P1259108127gBGAf

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Error Proofing - ReceivingScanning To Receive
MMUGMarch 21, 2005
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Challenges

• Lots of potential for error at the receiving
  dock
• Incorrect quantity recorded
• Incorrect part number recorded
• Receipt not entered
• Receipt entered more than once
• Reduce time spent processing receipts
• Validating receipt quantities
• Handling paperwork
• Processing payment

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Tools Available

• Supplier labels
• Advance Shipping Notices (ASNs)
• Shop Floor Technology
• MFG/PRO Evaluated Receipts Settlement (ERS)

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Process Overview
MFG/PRO
ASN Sent - PO Shipper Create
Supplier Ships
Receipt Discrepancy Report
AP Processing (ERS)
Receipt Transactions Processed
Quantities Compared
Material Arrives w/ Paperwork
Labels Are Scanned
PO Shipper Confirm PO Receipts
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Prerequisite 1 Supplier Labels

1. Publish a label specification see AIAG
   standards for information guidelines
2. Require supplier to start labeling to the spec
3. Enforce the standards via the supplier quality
   process

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Prerequisite 2 Supplier ASNs

• Publish an ASN specification see AIAG for
  information and guidelines
• Create technology to receive and process ASNs
  consider both EDI and web-based approaches
• Work with the suppliers to implement
• Note the scan to receive process should allow
  for receiving both with and without an ASN

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Prerequisite 3 Shop Floor Technology

• Use RF terminal technology
• Support both ASN and non-ASN scenarios
• Support multiple POs per inbound supplier
  shipment
• Validate part number / PO combination (use start
  end effective dates)
• Compare total quantities scanned to ASN or
  packing slip quantity by part number

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Prerequisite 3 Shop Floor Technology

• Allow for additional scanning if labels were
  missed
• Allow operator to start over
• Provide ASN look up from MFG/PRO
• Provide look up summary of quantities scanned
• Consider how to handle the MFG/PRO down scenario

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Lets Follow The Flow ..
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Step 1 Fill In The Header Information

• Receiver Number press Enter to generate a new
  receiver number. (Enter a Receiver number if you
  wish to resume receiving against a previous
  receiver or delete the receiver F8)
• Supplier Code scan the supplier code from a
  label.
• ASN - If the suppler is generating ASNs, enter
  the ASN number. (This is typically the BOL or
  packing slip number.) Press F3 to generate a
  list of ASNs from which to pick.
• Packing Slip will automatically be populated
  when an ASN is present. If no ASN is available
  enter the number from the packing slip.
• All info Correct? enter Y to continue or N
  to change the information on this screen.

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Header Information ASN Messages
Error message displayed if the ASN entered is not
valid. Press Esc to acknowledge the message
If an ASN is not entered and one is expected this
message is displayed. Enter N to re-enter the ASN
number or Y to continue without an ASN.
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Step 2 Scan The Container Labels

• For each label in the inbound shipment
• Serial - scan the serial number or Kanban
  number from the label. (A unique serial number
  is created using the supplier code and is then
  displayed.)
• Part Number scan the part number from the
  label.
• P.O. Number enter the PO number (this is not
  prompted for once it is entered or retrieved from
  the ASN)
• Packing Slip Qty the part quantity from the
  packing slip (this is not prompted for once it is
  or retrieved from the ASN.)
• Label Quantity scan the quantity from the
  label.
• When all labels have been processed press the Esc
  key.

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Step 2 Scan The Container Labels
Note 1 - the last serial number scanned is
displayed on the screen for reference
purposes. Note 2 when receiving without an ASN
press the F2 key to change either the PO number
or packing slip quantity Note 3 - press the F6
key to display a summary of the part numbers and
quantities scanned.
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Step 3 Upload Information

• Press Esc again to upload the receiver to
  MFG/PRO.
• Enter N to return to the label scanning process.

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Receipt Upload Quantity Validation Messages
Error message displayed if the quantities scanned
do not equal the ASN or packing slip
quantities. Enter N (or press Esc) to return to
label scanning. Enter Y to accept the discrepancy.
Message displayed to confirm that the quantities
scanned have checked against the ASN or packing
slip. Press Esc to send the receipt to MFG/PRO.
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Receipt Processing In MFG/PRO

• One receiver is generated for each PO received.

50 labels _at_ 12 pieces per were label scanned
Note the 5.13.1 Packing Quantity field is
populated with the packing slip qty entered by
the operator
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Error Proofing

• Data identifiers in bar code fields are used to
  insure correct field is being scanned
• Part number from label validated against PO
  ASN
• Quantity from label totaled by part number from
  labels scanned
• Each label can be scanned only once tracked by
  supplier serial number
• Part number quantities compared to ASN (or
  packing slip) operator notified of
  discrepancies
• Transactions are entered into MFG/PRO
  automatically

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Lessons Learned

• Create reports that summarize data scanned for
  each receipt
• Dont under estimate the challenges involving
  supplier label compliance
• ASN testing takes time
• Consider using Master labels for pallets of
  totes/boxes to speed up the scanning process