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WithoutWire Inventory Sciences

Great Plains (GP) Manufacturing Automation


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    Recently, Microsoft had their annual conference “Microsoft Convergence” for Microsoft Dynamics prospects, partners, and customers.  This year we heard discussions that seem to come up every year, “How can we achieve GP Manufacturing Integration?”  The challenge affects companies looking to create mobile automation using barcode scanning within their manufacturing process.

    Software that enables mobile automation to reduce labor and human error and streamline processes are in high demand.  Providing the ability to track the movement of lot-tracked raw materials to Work-in-process (WIP) to Finished Goods in real-time, further enables manufacturers to make quick decisions based on current and accurate data.  Lot tracking can introduce human error, making it even more challenging to do without mobile automation and barcode scanning.  Having visibility into the data allows agility for the organization and is often required for lot traceability requirements.  One product and company driving improvements in Manufacturing Automation  is Appolis and the WithoutWire™ (WoW) Warehouse Management System (WMS).

    A popular Enterprise Resource Planning (ERP) tool for Small and Medium sized Business is Microsoft Great Plains (GP).  As an Independent Software Vendor (ISV) Appolis offers three (3) solutions to enable GP Manufacturing Automation which can be referred to as Good, Better and Best in terms of their functionality.

    Good:  Job-less and Job-based Manufacturing.  Our kitting functionality also lives in this category as it is often used for light assembly.  This is delivered right out-of-the-box in our WithoutWire™ WoW WMS offering.

    Job-less Manufacturing:

    1. Import BOM’s from GP with UOM conversion factors and lot requirements.
    2. Scan or manually enter item, quantity, and lot number if applicable.
      1. The system uses a variety of decrement rules to pull out raw materials to make sure that traceability is maintained at the level needed.
      2. Finished goods are created and inventory adjustments are generated back into GP.
    3. Scan an unused or empty license plate that will create the bond between the finished goods, raw materials and the unique license plate barcode for future use.
    4. Repeat.

    Job-based Manufacturing:

    1. Import BOM’s from GP with UOM conversion factors and lot requirements.
    2. Create the Job in WoW assigning the raw material quantities and validating availability
    3. WoW will alert the user if they lack the required raw materials.  They have the options of substitutions or adding additional raw material with various lots that meet the requirements.
    4. Operator scans the license plate associated with the job and has the option to modify the quantity of the finish good.
    5. WoW completes the Finished Goods and consumes the Raw Materials

    Key Advantage:  Simple and Flexible out-of-the-box solution.

    Allows Lot-tracking in WoW only.

     

    Better:  WoW Quick MO’s:

     

    This process automates the creation of Manufacturing Orders, consuming Raw Materials, and posting Goods to Inventory, in Real-Time.  The product can be used at end of the line or at multiple locations throughout the line.

     

    1. Setup and configure the Quick Manufacturing Order Generator from GP
    2. Import BOM’s from GP with UOM conversion factors and lot requirements.
    3. Scan or manually enter item, quantity, and lot number if applicable.
      1. The system uses a variety of decrement rules to pull out raw materials from the manufacturing bin location being used to make sure that traceability is maintained at the level needed.
      2. Finished goods are created in WoW
      3. A Quick MO is created in GP based on the FG’s created
    4. Scan an unused or empty license plate that will create the bond between the finished goods, raw materials and the unique license plate barcode for future use.
    5. Repeat.

     

    Key Advantage:  Creates manufacturing records in GP

    Automatically decrements raw materials based on FIFO rules.

    Allows Lot-tracking in WoW only.

     

    Best:  WoW Full MO Manufacturing

    1. WithoutWire Warehouse imports BOM’s from GP with UOM conversion factors and lot requirements.
    2. Manufacturing Orders are created in GP
    3. Appolis WithoutWire WoW imports the manufacturing order when it is released.
    4. A job is generated based on the manufacturing order and the BOM.
    5. WoW replenishments are driven to fulfill the needs of the job.
    6. User scans or enters Work Order #, Manufacturing Bin, Lot Number, Quantity
    7. A new license plate is printed that binds the finished goods and the unique license plate barcode for future use.
    8. Components are back flushed based on actual lots within the manufacturing bin selected
    9. MO Receipts are generated with appropriate labor and job costs in GP

    Key Advantage:  Creates “Best” manufacturing records in GP

    Automatically decrements raw materials based on actual Lots consumed.

    Allows Lot-tracking in WoW only

    Allows for Labor tracking and Job costing

    Enables Scrapping and MO Receipt Reversals

    Enables the ability to implement MRP and Forecasting tools

    Three (3) different Manufacturing automation solutions designed for the small and medium sized North American Manufacturers utilizing Great Plains (GP) as their ERP platform.  Whether you are able to walk, jog or run toward Manufacturing Automation in pursuit of labor and process improvement savings, Appolis WoW has a good, better and best Manufacturing solution available for you!

    When you think of Great Plains (GP) as an ERP candidate for you, we do not want you to limit your thinking to a best fit for Distribution Clients only.  Think of Great Plains (GP) and Appolis WithoutWire™ WoW as a great automated Manufacturing Solution as well!

    By  Steve Dwyer, Vice President Appolis Inc, www.appolis.com

    One Response to “Great Plains (GP) Manufacturing Automation”

    1. Hello I am contacting you to please review what we are looking for in an ERP system.

      About us…

      • We are a small Co-packing company that specializes in the manufacturing/packaging of custom sauce and liquids.

      • We are roughly 4.5 million in sales annually

      • 25 employees

      • 1 shift operation – Mon through Friday

      • Currently run our financing through Quick Books Enterprise Solutions: Manufacturing & Wholesale 16.0

      • Running our production / scheduling / inventory through excel spreadsheets.

      We are as prehistoric as a company can be when it comes to how we use our computers to keep the company running.

      What we are looking for…

      • A small business level ERP system.

      • 2 super users – President & Director of Operations

      • 4 limited users – (2 administrative & manager/supervisor) CRM, Logistics and Financial

      • Scheduling, Production & Warehouse WMS views

      • Devices proposed for company operations – server needs & or upgrades, terminals on the shop floor and warehouse and scanning devices to move materials around in and out of system designated locations.

      • User friendly data collection / reporting methods. Production, warehousing, units, costs per units, labor financing etc….

      • Product traceability inbound to shipping capable of taking one lot received and showing me it went into 3 different products and shipped to 9 different locations / dates etc…

      Please advise…
      Stewart Riske