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The following modes of Dispensing are supported Full Container, Source Container and
Target Container however, customers can limit the modes that they want to be able to
use. In the Full Container mode, the entire container of material is used in the Batch. This
Dispensing process involves re-weighing the container to make sure that the net weight is
what is required, the container is labelled and sent to the shopfloor. The Source Container
mode involves taking some material out of the original container and then weighing and
labelling the original container for usage in a Batch. In the Target Container mode,
material is taken out from the original container and placed in a Target Container which is
then weighed, labelled and then consumed on the shopfloor. In some industries, there
maybe regulations against using material which is not in its original container, thus
prohibiting this Dispensing mode which may then be disallowed in the Dispensing.
Dispensing can be done not only for ingredients used in a Batch, but also for materials
issued for a process, for example, filters maybe dispensed for filtration process in a
Biotech environment.
Once Dispensing has been done, the dispensed material cant be used in any other batch,
it has to be used in the particular Batch or Operation it was dispensed for. Thus, checks
are put in the system so that once an ingredient in a Recipe is defined for Dispensing,
there is a check to ensure that there is a Dispensing record associated with that ingredient
before it allows it to be consumed in the Batch. When a Batch is cancelled, ingredients
dispensed for it can be used in another batch provided regulation permit. To do this, the
batch must be reversed dispensed and the ingredients re-dispensed for the other batch.
Dispensing does not create an Inventory transaction and happens at the same
subinventory that the ingredients are being consumed from in a Batch. The Dipensing
operation does not decrement Inventory although a Dispense record is associated for that
quantity. The inventory is decremented only when the material is consumed in the Batch.
Currently, the Dispensing functionality does not support Dispense Areas comprising of
Dispense booths having their own subinventory where ingredients would be moved from
the Stores to the Dispense area/ booth for Dispensing and then to the shopfloor. This is
earmarked for furure releases. Also, Dispensing currently supports only pre-weighing a
single ingredient. Although, mixing two or more ingredients and then dispensing them
out in a formulation, maybe presently modelled as a Phantom in the main batch, this is a
future enhancement known as Pre-Mix Dispensing. Some of the other future
enhancements in the Dispensing area are
Dispensing supervisor workbench
Reusable container management
The Batch Process Flow
The process flow for a Batch between the existing OPM Process Execution functionality
and the new Dispensing functionality can be depicted in the responsibilities of the
different Users as follows Process Engineer/Formulator - Creates and maintain recipes and advanced process
instructions.
actual material transactions, Records process parameter actual values, Creates quality
samples
Dispensing Operator - Performs dispensing tasks, Performs reverse dispensing
Dispense Example
In this Note, the setup and processing illustrating the Dispensing functionality is done for
Organization LA1 and thus all the setups are done in this organization. The Dispense
ingredient is Item 8804 (Stearic Acid) for Recipe 8301.
The Dispensing
rules can be
setup specific to
an Item, ItemOrg or for ItemOrg-Recipe
combination.
In the rule
hierarchy, a
more specific
rule takes
precedance over
higher level
rules.
The Dispense
UOM needs to
be convertible to
the formulation /
batch UOM.
The Dispense Required field would be Yes. However, this can be No when doing a
data load initially and be changed later on.
When dispensing, the system allows multiple partial dispenses below the lower tolerance,
but over-tolerance dispensing is not allowed.
The start-date needs to be specified to indicate when the rule becomes effective.
(iii) Setting up a Container Item
When performing Dispensing, a Source and Target Container needs to be selected. Thus,
at least one Container Item type needs to be setup in order to define a tare weight for the
container. Container management (e.g, container status- whether clean or not, reusable
etc.) is not available currently, but is earmarked for the future.
Container - checked.
Container Item
DKPCONT1 is
assigned to
Orgn: LA1.
For Dispensing,
Device Type =
Scale.
The Subinventory
defined here is
where the
ingredients will be
consumed from.
An Output Method of API also needs to be specified for the Device for it to be used
for Dispensing.
Although the Device definition is a part of the Warehouse Management System (WMS), a
separate license is not needed to access this form. The WMS User Guide would have
further details on the other fields on this form.
(v) Assigning Device to Business Events
This Device needs to be associated with the following Business Event in the Dispensing
organization Process Dispensing Event. (The other Business Event used by the MES
Operations module is Process Parameter Event.This is used to capture process
parameters e.g, temp., pressure, r.p.m, etc.). These are the two events for which the
device integration has been enabled to capture actual values.
The Device has
to be Enabled,
Auto Invoked
and have the
Verification
Level Required
set to
subinventory
In the current
example Recipe
8301 has a dispensable ingredient 8804.
Note the Dispensable flag checked for the ingredient 8804. This checkbox is not
updateable and is based on the Dispensing rules setup.
(ii) Dispensing currently requires that a detailed reservation exists prior to Dispensing,
i.e., a Lot needs to be specified for the ingredient. Only the Production Supervisor
currently does this, in future releases, a new responsibility Dispense Supervisor
would be available for this.
Creating a detailed reservation for the ingredient lines could be done either individually
for each line via Reservations or for the entire batch via Auto Detail Batch which
reserves all the ingredient lines on the batch by assigning their qtys to lots.
On the Tool bar: Inventory > Auto Detail Batch
All the
items
except the
Item 8804
have been
consumed
on the
Batch.
The View Material Transactions screen (Tool bar: Inventory > View Material
Transactions) is as follows -
(iv) Next, Release the first few Steps on this Batch so that the Operators can work on
them.
On the Batch Detail form: Steps > Actions > Release Steps:
Select the Dispense Item via the radio button and click on Dispense. This brings up the
Dispensing screen.
Entering in the Source Container, populates the Container Tare wt. and the Gross wt. of
dispense material.
2.
Label print request IDs 1053 and 1054 were submitted successfully.
The Label
Print request
Ids are output
files that are
available for
3rd party
labelling
software to
print labels.
This screen
also shows
that the
Pending
Dispense
Quantity for
Item 8804 is
now zero.
Production
Supervisor Responsibility: Transact Dispense Mtl. / Complete Batch
Now that the Item 8804 has been dispensed on the Batch 54003, this material can now be
transacted on this Batch and the Batch completed.
(i) Query up the Batch using Production Supervisor Responsibility >
This screen shows that Item 8804 has a Reserved Qty of: 330 LB.
This qty has now been dispensed to this batch and can be consumed in it.
(ii) [Transact Material] brings up the Material Transaction form indicating
that Item 8804 still has qty 330 LB yet to be transacted.
(iii) Checking the Transact check box and Transacting the Item 8804 consumes it in the
Batch 54003.
This Batch can now be Completed using the existing standard Process Execution
functionality.
REFERENCES