Re: BPCS Cycle counting- process vs. resource requirements -- BPCS-L

We are also working with BPCS Cycle Counting, but have
made substantial modifications to the logic.

Amongst those modifications:
1. Even though ALL our finished products are lot
controlled, we select based on Item/Facility
combination.
2. If a lot is created, it wont come up for counting
until the product comes up for counting (which will
depend on when was the last time it was counted in
that facility and if it is an A, B or C in that
facility).
3. If a lot had a physical and book quantity of 0 in
the last count, it will not reapear in the list.

There are a lot of other modifications we have
instituted.

If you need further assistance you can contact me off
line.

Regards,

Ruben.
--- John Braren <JBraren@cott.com> wrote:
>               We are in the 7th month of our first of 15 site
> installations and are hitting a few snags using the
> Cycle Count processes
> within BPCS 6.1.02.  While the theory and execution
> of that theory flows
> nicely, in practice we are finding the detail
> execution is extremely labor
> intensive.
>
>               Currently we are using Lot and Location control on
> all
> finished goods and only some raw materials.  Plants
> will carry inventories
> covering from 200 to 600 SKU's of finished goods.
> Because of shelf-life
> issues or extremely high volume on some SKU's,
> multiple productions per
> month are common.  Stringent quality standards
> require very particular shop
> order Lot controls.  Warehouse space consolidation
> is constant, so Location
> movement can be extensive.
>
>               Can anyone shed any light on their experiences in
> this area?
> Did you have to significantly increase staffing in
> order to use the full
> functionality of the BPCS Cycle Count process?  Is
> everyone counting the
> zero balance Lot/Locations on the worksheet?  For
> some brands with high
> volumes and low inventories we require several Cycle
> Counts per month, but
> with the generation of Lot/Locations to be checked
> with zero inventory
> balances, and because the ILI records are maintained
> until month-end and
> show on the worksheets even though the last
> transaction was a 'Y', the
> worksheets generated are huge, repetitive and become
> much too much work to
> be covered even on a monthly basis.
>
>               Adding to the size of the task is the fact that
> our staff is
> used to doing counts by total SKU inventory at one
> time, not just
> Lot/Location transaction verification.  This means
> that many or our SKU's
> have been set for a frequency of 366 so that a total
> SKU Lot/Location
> worksheet can be generated.  This means that all ILI
> records for the month
> for a SKU appear, growing until month-end into
> worksheet where 80% or more
> of the items to be 'counted' in fact have zero
> balances which already have
> been 'Y'd'
>
>               Any insights or suggestions would be very welcome.
>  We are
> quickly moving to put all raws on Lot/Location
> control and foresee creating
> an unmanageable monster.
>
>       Thanks-
>
>       JB
>
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