Module 3 Implement production methods

Case study 3B Process manufacturing

Exercise #1: Create and associate a batch attribute

Company USPI has a new requirement for part P4000, polypropylene pellets, to test and record the melting point for each batch is needed.

The product definition employee wants to create a batch attribute for the melting point as an integer attribute with a min of 0 and max of 500

The item specific requirements are 130 – 171° C. Customer
US-024 requires a melting point of 135 – 165° C for use in their manufacturing processes.

The product definition employee wants to associate the batch attribute with the item and the customer with the correct attribute ranges

You were called to help. Can you help the product definition employee?

You will have to do the following:

Create a new batch attribute
Set the attribute minimum and maximum
Associate the batch attribute with
the item
Set the item attribute minimum and maximum
Assign financial dimensions to the item
Associate the batch attribute with the customer
Set the customer attribute minimum and maximum

Steps

Create a new batch attribute

In USPI company go to Inventory Management > Setup > Batch > Batch attributes.
Select New.
In the Attribute field, enter or select MeltingPoint.
In the Description field, enter or select Melting Point (C).
In the Attribute type field, select Integer.

Set the attribute minimum and maximum

In the Minimum field, enter or select 0.
In the Maximum field, enter or select 500.
In the Increment field, enter or select 1.
Select Save.
Close the page.

Associate the batch attribute with the item

Go to Product Information management > Products > Released products.
Use the Quick Filter to filter on the Item number field with a value of p4000.
On the Manage Inventory tab, in the Batch Attributes group, select Product specific.
Select New.
In the Attribute relation field, select Melting Point.

Set the item attribute minimum and maximum

In the Tolerance action field, select Not allowed.
Set Minimum to 130.
Set Maximum to 171.
In the Target field, enter or select 150.
Select Save.
Close the page.

Assign the default financial dimension to the item

Go to Product Information management > Products > Released products.
Use the Quick Filter to filter on the Item number field with a value of M2005.
Select the link for M2005 to go to the details page.
Select Edit.
Expand Financial dimensions fasttab, select OJ B2B for the ProductGroup financial dimension.
Select Save.
Close all pages.

Associate the batch attribute with the customer

Go to Product Information management > Products > Released products.
Use the Quick Filter to filter on the Item number field with a value of p4000.
Select Customer specific in the Batch Attributes group on the Manage Inventory tab.
Select New.
In the Attribute relation field, enter or select Melting Point.
In the Account selection field, enter or select US-024.

Set the customer attribute minimum and maximum

Set Minimum to 135.
Set Maximum to 165.
Select Save.
Close the page.

Exercise #2: Create a new batch number and manually record the batch attribute

The inventory manager for company USPI wants to create a new batch number for part P4000.

He is not sure where to start or what to do.

Can you help?

You will have to do the following:

Create a new batch number
Manually record the batch attribute data

Steps

Create a new batch number

Go to Warehouse management > Setup > Inventory > Batches.
Select New.
In the Batch number field, enter or select GTL0001.
In the Item number field, enter or select P4000.
In the Manufacturing date field, enter today’s date.
Select Save.

Manually record the batch attribute data

On the Action Pane, select View.
Select Inventory batch attributes.
Select New then select Attribute dropdown icon and select MeltingPoint. Select Load item attributes.
In the Attribute value field, enter or select 163.
Select Save.
Close all pages.

Exercise #3: Create quality orders and verify batch attributes

At company USPI, item M2005 is set to have a quality order created upon the purchase order product receipt.

They would like to:

create a new PO for 500 pounds of material, receive the material, and enter the information in the quality order that is created.

Verify that the batch attribute data was updated upon completion of the quality order

They are not sure how to perform this transaction and asked for your help.

Can you help?

You will have to do the following:

Create a new purchase order for item M2005
Receive the purchase order
Complete the quality order
Verify the batch attribute data

Steps

Create a new purchase order

Go to Procurement and sourcing > Purchase orders > All purchase orders.
Select New.
In the Vendor account field, enter or select US-102.
Select OK.
In the Item number field, enter or select m2005.
Set Quantity to 500.
Set the Unit price to 6.99.
Select Save.
On the Action Pane, select Purchase.
In the Actions group, select Confirm.
Notate the purchase order number.
Close the page.

Receive the purchase order

Go to Inventory management > Inbound orders > Arrival overview.
Expand Arrival query details.
Set the value of Restrict to site to 1.
Select Update.
In the Arrival overview profile name field, enter or select Inquiry to view the purchase order in the Receipts grid.
Select Update.
Search for the purchase order created and select the record.
Select Start arrival in the Receipts FastTab. This will update the status on in the Receipt in progress field to Complete.
Re-select your PO.
Select Journals.
Select Show arrivals from lines.
Select Inventory.
Select Display dimensions.
Select the Site check box.
Select the Warehouse check box.
Select the Batch number check box.
Select OK.
Right select and view details on the Batch number field.
Select New.
In the Batch number field, enter or select GTLB001.
Expand Properties Fast Tab and enter in the Manufacturing date field.
Select Save.
Close the page.
Close the Batches page.
In the Batch number field, enter or select the batch that was created (GTLB001).
Select Post.
Select OK.
Select Functions.
Select Product receipt.
In the Product receipt field, enter or select 2.
Select OK.
Close the page.

Complete the quality order

Go to Inventory Management > Periodic tasks > Quality Management > Quality orders.
Select Results.
Select Edit.
Set Result quantity to 5.89.
Set Result value to 15.4.
Select Save.
Close the page.
Select Validate.
In the Validate 0d by field, enter or select Julia Funderburk.
Select OK.

Verify the batch attribute data

Select the Inventory dimensions tab.
Select to follow the link in the Batch number field.
On the Action Pane, select View.
Select Inventory batch attributes.
Close the page.

Exercise #4: Complete a batch reservation using an attribute requirement

At company USPI, part P5000 is set up with internal requirements for batch attributes.

The operations manager wants to enter the batch order, manufacture the material, and record the test results.

Then the shipping operator will use the batch reservation form to reserve a batch based upon the customer testing requirements

They both know that a new customer requirement for customer US-026 must be created.

A new batch order of 500,000 pounds of material shall be created to meet the requirements of a sales order from customer US-026.

They called you as the MFG functional consultant to help them achieve this. Can you help?

You will have to do the following:

Create a customer attribute requirement
Create a new batch order
Process the batch order
Complete the quality order
Create a sales order
Complete the batch reservation and shipment

Steps

Create a customer attribute requirement

In USPI go to Product information management > Products > Released products.
Use the Quick Filter to filter on the Item number field with a value of p5000.
Select Customer specific from the Manage Inventory tab.
Select New.
In the Attribute relation field, enter or select VolatilePct.
In the Account selection field, enter or select us-026.
Set Minimum to 98.
Select Save.
Close the page.

Create a new batch order

In USPI company go to Production Control > Production Orders > All Production orders.
Select New batch order.
In the Item number field, enter or select p5000.
In the Delivery field, enter a date.
Select Create.

Process the batch order

On the Action Pane, select Production order.
Select Estimate.
Select OK.
Select Start.
Select OK.
On the Action Pane, select View.
Select Picking list.
In the list, select the link in the selected row.
In the journal lines, select each row and complete the batch reservation.
Select Inventory.
Select Reservation.
Select Reserve lot.
Close the page.
Select Post.
Select OK.
Close the page.
Close the page.
On the Action Pane, select Production order.
Select Report as finished.
Select OK.

Complete the quality order

On the Action Pane, select View.
Select Quality orders.
Select Results.
Select Edit.
Set Result quantity to 5000.
Set Test result to 98.5.
Select Save.
Close the page.
Select Validate.
In the Validated by field, enter or select a value.
Select OK.
Close the page.

Create a sales order

Go to All sales orders.
Select New.
In the Customer account field, enter or select us-026.
Select OK.
In the Item number field, enter or select p5000.
Set Quantity to 500000.
Select Save.

Complete the batch reservation and shipment

Select Inventory.
Select Batch reservation.
Select Batch attribute search.
Select Customer attributes.
Select OK.
Select Reserve lot.
Refresh the page.
Close the page.
Select Post packing slip.
Select OK.
Close the page.

Exercise #5: Create a batch attribute for a potency item

At company USPI, part number M2004, ETDA, must be designated a potency-controlled item for the Acidity batch attribute.

The target value for Acidity should be 1.7. Set up the batch attribute, assign it to the product, and designate the product as a potency item.

The product manager is not sure how to configure the system to do that.

You were called as the MFG functional consultant to help.

Can you help?

You will have to do the following:

Create a batch attribute
Assign the attribute to
the item
Assign potency information

Steps

Create a batch attribute

Go to Inventory management > Setup > Batch > Batch attributes.
Select New.
In the Attribute field, enter or select Acidity.
In the Description field, enter or select Acidity.
In the Attribute Type enter or select field, select Fraction.
In the Maximum field, enter or select 10.
In the Increment field, enter or select 0.01.
Select Save.
Close the page.

Assign the attribute to the item

Go to Product information management > Products > Released products.
Use the Quick Filter to filter on the Item number field with a value of M2004.
On the Action Pane, select Manage inventory.
Select Product specific.
Select New.
In the Attribute relation field, select Acidity.
Set Minimum to 1.
Set Maximum to 3.
In the Target field, enter or select 1.7.
Select Save.
Close the page.

Assign potency information

Select M2004 product on the Release product details page.
Select Edit.
Select Save.

Note In case if Base attribute column is not visible select three dots and select Insert columns. Search for b and select Base attribute.
Select Update.
In the Base attribute field, enter or select Acidity.
Select Save.

Exercise #6: Modify and activate a copy of a potency item formula

At company USPI, were reviewing all their items and they found out that part M2004 has been determined to be a potency-controlled item.

The formula for item P2000 needs to be adjusted to set M2004 as an active potency item.

The formula for P2000 should be modified to indicate the change, and item M2007 should be set as a compensating material for part M2004 with a compensation factor of 1

They are not sure how to reflect this in the system and they called you to help.

Can you help?

You will have to do the following:

Copy the formula for item P2000
Modify the M2004 and
M2007 lines
Approve and activate the formula

Steps

Copy the formula for item P2000

Go to Product information management > Products > Released products.
Use the Quick Filter to filter on the Item number field with a value of 'p2000'.
On the Action Pane, select Engineer.
Select Formula versions.
Select New.
Select Formula and formula version.
In the Number field, enter 001 and in the Name field, enter or select Formula123.
Select Yes in the Copy field.
In the Site field, enter or select 1.
Select OK.
In the Formula version field, Enter 2000 and select for P2000 from the drop-down.
Select OK.

Modify the M2004 and M2007 lines

In the list, select row M2004.
In the Ingredient type enter or select field, select 'Active'.
In the list, select row M2007.
In the Ingredient enter or select field, select 'Compensating'.
Select Save.
Select Ingredients.
Select Compensation principle.
In the Active ingredient field, select M2004.
Select OK.
Close the page.

Approve and activate the formula

In the list, select the old formula version.
In the To date field, Enter current date
In the list, select the new formula version.
In the From date field, enter current date and select Formula version tab on the Action pane.
Select Approval.
In the Approved by field, select Glen John.
Select Select.
Select Yes in the Do you also want to approve the formula? field.
Select OK.
Select Activate.

Exercise #7: Set up pricing based on an item’s attribute (Bonus)

At company USPI, part M2004 has been determined to be a potency-controlled item.

The pricing of part M2004 shall be based upon the acidity level, where the ratio of the actual acidity level against the target is multiplied by the based price of $4.70 and a constant of 1.5 to determine the purchase price of the batch.

the purchase agent, want to setup the pricing for
the item and couldn’t.

The support team asked you to help the purchase agent.

Can you help?

You will have to do the following:

Create an attribute pricing expression
Complete and post the trade agreement

Steps

Create an attribute pricing expression

Go to Procurement and sourcing > Setup > Prices and discounts > Attribute-based pricing details.
Select New.
In the Name field, enter or select Pricing.
In the Description field, enter or select Pricing expression.
Select Add variable.
In the Equation element type field, select Unit price.
Select Add variable.
In the Equation element type field, select Constant.
Set Constant to 1.5.
Select Add variable.
In the Equation element type field, select Batch attribute - Target.
In the Attribute field, select Acidity.
Select Add variable.
In the Equation element type field, select Batch attribute - Actual.
In the Attribute field, select Acidity.
In the Equation field, enter or select (A/B)*(D/C).
Select Validate equation.
Close the page.

Complete and post trade agreement

Go to Product information management > Products > Released products.
Use the Quick Filter to filter on the Item number field with a value of m2004.
On the Action Pane, select Purchase.
Select Create trade agreements.
Select Edit.
In the Name field, select Price.
Select Lines.
In the Item relation field, enter or select M2004.
In the Site field, enter or select 1.
In the Warehouse field, enter or select 11.
Set Amount in currency to 4.7.
In the Attribute-based pricing ID field, enter the pricing ID USPI-00001.
Select Save.
Select Post.
Select OK.
Close the page.

Exercise #8: Record a potency attribute upon receipt (Bonus)

A new batch of item M2004 is to be purchased into inventory and received, with the batch attribute result being entered upon receipt.

You were asked to review the pricing of M2004 to verify that the calculation meets the requirements of the attribute-based pricing

Can you perform this task?

You will have to do the following:

Batch Number Creation
Create a purchase order for item M2004
Receive and enter a batch attribute value
Invoice and review pricing

Steps

Create a purchase order

Perform the below steps in USPI. Go to Procurement and sourcing > Purchase orders > All purchase orders.
Select New.
In the Vendor account field, enter or select US-102.
In the Warehouse field, select 13.
Select OK.
In the Item number field, enter or select m2004.
Set Quantity to 800.
On the line details FastTab, under Financial dimensions tab, Update the productGroup as OJB2B
On the Action Pane, select Purchase.
Select Confirm.

Receive and enter a batch attribute value

On the Action Pane, select Receive.
Select Product receipt.
In the Product receipt field, enter or select 1234
Select Update line.
Select Registration.
Select Add registration line.
Select Confirm registration.
Select Save.
Close the page twice until you reach the page where you are posting product receipt order page.

Invoice and review pricing

In the Quantity field, select Registered quantity.
Select OK.

Note If you get an error message while posting the order stating “Blank is not allowed in the ProductGroup field for the combination.” Please follow the below steps.
Navigate to General Ledger > Chart of Account > Structures > Configure account structures.
Search for Manufacturing PI P&L
Make sure for the main accounts, the “Blank values are allowed” option is checked
Select on Activate from the Action pane
Select on Activate

Note Once the above steps are completed, please perform steps from “Receive and enter a batch attribute value to post the order”.
On the Action Pane, select Invoice.
Select Invoice.
In the Number field, enter 123
In the Invoice date field, enter current date.
Select Update match status.
Select Post.
On the Purchase order lines . Select Inventory.
Select Transactions.

Exercise #9: Reporting and balancing batch orders (Bonus)

A new batch order is to be created for part P2000, including reserving batches of the active ingredients, performing batch balancing, and posting the picking list.

The production manager wants to create a production order and process the order for a new batch of part P2000

The production manager is new to the system and wants you help.

Can you help?

You will have to do the following:

Configuring Working time calendar
Create a batch order for part P2000 and process the batch order through Start
Complete batch reservation and balancing for active ingredients
Post the picking list and report as a finished batch order

Steps

Configuring Working time calendar

Go to Production Control > Setup > Calendars> Calendars.
Select 24hr and select Working times.
Select Compose working times.
In To date field, enter date.
In Working time template field, select 24hr. Select OK.
Close the page once the operation is completed.
Close it again till you reach Working time calendars page.
Select 8hr and select Working times.
Select Compose working times.
In Working time template field enter 8Hr. Select OK.

Create a batch order for part P2000 and process the batch order through Start

Go to Production control > Production orders > All production orders.
Select New batch order.
In the Item number field, enter or select p2000.
Select Create.
On the Action Pane, select Production order.
Select Estimate.
Select OK.
Select Start.
Select OK.

Complete Batch Reservation and Balancing for active ingredients

Select Batch balancing under Process > Production Order from the Action pane
In the list, select M2004, M2002 and M2005

Note If you do not see the Batch lines present for M2002 and M2005. Proceed with creating a Purchase orders for M2002 and M2005.
Select the Marked check box respectively for all the three items
Select Balance batch ingredients.
Select Confirm the formula.
Select OK.

Post the picking list and report as a finished batch order

On the Action Pane, select View.
Select Picking list.
In the list, select the link for the picking list.
Select Post.
Select OK.
Close the page.
On the Action Pane, select Production order.
Select Report as finished.
Select a value in Batch number field and then select on the same batch number
Select New.
In the Batch number field, enter or select a value.
In the Manufacturing date field, enter a date.
Select Save.
Close the page.
In the Batch number field, select the created batch number.
Select OK.