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Process vs. Discreet AX2009

  • 1.  Process vs. Discreet AX2009

    SILVER CONTRIBUTOR
    Posted Oct 22, 2018 01:12 PM
    We are on #AX2009 , when we implemented we were implemented with discreet manufacturing. We are a chemical manufacturing site, we make goop from raw materials, we fill the goop into different types of bottles, syringes, etc. these are then packaged into finished goods.

    Or bulk manufacturing process includes many process including sifting, drying, ect. of raw material chemicals, these are then used to manufacture the goop. We have a high adjustment rate on our bulks for color or other key specifications.

    We do own the process manufacturing module for #AX2009 but it was never installed. Based on conversations at the #D365UG/AXUGSummit2018Phoenix I believe we should explore moving in that direction. I need to make a business case for this, but I don't know enough about the Process manufacturing module to effectively explain the need. Could I get some help with the benefits of using process?

    Thanks in advance!
    Dave

    ​​

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    David Vezmar
    Supply Chain
    Dentsply Sirona
    Milford DE
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    Conference-AXUG_200x200


  • 2.  RE: Process vs. Discreet AX2009

    TOP CONTRIBUTOR
    Posted Oct 22, 2018 03:02 PM
    Disclosure:  I haven't worked with process mfg add-on in 2009, I have done a few process mfg implementations in 2012 R3.   That said, I don't believe much changed after MSFT acquired the code.  Also, this isn't its own module per-say, its functionality dispersed through out the application (Master planning, Inventory Mgmt, Production Control, Product Info Mgmt, etc).

    Here's what I generally see as good for process mfg and easy to implement:

    • Product structures - Allowed to define a Bulk item (BulkGoop), and the Packed products it goes into (2,000lb tote Goop, 55 gal drum Goop, 5 gal pail Goop, etc). 
    • Inventory visibility - See all Goop products, both bulk and packed, on hand converted to a common base unit of measure. Allows CSR to easily suggest alternate pack sizes if a given pack size is out of stock. 
    • Batch balancing - In planning, make bulk batches of BulkGoop to cover requirements from all packed products, and tie them together through a "Consolidated Batch Order"
    • Automatic substitution in formulas - If you make a product that is a blend of multiple packed products, or you have alternate ingredients you can use you can roll through packed product sizes in a sequence you define and drive requirements to what is actually available on hand, instead of driving new purchase / production orders. (Plan Group & Priority)
    • Rework batch orders - you can make an item from itself with formulas. You can't easily do this with discrete products. 
    • FEFO batch reservation logic - first expiring, first out. - This would be an area to scrutinize, since reservations changed from 2009 to R3.  Dates on each batch: Mfg Date, Shelf Advice Date, Best Before Date, Expiry Date. 
    • Inspection Orders - Generate quality orders to re-inspect inventory on hand that is past it's shelf advice date but not yet expired. 
    • Batch Attributes - create and enforce capture of batch attributes (Viscosity of goop, PH of goop, etc), search & reserve inventory based on batch attributes, restrict sales to customers based on batch attribute values, copy batch attribute values from Bulk's to packed products automatically. 
    • Batch disposition - create batch dispositions that control if batches can be used in production, sold, transferred, none of the above.  
    • Formula size increments - you can specify on the Formula version the incremental quantity that batches increase by instead of using order multiple on default order settings.  
    • Customer sell-able days - Ensure you ship product to a customer with enough time left for them to actually sell it or use it in their process.  IE don't sell them something that will expire two days after they get it.  

    Here's stuff that clients generally implement as a "phase next" or don't always use:
    • Sequencing - In master planning, schedule campaigns based on a color / viscosity / acidity / etc rules you define.  This is very capable, but takes some effort to set up. 
    • Restricted products - You can't sell a specific product into a specific state / region for some reason.  CSR will get a nag at SO line creation if conditions are met. 
    • Product Safety Data Sheets / product compliance - Automatically print / alert CSR's when a customer has not received the latest MSDS / Product Safety Data sheet for an item. 
    • Batch balancing - have active, filler, compensating, none type ingredients.  Based on batch attribute value of active ingredients and batch size, automatically adjust quantities required of filler and compensating ingredients, do nothing with the "none" type ingredients. 
    • Scalable / percentage controlled / Yield - different ways to manage formula ingredient quantities besides just "i need 10 lbs of ingredient 1 to make 1 batch of goop".  
    • Planning Items / Co-Products / By Products - output more than one item at a time during report as finished against a batch order.  This could have been enhanced in R3 vs. 2009. 


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    Colby Gallagher
    Manufacturing Systems Consultant
    Agility Business Solutions
    Brecksville OH
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    Conference-AXUG_200x200


  • 3.  RE: Process vs. Discreet AX2009

    SILVER CONTRIBUTOR
    Posted Oct 23, 2018 08:57 AM
    Seeing the description of your manufacturing process, I agree that you should be using process manufacturing.  I used the module in AX 4.0 and it is solid as long as you configure the system properly..

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    Dag Calafell, III
    Technical Solution Architect
    MCA Connect
    Houston, TX

    http://calafell.me/
    @dodiggitydag
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    Conference-AXUG_200x200


  • 4.  RE: Process vs. Discreet AX2009

    Posted Oct 24, 2018 08:58 AM
    At this point in the life-cycle of AX 2009, you should likely just plan to replace your manufacturing setup when you upgrade to D365 F&O.  It serves the process manufacturing space well.


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    Chad Back
    cback@bkd.com
    BKD, LLP
    317-748-0728
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    Conference-AXUG_200x200


  • 5.  RE: Process vs. Discreet AX2009

    Posted Oct 25, 2018 02:12 AM

    Hello David,

     

    I strongly recommend this article to begin your understanding: https://docs.microsoft.com/en-us/dynamics365/unified-operations/supply-chain/production-control/production-process-overview

     

    This provides a good overview when starting the Diagnostic phase of such a project.  Carefully document the entire value chain, preferably with:

    • Process flows and a business process library, including product, order, employee and contract lifecycles.   
    • Production characteristics required, such as batch or serial tracking, inventory tracking, location, container, inventory status, site, warehouse, legal entity relationships, quality control, etc
    • Financial dimensions for reporting, number sequences
    • Compliance, security, audit and regulatory tracking
    • Careful design for creation of Released products
    • Eventually even leveraging integration of IoT through azure.  So if you have valves, thermostats and other metrics in your manufacturing processes, you can leverage those too. 

     

    Perhaps this is more than you were asking, but when you begin to look at your organizational operations and an upgrade like this, you may need a blend of orders to facilitate the flow, while minimizing how you do things to simplify accounting.  Careful project management and architecture will help you maximize the value the system returns.  You will also want to consider reporting through PowerBI and other tools, such as FASTPATH, Dynaway,  etc. depending on your cost and revenue structure.

     

    Best regards,

    Gabor

     

    Gabor Fulop

    Consultant & Solution Architect

    Fulop Business Services, Inc.

    Cell: 760.683.4210

    https://www.linkedin.com/in/GaborFulop/

     




    Conference-AXUG_200x200


  • 6.  RE: Process vs. Discreet AX2009

    SILVER CONTRIBUTOR
    Posted Nov 02, 2018 12:09 PM
    Thank you everyone for the responses! All the info is greatly appreciated!

    Dave

    ------------------------------
    David Vezmar
    Supply Chain
    Dentsply Sirona
    Milford DE
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    Conference-AXUG_200x200


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