Job Order and Warehouse Modules – Detailed Study Notes

Job Order and Warehouse Modules – Detailed Study Notes

  • Target focus for today

    • Understand the Job Order (JO) module and the Warehouse module and how they interact

    • Azure screen activity is being recorded; filters and workflows are demonstrated

JO filtering and listing basics

  • Filtering criteria for JO listings

    • JO code

    • Product

    • Customer

    • Geo types

    • Multiple JO types exist

    • Product code

    • Status of the JO

    • Type (internal vs external)

    • Design name (from product settings) connected to the product name inside the JO

    • Work type (whether it is a rework or not)

    • Estimated delivery date

    • Unload software enable/disable (toggle)

    • Filter by estimated delivery date

  • JO listing details (in the listings element)

    • JO code

    • JO type

    • Type (internal or external)

    • JO details: name, customer name, estimated delivery date

  • JO connections to Sales Order (SO)

    • SO is required when JO type is a normal JO

    • Buffer JO: SO is disabled; you select a customer and a product under the customer’s product tab (the product tab discussed last time as “Seeds” or similar)

    • Other common JO types include CB tape, PE; behavior similar with slitting and replacements

JO types and their SO relationships

  • Normal JO

    • Requires a linked SO

  • Buffer JO

    • No SO required; select customer, then a customer product

  • CB tape / PE JO categories

    • Similar flow to JO; include slitting and replacement considerations

  • Replacements (for canceled or partial JOs)

    • Replacement JO for canceled quantities or remaining quantities

    • Replacement JO can be created for cases where the original JO is canceled or partially completed

  • Replacement with no SO

    • Replacement for JOs that does not require an SO, similar flow to PE and B tape creation (customer chosen, product under customer chosen)

Replacement requests and buy flow

  • Replacement request process (first approval flow)

    • A JO that is first approved triggers the creation of a replacement JO

    • This is linked to a “purchase request head office” flow

  • Purchase request (PR) and Purchase Order (PO) linkage

    • Upon approval of a replacement request, a PO is created

    • The approver settings come from ACL-based approval metrics

  • Internal tagging and subcon types (contextual flow)

    • Internal vs external tagging determines where processing occurs

    • Subcontracting types:

    • In-house: processed within the single company from start to finish (one operation to the last operation; QC as needed)

    • Full subcon: processing may occur outside the system or within a sister company (more complex)

    • Semi subcon: operations run internally, with selective external steps

    • Subcon flow affects how JO operations are scheduled and how PO/PR flow is managed

JO–PE flow, MKM, and lamination details

  • JOPE (JO + PE) flow on selecting an SO

    • Product name loads automatically when an SO is selected; product name can be a dropdown if multiple products exist for one SO

    • Upon selecting the product, MKM is auto-loaded and all required operations (RM, FG) are loaded

    • MKM is sourced from SO planning

  • PE JO-PE workflow (lamination-related)

    • Lamination steps: Lamination can be first, second, or third pass

    • Lamination is internal (internal red) and involves creating a separate JO and connecting to the main JO

    • Lamination sequencing: Lamination PERM lamination; the lamination steps are managed within the JO flow

  • R&D tagging

    • R&D JO tagging for research JO or trial JO

    • Normal approval process with approvers based on ACL approval metrics

  • General JO flow when PE is involved

    • Upon selecting PE, internal/in-house flow is used; bond-pack handling may occur; often PE involves a single operation (e.g., blowing)

    • Save action triggers the approval workflow and automatic second approval for certain customers (e.g., internal PE JO orders)

Approval workflow and production progression

  • Approval stages

    • First approval

    • Second approval (automatic in some cases for internal customers)

    • After approvals, the JO can proceed to production or be copied to another JO/GO request

  • Production progression

    • When JO proceeds to production, JO status shifts from Second Approved to Work In Progress (WIP)

    • An entry is auto-created (with a transaction code) for the first operation

  • GO request and JO monitoring

    • A GO request may be created for subsequent full subcon processing

    • JO monitoring can show limited data depending on the stage and the request

Material planning, MKM, and BOM-driven operations

  • MKM and SO planning

    • MKM data is pulled from SO planning and drives the JO-PE operation mapping

  • BOM and operation loading

    • Load BOM for RM: stock requests pull in BOM components

    • If a material has variants, there is a parent-variant relationship and issuance can be to the parent or to a specific variant

    • BOM outs drive how many outputs can be produced at a given operation

RM and FG stock management, stock requests, and warehouse issues

  • RM stock requests (parent RM flow)

    • Start from a JO/operation; select the operation for issue (e.g., printing)

    • Load BOM and current stock on hand

    • Approve stock request; then issue to warehouse

  • Issue varieties and variant handling

    • Materials can have variants (parent/variant) and the system decides whether to issue the parent or a variant

  • WIP and operational flow

    • After RM issue, WIP entries are created for subsequent operations (e.g., rewinding, lamination, processing)

  • Machine and operator settings per operation

    • Operation settings include operators, machines, and per-machine operation mappings

    • Each machine has its own operation availability and the ability to assign operators and machines

  • QC per operation and validation rules

    • QC criteria are defined per operation and per operator

    • QC criteria import/export capabilities exist

    • Resulting QA data feed into subsequent process steps

Detailed production steps: printing, rewinding, lamination, and transfer

  • Printing and rewinding workflow

    • Printing operation: define date start, date end, target production planning date, and waste allowances

    • Rewinding: plan output with maximum KM outputs, waste allowances, and target times

  • Lamination flow

    • Lamination steps occur after rewinding in some lines; lamination passes may be 1st, 2nd, or 3rd

    • The flow includes setting up outputs, waste, and transfer to next operation

  • Transfer to next operation

    • When all preconditions are met, transfer output to the next operation (printing, rewinding, lamination)

  • Transfer and WIP updates

    • Transferring updates WIP entries; the JO monitoring tracks status through operations

Subcontracting (subcon) processing in JO and PR/PO cycles

  • Subcon flow for JO operations

    • Subcon button creates WIP entries for subcon operations

    • WIP entries are tagged as subcon

    • For subcon processing, a separate purchase request (PR) and possibly PO are generated

  • PR and PO handling for subcon

    • Approvers apply toPurchase Request; after PR approval, a PO is created

    • PO entries have trade type (e.g., trader) and include last operation quantities

    • The system may require balancing across multiple PRs/POs for subcon processing

  • Receiving subcon goods

    • Upon PO creation, a RR (receiving) process may occur with FG/RM specifics and operator assignment

    • RR entries include conversion data (e.g., units, KMS to rolls to KGS to pieces)

  • Handling partial quantities

    • If partial quantities are received, remaining quantities trigger additional PR/PO flows or backfills

Returns, backlog, and post-delivery handling

  • Backlog and returns handling

    • Backlog RM and backlog FG are used to manage returns from WIP or deliveries

    • Returns may involve selecting the type of return (damaged, hold, or good) and corresponding warehouses

  • Return workflow details

    • Return documentation includes a hard copy identifier (for internal tracking)

    • Returned items can be moved to backlog RM or backlog FG based on type

  • SO/JO creation from returns and target dates

    • When returns are processed, there may be updated SO or JO creation or adjustment of target delivery dates

Archiving and data hygiene

  • JO archiving and web archiving

    • JO archives exist for inactive JOs (fulfilled, canceled, closed, disapproved)

    • Web archives exist for finished or closed WIPs

  • PO and warehouse issue archiving

    • Archiving for POs and warehouse issuance is used to optimize page load times

  • Warehouse stock archive and filters

    • Warehouse stock view includes filters per warehouse, per product group, per trade type, per product name, per product type, per customer, or per internal RN

    • Date added and the concept of adding stock (receipts from manufacturing or RR) are tracked

Practical notes and takeaways

  • Production data is crucial for the system

    • Production data impacts sales orders and deliveries; it is used widely across modules

  • Customer-specific production dates

    • Production date planning is heavily customer-specific and tied to end dates and delivery planning

  • Next steps and planning

    • Target next week: Account planning

    • Scheduling: next target time around 4 PM

Quick reference: key acronyms and terms

  • JO: Job Order

  • SO: Sales Order

  • PR: Purchase Request

  • PO: Purchase Order

  • RM: Raw Materials

  • FG: Finished Goods

  • MKM: Master/Key Material (data used from SO planning)

  • ACL: Access Control List (approval metrics and routing)

  • WIP: Work In Progress

  • BOM: Bill of Materials

  • QE/QC: Quality Control

  • GO: Go/Go-Request (context-dependent in the workflow)

  • PE: Process Engineering/lamination-related JO type

  • Subcon: Subcontracting

Mathematical notes and conversion formulas

  • KM and roll conversion (example relationships mentioned in workflows)

    • 1 KMS ≈ 1 roll ≈ 150 KGS ≈ 20{,}000 pieces

    • General conversion guidance used in planning and QC involves mapping KM to rolls and to downstream units

  • Maximum KMS roll output with allowance

    • Let Total ext{KMS} be the sum of outputs from the previous operation across all rolls, and N ext{rolls} be the number of rolls in the operation. Let ext{allowance} be an operational buffer (e.g., 0.25 for 25%). Then:
      \text{max_KMS} = \frac{\text{Total_KMS}}{N_{\text{rolls}}} \times (1 + \text{allowance})

    • Typical allowance observed: 25% (0.25); note that some cases mention a 20% (0.20) limit for higher volumes (e.g., when total exceeds certain thresholds)

  • Slitting output max based on BOM outs

    • If the preceding operation produces an output, the max for slitting can be computed as:
      \text{max_slitting_output} = \text{output}_{\text{last_op}} \times \text{BOM_outs}

    • BOM outs are defined in the BOM settings for the material

  • Example numerics (illustrative)

    • If Total_KMS = 149.98, N_{rolls} = 5, and allowance = 0.25, then
      \text{max_KMS} = \frac{149.98}{5} \times (1 + 0.25) = 29.996 \times 1.25 \approx 37.50 KMS

  • Operational data mappings

    • For production planning, KM, rolls, KGS, and pieces are interconnected; explicit conversion values are used for planning and QA checks

Connections to earlier topics and real-world relevance

  • JO and SO linkage reinforces standard ERP practice: sales orders drive manufacturing work orders, ensuring traceability and planning alignment

  • Replacement and subcon flows reflect real-world manufacturing scenarios where partial shipments, cancellations, and external manufacturing are common

  • Archiving and data hygiene are crucial for performance in large ERP systems; archiving inactive records reduces page load times and improves search responsiveness

  • The use of ACL-based approvals ensures organizational governance and role-based access control in manufacturing workflows

Ethical, philosophical, and practical implications

  • Data integrity and traceability are essential for audits and compliance in manufacturing environments

  • Subcontracting introduces external dependencies; proper governance and visibility are required to prevent supply chain disruptions

  • Accurate production planning data influence customer commitments, cost control, and waste management

  • Automation of approvals and WIP creation reduces manual error but requires robust controls to prevent misrouting

Questions you might encounter on the exam

  • Explain how a normal JO differs from a buffer JO in terms of required data and SO linkage.

  • Describe the end-to-end flow from a PE JO through lamination passes to WIP creation and QA checks.

  • What is the purpose of a replacement request, and how does it lead to PRs/POs?

  • How does the system handle parent/variant materials during RM issuance in stock requests?

  • What is the role of MKM in JO flow, and how is it sourced?

  • How are backlog RM and backlog FG used in returns processing and how do they affect inventory planning?

  • What are the main considerations for archiving JO records, and how does this affect system performance?

If you want, I can turn these notes into a printable study sheet or tailor them to a specific section of your syllabus (e.g., focus more on MSCM/MKM, or on QC procedures). Also, I can extract a condensed checklist for a quick review before the exam.