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All sorts of things can be setup globally, or by facility.We have BOM and Routings, Cost, all kinds of orders, accounting, General Ledger by facility. It might be useful for you to hear from other list members what THEY have by facility. We are 405 CD.
There may be some difficulties switching between different ways of doing things. You'll need to review a wide spectrum of implications ... # systems so that people not get confused, Security, Consolidated info and by facility. There can also be complexities like if you open a factory in Mexico & you want everyone there to see the data in Spanish. Do you have enough disk space for another BPCS environment for testing?
A problem with Security at 405 CD ... we want people in facility X to be able to see what the story is with inventory that is in common with facility X that is also in other facilities, but we do not want everyone in facility X to be updating stuff in other than facility X. Well in 405 CD, you can't do that kind of division, unless you give the people different sign-ons ... one person several sign ons ... one for inquiry only, access to all facilities, another can update stuff, but only access facility X.
Think of a facility as perhaps being in a different city, so you need to organize your planning, MRP differently. For example, suppose you had 100% of your inventory that is actually in New York and California in one facility. BPCS would say you not have to order any for New York because you got plenty in California, it would not recognize the concept of lead time for getting it from coast to coast, because BPCS thinks the same facility is like in the same city or building. When your factories & buildings are significant distance away from each other, it makes sense to have their contents in different facilities.
Another reason for different facilities if the COSTING rules are different. You might have a DISTRIBUTION warehouse that buys & sells items but does not MAKE any, so the costing structure needs to be different from a facility which is a factory. However, when inventory gets moved in BPCS, it carries copy of the cost with it, so you either have to know to clean up the mess, or use DRP to manage what is in one facility that needs to get to another.
We have several warehouses in each facility.Warehouses can be used to organize the inventory, even though they are physically contiguous.
One warehouse has finished goods ready to ship to customer. One has the actual factory production, consumption of raw materials.One is designated as non-nettable non-allocatable by BPCS ... in other words MRP can't say there's enough there, so we not need to order any more. Into this non-warehouse we place RMA ... returns from customers, rejects from production ... QC then decides what is repairable, what to scrap.
I currently have a proposal for an ACCOUNTING warehouse to store costs of WIP. Under our current arrangements, labor backflushes inventory at the instant it gets used, but there is value in the parts between discrete items, value that belongs to the company, but is now in a black hole as far as accounting is concerned, then when the part is finished, the inventory value comes back out of the black hole. My proposal is to replace the black hole with an ACCOUNTING warehouse that would store the WIP cost of what is now in the black hole. From factory production & MRP perspective, this would be a PHANTOM warehouse.
Al Macintyredue to turn-over, low profit margins, etc. it has now been 10 years since our BPCS settings were done by people no longer with us, and corporate memory is very dim, as to why things setup the way they are.
We have been installed for a long time, so some of the implementation decisions that were made have come back into question and our collective memory is failing us as we try and justify them. Can someone give me a concise high level definition of a facility in BPCS, including the ramifications of running multiple facilities in one BPCS instance? A quick look in the system seems to indicate that item masters and BOM's are global, but routings are specific to a facility, for example. Anyone have such a list they can share? I am also interested in the same information regarding a warehouse. We are on v6.0.04 if it matters. Thanks, Jim Reinardy Badger Meter, Inc. Milwaukee, WI
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