is turned off, any items that are not in consumable units will not be added to the bulk pick.
Create a Bulk Pick-Breaking the Bulk Item
The following procedure explains how to create a bulk pick for production orders that are due on a specific day. The bulk pick will break any items that aren't in consumable units, and then move the required quantity to the INBOUND bin.
To create a bulk pick that breaks the bulk item
Choose
, enter inventory movements, and then choose the related link.The Inventory Movements page opens.
On the action bar, choose New.
The Invt. Movement page opens.
In the Location Code field, select a location, for example, SEATTLE.
On the action bar, choose Process > Bulk Pick Production.
The Bulk Pick Production page opens.
In the Options section, turn off Move Full Break Bulk Quantity.
This means that an item will be broken into units that are required for the pick, and only the required amount will be moved to the INBOUND bin.
In the Prod. Order Component section, in the Where field, select Location Code, and then in the is field, select the location on your production order, for example, SEATTLE.
In the second filter line, in the And field, select Due Date, and then enter the date (MM/DD/YY) of the production order that you created.
Choose OK.
The lines display the quantities that must be taken and placed for all of the production orders that are due on 07/20/18 at the SEATTLE location.
You can see that the items for the released production orders are listed.
Production order MR114485 required 8.16 pounds of SALT and MR114486 required 12.24 pounds of salt, so 20.4 pounds of salt was moved to the INBOUND bin.
Because SALT was purchased in bags, and is consumed in pounds, a bag had to be broken to take the required pounds. A bag weighs 50 pounds. When creating the bulk pick, the Move Full Break Bulk Quantity was turned off. As a result, 1 bag was taken from the A1-01-01 bin and 50 pounds were placed back into the A1-01-01 bin. Then the required 20.4 pounds were taken from the A1-01-01 bin and placed into the INBOUND bin.
Because both production orders required YEAST, a total of 0.25 pounds of yeast were moved to the INBOUND bin. Production order MR114485 required 0.1 pounds of salt and MR114486 required 0.15 pounds of salt.
On the action bar, choose Process > Register Invt. Movement.
To register the inventory movement, choose Yes.
The items are moved to the INBOUND bin.
Creating a Bulk Pick-Moving the Full Quantity
The following procedure explains how to create a bulk pick for production orders that are due on a specific day. The bulk pick will break an item into consumable units, and then will move the full quantity to the INBOUND bin.
To create a bulk pick that moves the full quantity
Choose
, enter inventory movements, and then choose the related link.The Inventory Movements page opens.
On the action bar, choose New.
The Invt. Movement page opens.
In the Location Code field, select a location, for example, SEATTLE.
On the action bar, choose Process > Bulk Pick Production.
The Bulk Pick Production page opens.
In the Options section, turn on Move Full Break Bulk Quantity.
When Move Full Break Bulk Quantity is turned on, a full unit of the item will be moved to the INBOUND bin, and then it will be broken in to units that can be used for the production order.
In the Prod. Order Component section, in the Where field, select Location Code, and then in the is field, select the location on your production order, for example, SEATTLE.
In the second filter line, in the And field, select Due Date, and then enter the date (MM/DD/YY) of the production order that you created.
Choose OK.
The lines display the quantities that must be taken and placed for all of the production orders that are due on September 10, 2015 at the SEATTLE location.
You can see that the items for the released production orders are listed.
Because both production orders required SALT, a total of 20.4 pounds of salt is required to fulfill both orders.
Because SALT was purchased in bags, and is consumed in pounds, a bag must be broken to take the required pounds. A bag weighs 50 pounds. When creating the bulk pick, Move Full Break Bulk Quantity was turned on. As a result, the bag was converted to pounds. Then ALL 50 pounds were taken from the A1-01-01 bin and placed into the INBOUND bin.
Because both production orders required YEAST, a total of 0.25 pounds of yeast were moved to the INBOUND bin.
On the action bar, choose Process > Register Invt. Movement.
To register the inventory movement, choose Yes.
The items are moved to the INBOUND bin.