RE: physical inventory SKIP WIP -- BPCS-L

Hi Al,


I have used the basic INV650 (on V6.04) often to post the physical inventory
I want to post, and I mean the edited content that I really want to post.
What I do is I insert in IPH the edited records I want posted!!  I find a
lot easier to make the IPH file exactly how I want, rather than playing with
INV650 program. Besides, we no longer have programmers in my company, I
can't program RPG, I can't play with INV650 code, but I'm pretty good at SQL
to insert, combine, read, join, etc. all files I want, to make IPH look the
way I want before posting with INV650.

It's easy to use SQL to remove from IPH all records that match a particular
condition, in your case: delete records where IIM.iityp ='2': 

delete iph where exists (select * from iph where iph.phprod = iim.iprod and
iim.ityp = '2' )

I would make a copy of IPH, do all the changes in the backed up copy, empty
IPH , and reinsert into IPH the backed and edited copy. Then run INV650.


I do this regularly to exclude specific items, locations, warehouses. One
can even use this strategy to perform  cyclical counts in desired areas.

Also, we dont use the BPCS tag entry program. The client server windows are
totally non ergonomic (remember we are on 6.04), and it takes a lot of time
to enter a single tag. So I let the users enter the count on a plain excel
sheet with 4 columns: item, warehouse, location, and quantity (we dont use
lot control neither containers). I even prepare the excel sheets pre-loaded
with the item, warehouse, and location information and leave the qty field
empty. Easily done by downloading and manipulating ILI or IPH records. Users
return to me the excel sheets. I upload the excel sheet in a temporary file
on the AS400. I run SQL statements to check for invalid item numbers,
locations, warehouses etc. I update the following IPH fields with another
SQL statement: update iph set phid = 'PH', PHUM = 'EA', phpost = 'Y'. This
way you can also edit the content of the excel file before the final upload
in IPH. 


I let INV650 create the ITH records, and update ILI.lopb and IWI.wopb and
IIM.iopb as per it's normal process reading the records in IPH. No further
need to modify INV620 neither if you can use SQL. If you must use INV620 to
print tags, you can print the tags once, edit IPH for content, and use the
reprint function of INV620, which will not recreate tags, but reprint the
content of the IPH file . The physical count process in BPCS is easy, all
you need to tweak to meet your particular desires is the IPH file.

Regards

> Daniel Warthold
Business Analyst
> Eicon Networks Corporation            
>                                       
> 9800 Cavendish blvd                   
> Montreal (Quebec)                     
> Canada H4M 2V9                        
>                                       
> Tel:   (514) 832-3839                 
> Fax: (514) 745-5588
> Email: daniel.warthold@xxxxxxxxx      
> 





-----Original Message-----
From: Alister Wm Macintyre [mailto:macwheel99@xxxxxxxxxxx]
Sent: Thursday, November 11, 2004 14:24
To: BPCS_L discussion
Subject: physical inventory SKIP WIP



We are BPCS 405 CD

Here I am once again sharing a challenge, in hopes of helpful suggestions, 
and I would not be surprised if other companies here have similar needs.
I am still working on the last challenge involving items the MRP is 
planning NOT & thanks to ideas y"all suggested here, which led to still 
more ideas, I have managed to reduce the intensity from 1,500 items (peak) 
to approx 500.

I have been informed that between Christmas and New Years the company wants 
to do a physical inventory of our RAW MATERIALS and FINISHED END ITEMS but 
skip the inventory of the WORK IN PROCESS ITEMS and from me they want to 
know about the practicality of implementing this.

My first reaction was *censored* *censored* *censored*.

I thought perhaps we could create a modification of physical inventory 
programs to ignore items of item type 2, but I soon concluded "Oh Ghod, I 
do not want to be modifying INV650." and "How are we going to test any 
modifications?"  I think that we could create some TAGS, inspect results, 
then clear them and start over, without doing any damage, so modifying 
INV620 seems to be the least risk.

Once upon a time we had a warehouse for raw materials separate and distinct 
from warehouse for production work ... if it was still that reality, we 
could opt to inventory the RAW warehouse and the SHIPPING warehouse, and 
skip the WIP warehouse ... on the eve of physical, depopulate the WIP 
warehouse of any END or RAW items moving them to warehouse where counting 
will take place.
However, in the last year there has been a merger of warehouse contents, so 
that approach is not an option this year.

let's suppose the company had the self-discipline to REALLY shut down all 
operations from start of physical to end of it, with absolutely caught up 
on all transactions for December prior to start of physical and 
self-discipline to refrain from back dating any transactions in 2005 into 
2004 (I have a real hard time imagining such a reality based on my 20 years 
experience with the company, but the incentive of not having to inventory 
work-in-process could be a powerful motivator)

and let's suppose I modified INV620 which creates the tags
so as to identify which items are type-2 (WIP) and for those items populate 
the field that INV650 is going to use for physical inventory, which I THINK 
is PHQTY
to contain ON-HAND total associated with that ITEM WAREHOUSE LOCATION 
combination

only do this for type-2 ... all other types would need normal physical
counting

then when we dump the tags back into BPCS, what would go into type-2 items 
would be the inventory that existed at the time that we created the tags

I would also want to alter tags printing to show what is type-2 (easiest 
part of this) and perhaps instead of using ILI-logical 7 as the sequence, 
create a JOIN file with item master to sequence stuff by warehouse / item 
type / description / item / location

There is also a related issue of items that are wrongfully coded.
Let's suppose during the physical, a decision is made to fix some item that 
has wrong engineering information.
I think we will need a rule ... if you gonna do that,in the middle of the 
physical, you also gonna have to physically inventory every place that item 
is, irrespective of whether it ever was item type 2

So does this plan of action appear workable, or am I missing some major 
nuances?

-
Al Macintyre  http://www.ryze.com/go/Al9Mac
Find BPCS Documentation Suppliers 
http://radio.weblogs.com/0107846/stories/2002/11/08/bpcsDocSources.html
BPCS/400 Computer Janitor at http://www.globalwiretechnologies.com/
Replacement company web site (same company, new 
domain)  http://www.globalwti.com/

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