I have taken clients from uncontrolled to controlled. I do not have a detailed plan, but can offer the following.
This project affects not only inventory, but purchasing, and COM (customer shipments) as well.(lots of decisions need to be made in ref to I/M, Pur, COM, and MO processing). These decisions will dictate the definition and use of locations in your situation.
Inventory: When deciding on Location Control: you will have to decide how many locations are required?(more item location - will cause more inventory transactions and cycle count entries).
The idea is to better manage the inventory - 'where is this stuff?' assist in picking, and counting.(I'd have just as many location as required ).
You can have WH- stock locations as well as designated floor locations for consumption to an MO. (more later).
Each and every transaction must reference a location now. You can tailor I/M to use the default stock location if not a random location 'put away' and no floor locations. You would need to populate this field in the item Warehouse. I am a stickler myself, to have the system reflect reality - So if we move stock to another location - it warrants a transaction. ( i.e. I would not move inventory out of the WH location to the floor without some kind of transaction.) Controlled (TW) Uncontrolled (IS).
Cycle counting: Now I have the ability to count by location ! This gives me the ability to do a wall to wall count over an extended period of time. Map out the locations to be counted and count each stock location 3-4 times a year. Each floor location weekly or daily. Should be owned by the consumption location work center lead. Be careful not to count 'uncontrolled on the floor'.
I would typically allow locations to go negative and research these at day's end or early the next day. Root cause analysis.
Pur: we can now designate the original dock location and TW to the stock location. Or if Inspection is required we may want to implement the use of an INSP location? Flag the item as inspection required. then QC to stock. This is now an option.
MO: to backflush from a location other then the default stock location - i.e. Workcenter designated location - you would require ISE's paperless solution. This can be defined in MDCC or the latest MES. NOT available in just I/M alone.
COM - Shipping:You can now designate a discreet 'pick list' - this will allocate to the available stock location(s) for this order. You'll need to be very judicious about when you print a pick list - upon impending PICK. not days, or even hours before. The good news is the location inventory is unavailable to the next pick list ! So no duplication of available inventory on multiple pick list. You can also incorporate a 'pick complete' to a shipping staging area when the product moves to shipping. Again to reflect reality.
Hope you found this helpful. Let me know if I can be of further assistance.
Jeffrey G Snyder CPIM, CSCP
Senior Mfg Consultant
Guide Technologies, LLC
cell 724 699 2506jsnyder@xxxxxxxxxxxxxxxxxxxxx
Date: Tue, 3 Dec 2013 05:40:13 -0600
Subject: [MAPICS-L] Implementaton Plan to go from Uncontrolled to Controlled Warehouse
Has anyone gone from uncontrolled to controlled warehouses? If so, do you have an implementation plan? Also, in controlled warehouses, how to people manage backflushing of controlled floorstock from multiple locations? It appears to be very cumbersome.
Thanks for your help.
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