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Ralcorp Frozen Expire Logic September, 2013. Agenda 2 SectionsPresenter BackgroundDavid Friedli Picking Functions Expiration Functions Distressing Functions.

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Presentation on theme: "Ralcorp Frozen Expire Logic September, 2013. Agenda 2 SectionsPresenter BackgroundDavid Friedli Picking Functions Expiration Functions Distressing Functions."— Presentation transcript:

1 Ralcorp Frozen Expire Logic September, 2013

2 Agenda 2 SectionsPresenter BackgroundDavid Friedli Picking Functions Expiration Functions Distressing Functions Hawk (If time permits) Q & A Discussion

3 Who is Ralcorp Frozen? A $1.1B Leader in Private Label Frozen Bakery Products –Cookies (#1) –Pancake / Waffle (#1) –Refrigerated Dough (#1) –Bread / Biscuits 3

4 Environment Overview 4 Lodi Seattle Delta Ogden Louisville 1 & 2 Chicago/ Downers Fridley Brantford Grand Rapids Forest Park Carrollton

5 Environment Overview MfgPro eb2.1 service pack 5.Net 2011 MSW/PSW vs Eagle Barcoding since 2009 Both Lot/Serial and Reference number is populated for FG and RM pallets 5

6 Personal Overview My Experience –12 years in Automotive with QAD –4 years in Food with QAD –30 years with ERP systems 6

7 Picking Function 7 We are having Customers reject shipments due to insufficient remaining shelf life Each customer can have different requirements Cant rely on fork lift drivers to pick qualified pallets and memorize all the rules Customer Service being impacted

8 Picking Function 8 Very first thing, smart lot numbers –YYJJJSPLN (132101A01) –Production Reporting application modified

9 Picking Function 9 Next modified Eagles PPK pallet pick option –Gen Codes Generated to restrict age of product being shipped By ship-to/product line By ship-to/marketing group By part number

10 Picking Function 10 –Modified PPK so the find function would only show pallets that qualify for the customer –Modified PPK so the find function by Lot –Also added warnings

11 Expiration Functions 11 So we have individual customers satisfied now How do we prevent shipping out of date product? We have: Dated Lot Code Shelf life in a custom table Want to use as much standard QAD logic as possible (item status, inventory status)

12 Expiration Functions 12 Two New Applications Run Nightly Looks at all ld_det records that are missing an Expire or Distress Date For Expire dates, we turn the Lot number into a date and add the shelf life. FYI, for distress dates, go thru the logic in the Eagle pick program and add the lowest MaxLife value to the Lot number.

13 Expire Functions 13 Run Nightly after Expire Date Calc Setup in batch for each sites needs Able to update the status of the inventory based upon a horizon (e.g. Expire all material with an expire date within the next 7 days) Able to enter a Reason Code and Comment into the ld_det table so can see why it is on Hold also updated so QA can manage reason code and comment for QA reasons. Ran for inventory with a Current status and changes ld_det to the new status (RCT-CHL created) (Runs thru CIM).

14 Expire Function 14 Plant has two primary ways to look at inventory

15 Expire Function 15

16 Distress Function Distress Function is for the material that can no longer be shipped to a standard customer Handle two ways –Have Distress date in the ld_det table, run Auto Expire Utility on this date (GOOD > HOLD-DIS) –Have Expire date, run Auto Expire Utility for all items that do not have a distress date (e.g. 30 days before expire) 16

17 Interface - DS1 (Data Source One) 17 Purpose –Home-grown tool for centralized maintenance of Raw, WIP, and Packaging items (QAD BPM handles FG items) –Centralized maintenance of Customers/Suppliers –Data flows from QAD thru Pro2SQL to SQL Data Warehouse to DS1 application back to QAD –CIM loads into QAD with auto- ing and auto-reprocessing of errors Frequency –Every 30 minutes Mechanism –SQL ODBCs to custom staging table in QAD along with an automated Cron job to load into QAD

18 HAWK 18 Purpose –Home-grown efficiency tool used for FG reporting and inventory transactions to avoid manual QAD data entry and other slow processes –Data flows from QAD thru Pro2SQL to SQL Data Warehouse to HAWK application back to QAD –CIM loads into QAD with mass auto- ing and auto-reprocessing of errors –To date, 5.0 million loads completed in QAD (now averaging 170k QAD loads per month) –9 transaction types: BKF (backflush), WOR (work order receipt), PDL (pallet delete), PMV (pallet move), POR (purchase order receipt), CYC (cycle count)

19 HAWK 19 Production Reporting –Hawk (7 Plants) Runs regionally on SQL servers Reports Sub Assemblies and Finished Goods –Can be used with Repetitive and Discrete Orders –Collects/Uploads production within seconds to QAD –Creates Pallet Labels for Eagle/Inventory If QAD is down, still collects production and prints

20 Hawk – Front End 20

21 Hawk – Back End Back End is in QAD Custom Table and Utilities Upto 10 transactions/second capability Sends s on errors Serves as interface to multiple external applications –Hawk –PO receipts at external sites –Cycle Counts by external sites 21

22 Hawk – Back End 22

23 Hawk – Back End 23 Used in batch for each site Each site has its own processing queue Runs every 20 seconds Can setup to run all transaction types, or only specific ones if needed Each transaction type has a pre-cim validation If an issue, do not want to submit thru CIM, it will just delay 20 seconds Each transaction creates an (can be setup for P or E)

24 Hawk – Back End 24

25 Hawk – Back End 25

26 Hawk – Back End Reprocesses Errors Runs every hour Can run manually Can run for a single record Can run for entire site Can cancel a single record 26

27 Hawk – Back End Runs every 8 hours Does send out that errors still exist Purges old records based upon GenCode settings 27

28 Questions? 28


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