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From Flames To Fork, Comes Freedom • View topic - Manufacturing Make To Order

Manufacturing Make To Order

Automated Testing Tools are used to assure modifications are always backward compatible and safe for production
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This forum is personally pruned to avoid redundant posts. Related topics are moved to the same sub-forum. Language will be corrected for readability.

Manufacturing Make To Order

Postby red1 » Wed Mar 30, 2011 5:29 pm

Make To Order is a simplified Assembly Manufacturing process. You can consider it as a go between the Compiere BOM Production with the Libero Assembly process. In order for Make to Order to work you need the following specific assumptions that differ from the Assembly process:
1. The Product's BOM Type has to be set to MakeToKit ("K" value)
2. Customer's Delivery Rule has to be Complete Line
3. BOM Components Issue Method has to be BackFlush

Below is an output of a Fitnesse Test done successfully for a MakeToOrder process. Further assumptions:
1. Accounting Schema Costing Method has to be set to Standard Cost
2. Product Planning Safety Stock for PChair set to 20 as available stock is insufficient
3. Inventory moved to Furniture Store for sufficient raw material to make the finished PatioSet.
(All assumptions above is set in the Fitnesse Story uploaded to SVN. You can test it on a fresh Libero instance with latest DB from trunk).
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Re: Manufacturing Make To Order

Postby red1 » Thu Mar 31, 2011 6:28 am

The Forward Backward setting occurs in the CRP process. During debugging they have their respective tracks in resolving the start and finish times. However they always show the same results, so I open an issue in the SourceForge.net Libero tracker.
The assumptions have to be committed to DB except for Safety Stock setting as they do not persist during the tests. These tests can be run over and over without resetting anything else. The results will always be similar or true where colored green.
Image
Available Storage is checked on the onset to monitor their conversion during the proses. The Sales Order triggers the MRP records (determined by its BOM structure and Product Planning Data). A Promised Date in the Sales Order is set 15 days ahead to test the Finish Date setting. The storage qtys are also affected as stock are put under reserve. Note that in the longer Assembly process, the MRP production records will be in Draft status instead of In-Progress.
Image
Calculate Material Plan will open a Mfg Order record under In-Progress status (Draft status if Assembly, as a Planned Order Approval process takes care of In-Progress status). As insufficient stocks are detected in the Furniture warehouse, more MRP records are drafted and Requisition records created. Since a safety stock is set at 20 for Chairs, the requisition takes care of the additional qty.
Image
Other records are also triggered from the Product Planning Data template to govern the whole Manufacturing Worfklow particularly the Activity (WF Node) tab. The Calculate Requirements Planning or CRP traverse the WF Node and Mfg Resource to figure out the available times and readjust the start and finish times according to the Forward/Backward method. We then make some Inventory Movement to the Furniture warehouse in order to fulfill the raw material needs.
Image
Create Issue triggers the MakeToOrderKit function (is equivalent to the old Compiere Production or the longer Libero Assembly process which comprises of Order Issue and Receipt processes. Here we combined both when we set the BackFlush option earlier. The Issue and Receipt of the finished goods is passed to the Cost Collector framework that will finalised the storage qtys and assign a serial number (AttributeSetInstance) to the finished PatioSet. Then we complete the Mfg Order as the Reserved Qty has passed to the Delivered Qty.
Image
When we closed the Mfg Order, it also checks and close other Workflow items or activities. The related MRP records also close off.
Image
Notices are made at the onset and they are displayed at the end so as not to confuse the reader. They are triggered as there were not sufficient stock of raw material. The expedite notice is due to the BackFlush option that allows immediate operations as opposed to the Assembly line approach.
Image
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Re: Manufacturing Make To Order

Postby red1 » Thu Mar 31, 2011 6:47 am

Here is my scratchpad of issues encountered. So far they are not criticaI so i will take my time to assign them into the Project Issue tracker. I need some cooling off period as there are many learning points encountered and more issues may arise.

ISSUE - if (p_ScheduleType.equals(FORWARD_SCHEDULING))
{
Timestamp date = order.getDateStartSchedule(); // red1 - Mfg Order Date Start already set as backward calculated from Due Date.

ISSUE - Feature / Bug? Mfg WorkFlows Window - Main Tab shows Simulation Group Fields that are also present in child Activity Tab which CRP derived from. I think main tab should summarize up from child tabs.

ISSUE - Check AD Note //assign exact params in Calculate Material Plan (MRP.java) ensures Notes get written. This seems to be a small bug.

ISSUE - PPOrder.java
line 1731: MOrderLine oline = oline = (MOrderLine)getC_OrderLine();
Unnecessary assignment -

ISSUE - MPPOrder CompleteIt() during Receipt does not update PPOrderLine.

ISSUE MPPOrder .. always true IFs
// Necessary to clear order quantities when called from closeIt - 4Layers
if (DOCACTION_Close.equals(getDocAction()))
{
if (!MStorage.add(getCtx(), getM_Warehouse_ID(), M_Locator_ID,
getM_Product_ID(), getM_AttributeSetInstance_ID(),
getM_AttributeSetInstance_ID(), Env.ZERO, Env.ZERO, ordered, get_TrxName()))
{
throw new AdempiereException();
}
}
else
(same as above)


ISSUE - Doc_MatchPO has null trxName
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Re: Manufacturing Make To Order

Postby collazosc » Fri Jan 13, 2012 3:41 am

I am still trying to understand the libero package inside adempiere. I see that on the adempiere.com side victor made a fix for . How this kind of changes (if applicable) are going to be commited to globalqss361 (and of course later to idempiere)?.

It seems that redhuan (as posted here) also found some problems in libero and they are closed in tracker. DO they really were solved? and included in globalqss361?

Please let us understand this issues to the just arrived.
---------------------------
Carlos Collazos
---------------------------
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Re: Manufacturing Make To Order

Postby red1 » Fri Jan 13, 2012 5:50 am

In my tests and shared experiences with most Libero enthusiasts around the world, we are not in favour of having Libero Mfg inside the present iDempiere roadmap. Rather we are looking at MfgLite from Adaxa and Andre Legendre's MfgScm, which i been meeting him in Paris and worked out a roadmap to deliver this as priority this year. Andre is coding the PluginManager for committing to , his old project space.
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Re: Manufacturing Make To Order

Postby red1 » Fri Sep 20, 2013 2:14 pm

Under sponsorship from SYSNOVA, i am revisiting this project and has converted it into an OSGi plugin for iDempiere . So real feedback and collaboration from users and implementers are important if we wish to see this further improved.
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