Difference between revisions of "A Step by Step Guide to Libero Manufacturing"

Revision as of 23:32, 18 November 2010

This page is under construction --Kittiu 11:59, 4 November 2010 (UTC)

Overview

This page is based on the attempt to understand ADempiere Libero Manufacturing module of the author. It will be illustrated as a step by step guide for the reader to have the FEEL of what Libero Manufacturing can do and how to do it. Here I am referring to the Libero Manufacturing Work Shop conducted by Victor Perez some time back in 2009.

As such, this is by no mean the as the reference manual of Manufacturing Management in ADempiere and you can always find more reference from the original source in LIBERO

Briefing about Manufacturing Process

Libero Manufacturing Process is the mean of producing new Product based on specified Bill of Material (BOM & Formula), Manufacturing Resources, Workflows (how to produce) and Distribution (where to deliver).

1) First, we have to tell the system on how to produce products.

Product Planning Data is the master data that store the relationship between Product & BOM & Resource & Workflow, it also store the initial data about manufacturing process of each product, such as, Order Policy, Order Period, Batch Quantity, etc.

2) After the relationship of How to produce a product is defined we can start producing things.

Without planning, we can simply use Manufacturing Order manually. We then use the Component Check process to verify and use Print and Release Order process to print out checklist for user on the field. Once completed, store can use Order Receipt & Issue to accepted the newly created products into warehouse.

With Planning, we can use MRP. First the Forecast window will be used to store forecasting information (calculated outside ADempiere). Then we can run Generate Material Plan which will lookup Forecast data and based on it generate Manufacturing Order, Distribution Order, Purchase Requisition for the shortage products.

??? What is Calculate Low Level and Calculate Record MRP ???

Business Case 1: Chemical Industry (Process Production)

The Management of Garden World evaluated the possibility of getting a profits increase by manufacturing the fertilizer and took decision to open a new manufacturing plant to produce the fertilizer which before Garden World only purchased and sold.

So the engineering department designs two bills of materials to produce the Fertilizer in 50 and 70 kg packages and also a formula used for gross production of the fertilizer. The Lawn Fertilizer uses following raw materials:

• Phosphorus 17%
• Nitrogen 17%
• Potassium 17%
• Water 49%

Step 1: Define BOM

• &Menu → Manufacturing Management → Engineering Management → Bill of Materials & Formula
• Prepare BOM for Fertilizer_Lawn Fertilizer, which has the formula in % as above
• Prepare BOM for Fertilizer#50 and Fertilizer#70, of which components are Fertilizer and Bag
• See the summary of prepared BOM in BOM & Formula Info

Step 2: Define Manufacturing Workflow and Resources used in Production Process

• Define the Plant (Manufacturing Resource with Manufacturing Resource Type = Plant) that govern the production process
  • Fertilizer Plant with Planning Horizon = 120

• Defines the Manufacturing Resources (Manufacturing Resource Type = Work Center) that will be used to produce any product in the Manufacturing Workflow
  • Mixed Area
  • Inspection Area
  • Packing Production Line

• Define Manufacturing Workflow process to produce the fertilizer products
  1. Lawn Fertilizer
  2. Lawn Fertilizer Packing

• Define Workflow Activities and Resources

Step 3: Generate Demand for Manufacturing

The MRP system takes in a number of parameters as inputs and performs some level of analysis and generates recommendations that can either be accepted or rejected by the planner. One of the inputs of MRP is the bill of material, which is a list of all components (and in what quantity) needed to produce finished good(s). For example, the bill of material needed to produce a dinning set is 6 chairs and 1 table (supposedly). The demand for the dinning set here is independent while that for the chairs and table are independent.

An independent demand is a demand that is not based on the demand for another item while a dependent demand is based on the demand for another item. Hence, it can be concluded that the demand for the 6 chairs and the table is based on the demand for the table. Thus, you can forecast an independent demand while dependent demands are calculated based on the independent demand item. The role of the MRP therefore is to perform this calculation.

And so, now, we will be creating demands from outside, both from direct order and planning

1) Generate Independence Demand from Sales Order

• Create 2 Sales Order,
  • Sales Order #1> Org: Fertilizer | DocType: Standard Order | Date Promised: <same date next month> | BPartner: Seed Farm | Delivery Rule: Available
    • Sales Order Line> Product: Fertilizer#70 | Quantity: 70 | Price: 33 | Tax: Standard
  • Sales Order #2> Org: Fertilizer | DocType: Standard Order | Date Promised: <same date next month> | BPartner: Seed Farm | Delivery Rule: Available
    • Sales Order Line> Product: Fertilizer#50 | Quantity: 60 | Price: 20 | Tax: Standard

2) Generate Independence Demand from Forecast and Planning

ADempiere do not provide sophisticated Forecasting module but rather providing Forecasting Data Input window. The calculation need to be done elsewhere using 3rd party software. I.e., Lokad business forecasting

• &Menu → Manufacturing Management → Planning Management → Forecast Management
• Define Forecast Data for manufacturing of fertilizer

• View the total amount of Forecast by Forecast Report

• View Material Resource Planning by MRP Info
• Note that we are focusing on Fertilizer only. The view will display both demand from Sales Order and from Forecast
• In this view you can look both demand as gross requirement and an On Hand project quantity that indicates the availability of material in the future. If this is negative then is necessary to generate a supply.

• And before we will be running Calculate MRP to create business activity (i.e., Production, Purchasing, etc) to full fill the material requirement, we will want to check out the Product Planning Data.
• Product Planning Data is the master data that store the relationship between Product and BOM / Manufacturing Resource / Manufacturing Process (Workflow) / Distribution, it also store the initial data about manufacturing process of each product, such as, Order Policy, Order Period, Batch Quantity, etc.

Note:

• Use Create Product Planning process to create this data. Running this process help to create/update data in bulk.
• Following are the meaning of other parameters
  • Resource: Only Resource Type = Plant is available. I.e., Fertilizer product is produced in Fertilizer Plant
  • Workflow: Process that use to product this product
  • Distribution Network: ???
  • Is MPS: ???
  • Create Plan: ???
  • Order Policy: ???
  • Order Period: ???
  • Batch Quantity: ???
  • Yield %: ???
  • etc...

Now that we have the independent Demand and Planning data we need to calculate the Material Plan to get the supply orders.

Step 3: Calculate MRP

• &Menu → Manufacturing Management → Planning Management → MRP → Calculate Material Plan
• Supply parameters and run the process
  • Organization: Fertilizer
  • Resource: Fertilizer Plant
  • Warehouse: Fertilizer Plant

Note:

• What Calculate Material Plan process is doing can be found here at Calculate MRP logics
• Following are the meaning of other parameters
  • Required calculated DRP = ???

When this process ends it shows that Manufacturing Orders or Material Requisitions and Notice Messages that were generated.

Repeating MRP Info we can see how MRP generated the Planned Orders and material requisitions.

Notes

Manufacturing Resources

• The Resource Type is used to calculate the available time in a Manufacturing Resource. It allows input of starting time and end time for the slot according to the working days.
• The Planning Horizon in Manufacturing resources is used for ???

Manufacturing Workflow

• If the workflow name is the same as the product name this Workflow will be the default Workflow for the product.
• The time constraint (i.e., Queuing Time, Waiting Time) in Manufacturing WF and Manufacturing Resource is different in that = ????