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Validation Session
LOG -IM/WM-Validation
LOG-IM/WM-Validation
January 6, 7, 8, 2009
LaGov
Version 2.2
Updated: 12/17/08
Visit our website for Blueprint Presentations, Meeting Minutes and Project News!
www.doa.louisiana.gov/ERP/index.htm
1/21/2009 2
IM / WM Validation Session Agenda
Purpose
Work Session Recap
Master Data Design
Key Design Elements and Decisions
Changes and Challenges
Open Issues
Benefits/Improvements
FRICE-W objects
To-Be Processes by Topic
Key Design Elements and Decisions
Changes and Challenges
Open Issues
Benefits/Improvements
FRICE-W objects
Conversion Strategy and Interim Solution
Organizational Impacts
Next Steps
Questions
1/21/2009 3
Purpose of Validation Sessions
Validation Sessions are intended to provide feedback to the workshop
participants regarding the TO-BE process design:
1/21/2009 5
IM / WM Workshop Session Recap
Work
Business Workshop AM/
Goals Session
Process Codes PM
Date
Define differences between Warehouse Management and
WM Specific
LOG- Inventory Management 8:30am-
Material 9/23-24/08
MD-005 Review Warehouse Management structure 4:30pm
Master
Define key Warehouse Management material master data
1/21/2009 6
IM / WM Workshop Session Recap
Work
Business Workshop AM/
Goals Session
Process Codes PM
Date
Inventory and
LOG- 8:30am-
Warehouse Review physical inventory processes 10/16/08
IM/WM-003 4:30pm
Stock Taking
Review process for monitoring transfer requirements
Warehouse Review inbound and outbound delivery monitors
Management LOG- Review process for generating a pick list for items in multiple 8:30am-
10/29/08
Planning and WM-001 locations 4:30pm
Monitoring Review process for combining multiple storage units into a single
storage unit
Define MRP execution control parameters
Review and live demo of MRP execution process
MRP Planning LOG- Review and live demo of MRP evaluation and output processing 8:30am-
11/5/08
Run IM-001 Live demo of purchase order cycle 4:30pm
Live demo of stock transport order cycle
Live demo of reservations and issues for consumption
1/21/2009 7
Organizational Structure
Inventory and
Warehouse Management
Organizational Structure
1/21/2009 8
IM / WM Organizational Structure
Plant:
Is an operational unit within a single Company Code.
Is embedded in the organizational structure as follows:
A Company Code can have several plants.
Several Storage Locations in which materials (stock) are
managed belong to a Plant.
A Plant can have both Inventory Management and
Warehouse Management.
The valuation of inventory is instrumental in the
determination of Plants within an organizational structure.
1/21/2009 9
IM / WM Organizational Structure
Storage Location:
Is an organizational unit allowing a physical delivery location, as
well as the differentiation of material stocks within a Plant.
Is where stocks of materials are delivered and where inventory
exists.
MRP Areas:
Will be utilized to subdivide Plants into individual replenishment
units.
Materials managed in MRP Areas will have both a Plant and
MRP Area control data.
1/21/2009 10
Inventory and Warehouse Management
Proposed Organizational Chart
DPS
PLANT MRP
INVENTORY
PLANT PLANT
MANAGEMENT
WAREHOUSE
CENTRAL
WAREHOUSE
WM
1/21/2009 11
Inventory and Warehouse Management
Proposed Organizational Chart
DOTD
STORAGE
STORAGE ADDR CENTRAL YARD
LOCATION PARISH 2 PARISH 3
LOCATION
WHS
WAREHOUSE
1/21/2009 12
Inventory and Warehouse Management
Organizational Chart
Plant
Storage Location
XXXX
XXXX
DPS
DPSDepartment
DepartmentofofPublic
PublicSafety
Safety
Purchasing
Purchasing Organization
Organization
Purchasing Office of State
Purchasing Group
Group
Purchasing
XXXX
XXXX
IM Inventory
Department of
Public Safety
Warehouse
WH
Other Photo
PhotoLab Troop E/Region 22HQ
HQ(Fleet
(FleetSR)
OtherDelivery
DeliveryLocation(s)
Location(s) Lab
I M Troop E/Region SR)
Other
OtherDelivery
Delivery
<City>,Location(s)
Location(s)
LA IM Baton
BatonRouge,
Rouge,LA
LA <City>, LA
<City>, LA
Other <City>,
Delivery
Other Delivery LA
Location(s)
Location(s)
<City>,
<City>, LA
LA
<City>,
<City>,LA
LA
Troop
TroopGGHQHQ(Fleet
(FleetSR)
SR)
Troop
TroopFFHQ
HQ(Fleet
(FleetSR)
SR)
IM <City>,
<City>,LALA
IM <City>,
<City>,LALA
Troop
TroopIIHQ
HQ(Fleet
(FleetSR)
SR) Troop
TroopLLHQ
HQ(Fleet
(FleetSR)
SR)
<City>,
<City>,LA
LA <City>,
<City>,LALA
IM IM
1/21/2009 13
Inventory and Warehouse Management
Plant
Organizational Chart
Storage Location XXXX
XXXX
Office of State
Purchasing
Purchasing Organization
Organization Purchasing
XXXX
XXXX DOTD
DOTDDepartment
DepartmentofofTrans.
Trans.&&Dev.
Dev.
Department of
Purchasing
Purchasing Group
Group Transportation &
Development
IM Inventory
Section Plant
Section76 76 District
District99
IM <City>,
<C ity>,LA
LA IM <City>,
<City>,LALA
XXX
XXX
1/21/2009 14
Inventory and Warehouse Management
Organizational Chart
Plant
Office Office
Officeof
ofthe
theAssistant
AssistantSecretary Office
Officeofofthe
theAsst.
Asst.Secretary
Office
Officeofofthe
theSecretary
Secretary(HQ)
(HQ) IM Officeofofthe
theUndersecretary
Undersecretary Secretary Secretary
Baton Baton
BatonRouge,
Rouge,LA Baton
BatonRouge,
Rouge,LA
Baton
BatonRouge,
Rouge,LA
LA XXX BatonRouge,
Rouge,LA
LA LA LA
XXX
Seafood
SeafoodMarketing
Marketing Finance
Finance Administration
Administration Administration
Administration
Baton
BatonRouge,
Rouge,LA
LA Baton
BatonRouge,
Rouge,LA
LA <City>,
<City>,LA
LA XXX <City>,
<City>,LA
LA XXX
XXX
XXX XXX
XXX XXX XXX
Enforcement
Enforcement Human Environmental
EnvironmentalEducation
IM Humanresources
resources Education
IM
Inland
Inland
Baton
BatonRouge,
Rouge,LA
LA Baton <City>,
<City>,LA
XXX BatonRouge,
Rouge,LA
LA LA XXX
XXX
<City>,
<City>,LA
LA XXX
XXX XXX
Region
Region11--99 Wildlife Marine
Region Wildlife Marine
<City>,
<City>, LA 33
LA
Region <City>,
<City>,LA
LA <City>,
<City>,LA
LA
<City>,
<City>,LA
LA XXX
XXX XXX
XXX XXX
XXX
Coastal
Coastal&&Non-Game
Non-GameResources
Resources Fish
FishResearch
Research&&Assessment
Assessment
<City>,
<City>,LA
LA <City>,
<City>,LA
LA
XXXXXX XXX XXX
Facilities
Facilities
<City>,
<City>,LALA
XXX
XXX
Rockefeller
RockefellerWildlife
WildlifeRefuge
Refuge
IM Grand
GrandChenier,
Chenier,LA
LA
XXX
XXX
1/21/2009 15
IM / WM Organizational Structure
1/21/2009 16
IM / WM Organizational Structure
Key Decisions
Phase one of LaGov project:
1/21/2009 17
IM / WM Organizational Structure
Changes & Challenges
Organizational impacts:
Ability to have MRP generated replenishment proposals for
local inventories, such as parishes, managed by one MRP
Controller
Reduction of workload required to manage inventory at a
stock location
Training requirements:
Educating MRP Controller on inventory functions related to
MRP Area
1/21/2009 18
IM / WM Organizational Structure
Resolved Issues
Wildlife & Fisheries will have four Plants and will utilize
Inventory Management only.
1/21/2009 19
IM / WM Organizational Structure
Open Issues
1/21/2009 20
IM / WM Organizational Structure
Benefits & Improvements
1/21/2009 21
Material Master Data
1/21/2009 22
Material Master Data - General
1/21/2009 23
Material Master Data General
Key Decisions
1/21/2009 24
Material Master Data General
Create Material Master Record
Requester
Central Group
1/21/2009 25
Material Master Data General
Changes & Challenges
Organizational impacts:
Material Master Number Request forms will be completed by the requestor and
sent to the centralized work group.
The centralized work group will create new Material Master Records and extend
appropriate IM & WM views.
Policy impacts:
Policy and procedures will need to be established for completion of information
sent to the centralized work group for additions, changes and deletions of Material
Master Records.
Develop a policy and procedure for the maintenance of Material Master Records
at the localized level.
Training requirements:
Personnel to complete required form for additions, changes or deletions of
Material Master Records.
Maintainers must know the master data well and have the knowledge of which
areas the master data impacts.
1/21/2009 26
Material Master Data General
Changes & Challenges
Organizational impacts:
Replacement of current stock numbering system
Training requirements:
Online search by selection criteria of Material
Master Records (Description, Material Group,
Plant, Material Type, etc.)
1/21/2009 27
Material Master Data General
Open Issues
Office Supplies
Janitorial Supplies
Automotive Parts
Safety Supplies
1/21/2009 28
Material Master Data General
Benefits & Improvements
1/21/2009 29
Material Master Data General
FRICE-W Objects
Forms:
Material Create / Change form (PDF form sent
electronically to the centralized work group).
Conversions:
Conversion strategy needed for material masters,
inventory, bins, etc.
Current systems to be converted:
PIMS
Venice
Wildlife & Fisheries ?
1/21/2009 30
Material Master Data
Inventory Specific
Material Master Data
1/21/2009 31
Material Master Data
Inventory Management Only
The centralized work group will extend the Material Master
Record to specific Storage Locations that are utilizing Inventory
Management.
The extension of the Material Master Record will result in the
addition of the following views:
Plant data/Storage Location data 1 & 2
Plant Stock (display only)
Storage Location Stock (display only)
1/21/2009 33
Material Master Data
MRP Specific
Material Master Data
1/21/2009 34
Material Master Data MRP Specific
The extension of the Material Master Record will result in the addition of
the following views:
MRP 1, 2, 3 & 4
Forecasting
1/21/2009 35
Material Master Data MRP specific
The statistical forecast and automatic reorder point and safety stock
determination option will be available once an appropriate
consumption history has been generated where:
The material has a non-sporadic consumption history.
A realistic replenishment lead time and service level can be defined.
1/21/2009 36
Material Master Data MRP Specific
Key Decisions
1/21/2009 37
Material Master Data MRP Specific
Key Decisions
1/21/2009 38
Material Master Data MRP Specific
Creating / Adjusting MRP Master Data
1/21/2009 39
Material Master Data MRP Specific
Changes & Challenges
Organizational impacts:
Inventory Manager to maintain information specific to their
Plant/Storage Location.
Policy impacts:
Policy and procedures will need to be established for completion
of information specific to a Plant and/or Storage Location.
Training requirements:
Training of personnel to maintain information on the Inventory/
MRP/Forecast related views of the Material Master Record.
1/21/2009 40
Material Master Data MRP Specific
Changes & Challenges
Organizational impacts:
Establishing at least one MRP controller per MRP Area.
Policy impacts:
Policy and procedures need to be developed for maintenance
of inventory within an MRP Area. For example:
Min/max
Reorder points
Safety stock
Training requirements:
Train the MRP Controller.
1/21/2009 41
Material Master Data MRP Specific
Changes & Challenges
Training requirements:
Training of personnel to properly identify materials
that require MRP functionality and appropriate
forecasting parameters.
1/21/2009 42
Material Master Data MRP Specific
Resolved Issues
1/21/2009 43
Material Master Data MRP Specific
Resolved Issues
Look into MRP generated Stock Transfers being 2 step
(issue/receipt).
Stock Transport Orders will be utilized for moves from:
Central Warehouse to district
Central Warehouse to parish
district to district
district to parish outside of plant
Stock Transfers will be used for local moves within the same
stock location, such as a district moving an item from inside
storage to stock yard.
1/21/2009 44
Material Master Data MRP Specific
Resolved Issues
1/21/2009 45
Material Master Data MRP Specific
Tasks to be Completed
1/21/2009 46
Material Master Data MRP Specific
Benefits & Improvements
1/21/2009 47
Material Master Data MRP Specific
FRICE-W Objects
Forms:
In-house form for changes pertaining to MRP specific
master data
Reports:
Replenishment report
Conversions:
Additional required information needed for Material Master:
MRP Types
Lotsizing Procedures
Special Procurement Types
Lead Time Elements
1/21/2009 48
Master Data
Warehouse Management
Specific
Master Data
1/21/2009 49
Master Data WM Specific
1/21/2009 50
Master Data WM Specific
1/21/2009 51
Master Data WM Specific
1/21/2009 52
Master Data WM Specific
Key Decisions
1/21/2009 53
Master Data WM Specific
Flow Chart - Extend WM Views
1/21/2009 54
Master Data WM Specific
Flow Chart - Storage Bin Creation/Maintenance
1/21/2009 55
Material Master Data WM Specific
Changes & Challenges
CHANGE: Inventory personnel to be responsible for
the maintenance of WM specific Material Master
information.
Organizational impacts:
Warehouse Manager to maintain information specific to
their warehouse.
Policy impacts:
Policy and procedures will need to be established for
completion of information specific to a warehouse
location.
Training requirements:
Training of personnel to maintain information on the WM
related views of the Material Master Record.
1/21/2009 56
Master Data WM Specific
Tasks to be Completed
Identify warehouse layout
pick zone/fixed bin/packing area, etc.
1/21/2009 57
Master Data WM Specific
Benefits & Improvements
Can specify WM unit of measure, which is different than the basic unit
of measure. This allows movement of materials within the warehouse
based on the larger unit of measure.
1/21/2009 58
Master Data WM Specific
FRICE-W Objects
Forms:
In-house form for changes pertaining to WM specific master data.
Reports
Material Master listing with bin locations, min/max, quantity, etc.
Conversions:
Additional required information needed for Material Master:
Storage Types
Storage Sections
Storage Bin Types
Minimum Bin Weights
Maximum Bin Weights
Bin Capacities (if relevant)
1/21/2009 59
Inventory and Warehouse Management
Requests for
Inventory Items
1/21/2009 60
IM & WM Requests for Inventory Items
GAPS
1/21/2009 61
IM & WM Requests for Inventory Items
Open Issues
1/21/2009 62
IM & WM Requests for Inventory Items
FRICE-W
Reports
1/21/2009 63
Inventory and Warehouse Management
Goods Movements
Transfers
1/21/2009 64
IM & WM Transfers
Stock Transfer
Used for internal physical movement of a material where the account
assignment does not change (i.e. Storage Location to Storage Location, bin to
bin).
Inventories will decrease at the source location and increase at the destination
location.
Financial implications do not occur with this transaction.
Stock Transport
Used for physical movement of a material where the ownership changes from
the source location to the destination location (i.e. from Plant to Plant; district
to district).
Inventories will decrease at the source location and increase at the destination
location with this transaction.
Financial implications will occur with this transaction.
Transfer Posting
Used for the logical movement of a material from one category to another
within the same location (i.e. from blocked stock to unrestricted use).
Financial implications do not occur with this transaction.
1/21/2009 65
IM & WM Transfers
1-Step method:
Step 1 - issue the item to the final destination.
2-Step method:
Step 1 - issue the item to an interim location.
Step 2 issue the item from the interim location to
the final destination.
1/21/2009 66
IM Transfers
Storage Location to Storage Location 1 Step
Receiving Storage
Location
Sending Storage Location
1/21/2009 67
IM Transfers
Storage Location to Storage Location 2 Step
1/21/2009 68
WM Transfers
Bin to Bin
1/21/2009 69
WM Transfers
Stock Replenishment at Bin Level
1/21/2009 70
WM Transfers
Stock Replenishment at Bin Level
1/21/2009 71
IM & WM Transfers
Open Issues
1/21/2009 72
IM & WM Transfers
FRICE-W Objects
Forms:
Enhancements:
Workflow:
Goods Receipts
1/21/2009 74
IM & WM Goods Receipts
1/21/2009 75
IM & WM Goods Receipts
1/21/2009 77
IM & WM Goods Receipts
Key Decisions
1/21/2009 78
IM Goods Receipts
GR for PO Item
1/21/2009 79
Warehouse Management
Receiving Process for PO and STO
1/21/2009 80
Warehouse Management
Goods Receipts Putaway
1/21/2009 81
IM & WM Goods Receipts
Changes & Challenges
CHALLENGE: If the account assignment field is left blank on the
purchase requisition/purchase order and the item has a Material
Master Record, then the item is received as an inventory item.
Organizational impacts:
Item would have to be received into inventory via a Goods
Receipt and then issued to the requestor via a Good Issue.
Training requirements:
Strong emphasis should be placed on the importance of correct
entries to the account assignment field of purchase requisitions/
purchase orders.
Option:
Authorization for ordering inventoried items may only be given to
inventory personnel through user profiles.
1/21/2009 82
IM & WM Goods Receipts
Resolved Issues
Look into necessity of printing a GR slip with every GR transactions
vs. using the online system.
Utilization of online system with ability to print GR information as needed
Development of a GR slip
1/21/2009 83
IM & WM Goods Receipts
Open Issues
1/21/2009 84
IM & WM Goods Receipts
Tasks to be Completed
1/21/2009 85
IM & WM Goods Receipts
FRICE-W Objects
Forms:
Barcoded inbound worksheet for RF device use in
receiving items into the warehouse
Standardize GR form needs to be developed
Reports:
Development of customized reports regarding GRs
Enhancements:
RF transactions for receiving/putaway
1/21/2009 86
Inventory and Warehouse Management
Goods Issues
Goods Issues
1/21/2009 87
IM & WM Goods Issues
1/21/2009 89
IM & WM Goods Issues
Key Decisions
1/21/2009 90
IM & WM Goods Issues
Key Decisions
1/21/2009 91
IM Goods Issues
GI for Cost Center Planned Pickup
Full/partial GI for
account
Inventory
Yes assignment with
available?
reference to
reservation
Warehouse
No
MRP
Procurement
repenishment GR for PO
Sourcing
processing
1/21/2009 92
IM Goods Issues
GI for Cost Center Unplanned Pickup
1/21/2009 93
IM Goods Issues
GI Stock Transport
1/21/2009 94
WM Goods Issues
GI Stock Transport with WM
1/21/2009 95
IM Goods Issues
Return to Vendor
1/21/2009 96
IM Goods Issues
GI for Scrap
1/21/2009 97
WM Goods Issues
WM Picking Process
1/21/2009 98
WM Goods Issues
Delivery Out of Inventory
1/21/2009 99
IM & WM Goods Issues
Changes & Challenges
Organizational impacts:
Employees must be knowledgeable of account
assignments (i.e. work order number, cost center, project
number).
Training requirements:
Inventory staff must have knowledge of appropriate
approver(s) per agency.
1/21/2009 100
IM & WM Goods Issues
Resolved Issues
1/21/2009 102
IM & WM Goods Issues
Open Issues
1/21/2009 103
IM & WM Goods Issues
GAPS
1/21/2009 104
IM & WM Goods Issues
FRICE-W Objects
Forms:
Development of pick list, issue ticket, and packing slip to include barcoded
information.
Enhancements:
Transformation of Reservations into Outbound Deliveries for triggering of
WM picking for reservations. Reservations will need to be deleted after
transformation.
Development of custom tables for status management and mapping of cost
centers to ship to addresses in regards to transformation of Reservations
into Outbound Deliveries.
RF transactions for WM picking process.
Workflow:
Approvals for Goods Issues based on Reservations as well as walk up
customers.
1/21/2009 105
IM & WM Goods Movements General
GOODS MOVEMENTS
GENERAL INFORMATION
1/21/2009 106
IM & WM Goods Movements General
Open Issues
1/21/2009 107
IM & WM Goods Movements General
Benefits & Improvements
1/21/2009 108
IM & WM Goods Movements General
Benefits & Improvements
1/21/2009 109
Materials Requirement Planning
MRP Run
1/21/2009 110
Materials Requirement Planning
MRP Run
1/21/2009 111
Materials Requirement Planning MRP Run
Key Decisions
1/21/2009 113
Materials Requirement Planning MRP Run
Changes & Challenges
Training requirements:
MRP Controller training to involve both system
training and forecasting analysis training.
1/21/2009 114
Materials Requirement Planning MRP Run
Resolved Issues
1/21/2009 115
Materials Requirement Planning MRP Run
Open Issues
1/21/2009 116
Materials Requirement Planning MRP Run
GAPS
1/21/2009 117
Materials Requirement Planning MRP Run
Benefits & Improvements
1/21/2009 118
Materials Requirement Planning MRP Run
FRICE-W Objects
Reports:
Need report listing purchase requisitions/purchase orders by
Storage Location.
Conversions:
Current Material Master MRP data
Workflow:
Approval process for Stock Transport Requisitions
1/21/2009 119
Warehouse Management
1/21/2009 120
WM Planning and Monitoring
1/21/2009 121
WM Planning and Monitoring
Changes & Challenges
Organization impacts:
Establish infrastructure for RF devices
resulting in purchase of RF guns, barcode
printers, etc.
Training requirements:
Employee training of RF devices.
1/21/2009 122
WM Planning and Monitoring
Resolved Issues
1/21/2009 123
WM Planning and Monitoring
Tasks to be Completed
1/21/2009 124
WM Planning and Monitoring
Open Issues
1/21/2009 125
WM Planning and Monitoring
Benefits & Improvements
1/21/2009 126
Inventory and Warehouse Management
Stock Taking
1/21/2009 127
IM Stock Taking
Cycle Counting
A count of all inventory items at regular intervals within
a fiscal year.
The cycle counting indicator determines the intervals of
the cycle count.
Inventory Sampling
Random selected stocks to be physically counted on a
specific date.
If the variance between the count and the book
inventory balances are within a certain range, it is
presumed that the book inventory balances are correct
for all other items.
1/21/2009 129
IM Stock Taking
1/21/2009 130
WM Stock Taking
WM Stock Taking:
Annual
Random
Periodic
1/21/2009 131
WM Stock Taking
1/21/2009 132
IM & WM Stock Taking
1/21/2009 133
IM & WM Stock Taking
1/21/2009 135
IM Stock Taking
Cycle Counting
1/21/2009 136
IM & WM Stock Taking
Changes & Challenges
Policy impacts:
1/21/2009 137
IM & WM Stock Taking
Changes & Challenges
Organizational impacts:
The establishment of RF device infrastructure including
purchase of RF devices, barcode printers, etc.
Training Requirements:
Train personnel on use of RF device.
1/21/2009 138
IM & WM Stock Taking
Resolved Issues
1/21/2009 139
IM & WM Stock Taking
Open Issues
1/21/2009 140
IM & WM Stock Taking
Benefits & Improvements
1/21/2009 141
IM & WM Stock Taking
FRICE-W Objects
Reports:
Enhancements:
1/21/2009 142
Organizational Impact Summary
Establishment of Controlled Work Group as owners/maintainers of
Material Master Records who will also be responsible for the extension
of the IM & WM views to the appropriate Plants and Storage Locations.
Training of personnel
to maintain information on the Material Master view related to Inventory
Management, Warehouse Management, MRP functionality and appropriate
forecasting parameters.
on inventory functions related to MRP Area and MRP Controller duties
on use of RF devices for WM functions
1/21/2009 143
Next Steps - General
System Configuration
Unit and Confirmation Testing
Document Business Process Procedures (BPPs)
Integration Testing
1/21/2009 145
Questions?
1/21/2009 146