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Advantages of Warehouse Advanced Production Integration
Advanced production integration allows you to have real-time material flow between the shop floor and the warehouse. You can plan the staging of components to production over time so that PSA capacity is used reasonably. You can monitor and control the staging process. Consumption can be posted directly from WM, and the consumption status can be monitored using an app or RF. Consumption posting can be reversed directly from WM using an app or RF.
You can receive produced stock as soon as the goods receipt request is triggered from the shop floor (both the Post Goods Movement app and the RF are available for use). You can also clear the stock reference for leftover stock in the production supply area and move it back to the warehouse after the manufacturing process is complete. In that way, you can free up some capacity from the production supply area for other staging activities, using an app or RF.
Using the Warehouse Advanced Production Integration offers you the following benefits:
- Plan staging activities flexibly at a reasonable time and with reasonable quantities, to fully utilize capacity in the production supply area in your warehouse.
- Use more options to trigger consumption or consumption reversal (for example, via radio frequency (RF) or an app (besides the Post Goods Movement app)
- Track the staging and consumption processes more transparently regarding PSA stock and manufacturing orders
- Improve TCO for the reduced number of system documents
The process consists of the following main steps:
- Define the control cycle and the assignment of the storage bin in the production supply area.
- Create manufacturing orders and trigger the creation of production material requests.
- Stage for production with multiple staging methods.
- Monitor consumption for production.
- Reverse consumption for production, if required
- Perform receipt of finished and unfinished products
- Clear product supply area by moving unused components back to the warehouse.
Production Supply Area (PSA)
The production supply area (PSA) is an area on the shop floor where products are staged or withdrawn. To stage products for a production order, a warehouse must know where to take them. In the ERP system, the PSA contains this information for production orders.
In advanced production integration, the PSA will always contain a storage location that is connected to the same warehouse as the storage location supplying the material, or it is the same storage location. A shuttle scenario, that is, one where the PSA storage location is not connected to the warehouse or is connected to another warehouse other than the supplying storage location, is not supported.
Staging Products for Advanced Production Integration
When using the advanced production integration, for each manufacturing order, the system creates a Production Material Request (PMR) directly in warehouse management, using the required information from production when the manufacturing order is released, and triggers WM material staging. If the manufacturing order is changed, the system updates the PMR with changes relevant to warehouse management, such as a changed staging quantity.
This PMR contains the receiving product and all the components from the manufacturing order in their required quantity.
Staging Single Order versus Cross Order Items
Depending on the bin assignment settings, components are staged differently as follows:
Single Order Staging:
The system creates a warehouse task to move each production material request (PMR) item to the PSA. Each warehouse task references a single PMR. After the warehouse task is confirmed, the stock on the PSA references the PMR item, so the stock is reserved for that PMR item. Only this PMR can be used to consume the stock. You can manually release the reference to the PMR item for the stock.
Cross-Order Staging:
The system aggregates products from multiple PMRs and creates a warehouse task to move them to the PSA together. The warehouse tasks have no reference to the PMR item. After the warehouse task is confirmed, the stock no longer references a PMR item. Each PMR that has an item with the product can be used to consume the stock. This is a flexible method, which allows you to stage products, whether the product is required for one PMR in particular, or by several PMRs.
Product Consumption with a Production Material Request
For components that have not been marked for backflush, the consumption posting is triggered through the production material request (PMR). Consumption can be posted in a desktop transaction or using RF; a reversal of the consumption posting is also possible. You can post consumption for the entire quantity of the product at once, or for partial quantities at intervals. You can also post consumption for a greater quantity of a product than was planned in the PMR. For partial consumption, you can post the consumption based on the quantity consumed or the quantity remaining.
Clearing the Production Supply Area
After a PMR is completed and the production process is finished, it is possible that there is still a quantity of the product on the PSA, and that no other PMR needs the product. In this case, the product should be returned to the warehouse to avoid occupying space on the PSA. You create warehouse tasks for this movement with the transaction, Clear Production Supply Area.
Clearing the Production Supply Area
For products staged using the single-order staging method, you must first release the reference document to clear the reference in the stock (with the same transaction). If you do not release the reference document, the stock can never be used for another PMR.
