Requirement

AMVOP would like to implement the WMS in their business and would like to do some configurations to achieve the below workflow:

Flowchart:

NetSuite WMS Barcode SOP:

1. Receive items from vendors with multiple UOM & after QC approval:
   1. Once the items arrive at the store, the storekeeper will submit the PO for QC approval.
   1. QC staff will then receive the approved quantities in the inbound staging bin, either in pieces or pallets if it is predefined in the item record. As they receive, they must print the item or pallet label. The label should mention the item, item description, quantity, UOM, inventory status, lot name, and expiry date.
   1. The storekeeper will use putaway to move the items from the inbound staging bin to the store bin by scanning the barcode, and it can be done either in pieces or in pallets. The storekeeper will then have the option to pack items with pieces UOM in pallets and print pallet labels for each pallet.
   1. If needed, the storekeeper will use pack station to unpack the pallets and restore the pieces quantities.

• The production manager will create a transfer order to assemble the open work orders.
• The Storekeeper will then fulfill released Transfer Orders by using the quick ship and by scanning the pallet’s barcode and without entering any quantity or lot information, just by scanning the pallet label or item label, the pallets or the item quantity is fulfilled.
  • Lot status must be Good.
  • The fulfillment can be in multiple UOM (pallet, carton, pieces…. etc.).

• The Production Manager will then receive the items from the transfer order also by scanning and without entering any quantity or lot information.

• Once the items are inside the WIP location, the Production Manager must then allocate (pick) the items for a specific Work Order. We need to allocate the PO to its related WO.

• Production Manager will then use enter completion with backflush on NetSuite.
  • The items at this stage are packed in boxes and then placed on a pallet. We need to print a carton label and pallet label.

• The Production Manager will then create a Transfer Order and fulfill the assembled items to the FG warehouse (can be done in multiple UOM) by scanning the barcode and without entering any quantity or lot information.

• The Warehouseman will then receive the assembled items by using the barcode and without entering any quantity or lot information.

• The warehouseman will then submit the SO for QC approval.

1. The QC staff will fulfill only the approved quantity in the outbound staging bin by scanning the barcode.

1. The warehouseman will pick the approved items from the outbound staging bin on the truck by using the barcode.

1. Once the truck is fully loaded, the Warehouseman will then enter the delivery order information (courier, driver name & license, truck plate number…etc.) and then ship the whole truck’s quantity to be able to print the Delivery Order for this truck.
   1. It is more convenient to have the delivery order information on the SCM mobile app. Please study the possibility.

Notes:

• We must be able to receive items from vendors in multiple UOM (Piece, Pallet, Kilo…. etc.).
• We must specify the quantity of pieces in each pallet when receiving them from vendors.
• We need to transfer items between locations in multiple UOM (Piece, Pallet, Kilo…. etc.).
• We must allocate items to WOs from the related PO.
• We must pick items to SO from the related WO.
• The barcode must contain inventory status, lot number, quantity and UOM so we can immediately fulfill or receive without entering a quantity, just by scanning.
• When shipping to customers we need to ship the whole truck to print one delivery order per truck. Not with each pallet.
• We will use auto-generated carton and pallet numbers, it is based on the PO number (example PLT-PO-XXX, CTN-PO-XXX. XXX represents PO number).
• We will use auto-generated lot number when receiving from vendors and based on the PO number (example PO- XXX. XXX represents PO number).
• This will be applied for both AMVOP & AMMP.

Solution

Prerequisite Set Up for Adding Print Option

Print Functionality

Analysis on Print Node Functionality

We did analysis on Print Node software and WMS settings on how the system has been integrated.

Also, we checked whether it is possible to have a manual printing option in the WMS.

NetSuite WMS integrates with Print Node, a third-party provider of hosted printing services. Through computers installed with the Print Node client, Print Node can access the printers set up on your computers. We can submit your mobile print requests through Print Node, which manages the requests and routes them to the appropriate printers.

Enabling Mobile Printing

We need to enable the mobile printing functionality in NetSuite to enable the print node integration done between NetSuite and Print Node software. While enabling the mobile printing option, we will be adding the print Node system devices and software connection URLs to access the software.

• Print Node URL for View Printers API – In case Print Node changes their default URL, enter the new Print Node URL for the view printers API.

This API enables you to retrieve the list of printers.

• Print Node URL for Create Print Job API – In case Print Node changes their default URL, enter the new Print Node URL for the create print job API.

 

Print Security Setting

We need to set up the print security settings in the sandbox by adding the IP address and Printer API keys

Label Printing Set up

In the label printing set up, we must select the and in the printer type field, we must select either Report or Label. All type option is also available 

SCM Mobile customization for Print Button for item label printing

We need to customize the mobile pages to display the print button in the Item quantity entering page as shown below:

When user clicks on the print button, the user will be navigated to following popup:

Here the user can select the printer and template and the print will be delivered to the print node software.

 

WMS configuration to achieve Print option

We need to enable the rules to achieve the following cases:

• Enable Warehouse management system rule  
• Enable the label printing option to activate the third-party integrations

Prerequisite Set Up for NetSuite configuration customization 

 
Auto Carton and Pallet generation  

 

In the packing station, we can assign auto generated numbers for pallets and cartons. We can auto generate the PO number for carton by NetSuite configuration customization. 

Pallet Number:

The auto generated pallet numbers will have a prefix as PLT-PO- along the order # will be used.

• (Example PLT-PO-XXX, PO-XXX. XXX represents PO number).

Carton Number
The auto generated carton numbers will have a prefix as PLT-PO- along the order # will be used.

• (Example CTN-PO-XXX. XXX represents PO number).

 

Auto lot number generation 

We can auto generate po number though customization or whatever values from the transaction id form, but we cannot add prefixes to lot numbers by WMS customization

Receive Items from Vendors

We assume that the purchase order is already created in the NetSuite. Once the items are arrived at the store, the items will be received to the inbound staging Bin.

Multiple Unit of Measure Handling

Purchase orders can be received to the warehouse with multiple units of measure as pallet, pieces, each, etc. The conversion rates should be defined in the unit of measure records in the NetSuite. The quantities will be updated dynamically according to the unit of measure defined in the UOM records.

As we have discussed, if the quantity per pallet is varying every time, we must use the tally scan feature of the WMS. In this, the user must scan each individual items in the pallet every time. Here, every time an item is scanned the quantity received will be increased by a quantity 1. Then the total quantity received will be updated dynamically.

If the quantity per pallet can be predefined, the user can select the pallet option the dropdown available (illustrated in below screenshot) for unit of measure selection in the SCM Mobile and the quantity will get dynamically updated.

QC Approval Stage

To implement the QC approval stage in the WMS, we will be using the Staging Bin functionality. Once the items are received in the inbound staging bin it is considered under inspection, and whatever is transferred through Bin Put away to the picking bins will be considered the QC approved quantity.

Here, all the items received will be received to a staging bin and warehouse people must do Bin Put away option in WMS mobile for bin transfer it to the picking Bins by pieces or receiving units and not in pallets.

Transfer order creation 

The user will be creating a transfer order in NetSuite UI for all the items received in the warehouse and save the transfer order number. 

We can generate a transfer order barcode for the scanner to scan the transfer order number. After picking the transfer order items, the item fulfillment records will be created with picking status. 

Fulfill Items from the Store 

Picking of the item  

We will remove the label from unreleased items in the picking stage. In the picking stage there are options to see released and unreleased status items. We can create a “Wave” record for setting transaction status. 

Wave  

A wave transaction is used to consolidate orders for release to the warehouse. When you release a wave, the items from the order become available for picking and further fulfilment processing on a mobile device. Released waves display pick tickets and pick tasks generated from items in the orders, as well as status updates that enable tracking of fulfilments tasks. 

We will be customizing the “Select Picking Mode” page in the SCM mobile picking function to remove the “Unreleased option” in the page in order to bring the approval staging option in the supply chain management problem.

Packing of the item fulfilment

We will be enabling the pallet and carton number auto generation feature to auto generate the number while fulfilling the orders.

We will be packing the cartons to the pallet. When the user enters the packing details of the cartons, user will get an option to add the cartons to the pallet.

Here we will be using the pack station app in the NetSuite WMS for packing the item into the pallet.

Pallet label printing

We will be configuring the WMS for printing the pallet label from the SCM mobile.

QR code of the pallet label will be generated with the following fields associated with each item:

• Item Name
• Item Description
• Lot number
• Quantity
• Inventory Status
• UOM
• Expiry Date

Note: Here we will be assuming that only one item will be packed in the pallet.

QR code Generation

The .XML files are used in the following advanced PDF templates:

• Standard WMS Item Label PDF Template
• Standard WMS Pallet Label PDF Template

We can copy these advanced PDF templates and customize your copy according to our printing requirements.

QR code will be generated with the following fields associated with each item:

• Item Name
• Item Description
• Lot number
• Quantity
• Inventory Status
• UOM
• Expiry Date

Report Type

We will creating a custom report type for the custom pallet label printing and define the source records for the values that to be used in the PDF template

PDF Template Sourcing

We will be using the WMS auto evaluation data custom record as the source record for the label template sourcing

Custom PDF label template

We will be creating custom PDF template for printing the QR code from the Enter quantity page in the SCM mobile. The label will be printing per item, and it can be attached to pallet containing the item only.

Create a custom template custom record

Once the template is ready, we must create a custom template record and provide the print-template path to the template file.

Shipping items

We will be using the quick ship option in the NetSuite WMS for scanning the pallet label and create the item fulfilment record with shipped status

Scanning the pallet label has been added in the WMS page as shown above.

The scanned pallet label can be used for shipping the orders and make the item fulfilment status to shipped status.

Receiving the transfer order

We will be implementing a custom icon in the WMS app and user will have the flexibility to scan the pallet label and enter the transfer order.

Custom icon in Main Menu 

In WMS, we will add an icon in Main menu page as shown below. On clicking the “Receive TO with QR code” icon, the user will navigate to a custom(suitelet) page on another tab.  

Scanning Page 

We will be implementing a suitelet script to scan the QR code of the pallet. There will be a field available on the page to enter the transfer order details. We will be setting up a button in the suitelet page “Scan QR code” and a popup button will appear while clicking the button.

When the user scans the QR code, we will be using the data enclosed in the QR code for creating the item receipt for the transfer order selected in the popup window.

Note: Page will be loaded in another tab. 

On clicking the Upload button, the Item receipt record corresponding to the transfer order will be created

Work Orders Picking

Once the items are inside the WIP location, the Production Manager must then allocate (pick) the items for a specific Work Order. Managers need to allocate the PO to its related Work order. Then release the work order for picking and all these steps need to be completed in NetSuite UI.

Picking Component Items for Work Orders

Use your mobile device to pick component items for released work orders. If you use the Manufacturing Work in Process (WIP) feature, you can also pick component items for WIP-enabled work orders. However, you cannot use the mobile device to build assembly items for WIP-enabled work orders.

Building Assembly Items for a Work Order

For WIP enabled work orders the enter completion with Backflush and issue components steps will be completed from NetSuite UI.

NetSuite records a completed assembly build on the work order and assigns the work order to “Built” status. It increases the assembly item’s stock level in the storage bin location where you put it away. It also decreases the component items’ individual stock levels in the work-in-progress (WIP) bin from which you built the assembly.

Fulfil Second transfer order for transferring assembly build from WIP location to Finished store

Users must scan individual items using tally scan feature and add the components to the pallet while packing the order.

Again, the process will be like the steps mentioned above.

 

Automatic Lot number generation in work Order Completion record with a sales order number as suffix

There is a script running in the SB and production account to auto generate lot numbers for the items in the work order completion record.

We will be updating the following script

Script URL: Script – NetSuite (Arab Malaysian Vegetable Oil Products – AMVOP)

In the script, we will be adding a suffix to existing lot number generated automatically for each work order completion record. The suffix will be the sales order number populated in the corresponding record as highlighted in the screenshot below:

The body level inventory detail sub record field will be updated.

The auto generating field is highlighted in the screenshot below:

Delivery Information entry during item fulfilment record creation with shipped status

The delivery information entering while creating the item fulfilment record need to be entered by the user in NetSuite UI. If it is required to enter in the SCM mobile, we must develop a new page in WMS app as shown below:

In WMS, we will add an icon in Main menu page as shown below. On clicking the “Enter delivery information” icon, the user will navigate to a custom (suite let) page on another tab.  In this page, user can enter the field details and can select the item fulfilment record and these details will update in NetSuite after submitting the form

Delivery information entry from SCM mobile to NetSuite will be out of scope of this proposal and will be submitted as a separate one.

Assumption

1. Pack Station supports the following types of transactions and items:

Sales and transfer orders in Pending Fulfilment status

• Fulfilment records associated with the orders must be in Picked status.
• Fully and partially picked orders are supported.
• If you use the Warehouse Management feature, you can pack orders released in wave transactions after you pick them using your mobile device

            Items must belong to the following supported item types:

• Inventory and assembly items, including, matrix, lot numbered, and serialized items
  • Kit/package and non-inventory items (for sale and for resale only)
  • For Warehouse Management, order transactions that contain only non-inventory items cannot yet be packed for warehouses with bins.
  • Item groups

• We assume that the device will have option to scan the barcode
• User will select the transfer order record on the suitelet page
• The page will be responsive to all screens. 
• Device should support to open link in the browser 
• We assume that assembly, inventory, and lot numbered items are there
• Inventory status needs to be entered by the user in the SCM Mobile
• User will have Transfer order number to receive the pallet

Risk

• Items in the pallet might be damaged and we are not validating the same while receiving the transfer order
• Suite let pages concurrency limit will be there
•  Assume that the expired items will not be picked up in the pallet
• ·         We will not be validating the expiry date of lot items
• ·          Role customization will not be considered in this scope of development
• We have not considered the multiple items in one pallet
• Multiple item receipts might be creating for transfer order as we are creating item receipt for each pallet
• Approval process in NetSuite UI is not possible in the SCM Mobile
• Custom solution used in the solution are the steps to receive the TO by QR code scanning, delivery information entry and QR code generation.
• We depend on the NetSuite WMS standard features and any enabling of features like fulfilment request might affected the WMS feature.

Milestone – II: Time

80 Hours

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