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Making it Work Together

Why Manco Systems ?

Interface with MANMAN

Understanding of Bullard’s Needs

Willing to Modify ManBar System

Completeness of System

• Lean Manufacturing Company

• No Work Orders

• No Finished Goods Inventory

• Product Built to Customer Order

The Requirement

• A system that would compliment Bullard’s process

• From Order Entry

• Through Production

• To Ship and Invoice

The Process

Nightly Job Stream

OM UT,205 Copy Sales Order Demand to the Order Demand File

OM UT,886 / OM UT,001Brings Sales Order Demand from MANMAN to the ManBar Database.

Schedule created using Crystal Reports (by work center)

Entering the DataVia Telnet

ManBar Main Menu

1. Receiving Menu

2. Shipping Menu

3. Reports Menu

4. Reprint Labels

5. Utility Menu

0. Exit ManBar

Entering the DataManBar Shipping Transaction Menu

Barcode Printer

1. Fire

2. Shipping

3. CC20

4. Deco

5. Head Protection

6. Imager

7. Respirators

Entering the DataShipping Transaction Menu

1. Request a New Sales Order Pick List

2. Pack A Sales Order

3. Receive into Staging

4. Resale

5. Release to Shipping

6. Ship / Invoice a Sales Order

7. Void a Sales Order

8. Change a Order Quantity on a Sales Order

9. Transfer Sales Order from Staging Location

10. Retry Ship / Invoice

0. Exit Shipping Menu

How the Packaging Label Works

Sales Order Number

Sales Order Line Item

Part Number

Quantity being produced

Quantity per carton

What one must know:

The Schedule

The Packaging Label

Sales Order

Customer Purchase Order

Bullard Part Number

Serial Number (if serialized)

Customer Part Number

Unique Package ID

The Packaging Label(s)

Every Packaging Label has a unique Package ID

The Packaging Label

As the Schedule is scanned there is abackflush transaction being performed for the quantity being packed.

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Updating of Finished Goods Inventory

andDecrementing of Raw

Material Inventory

Consolidating Parts

When Finished Goods are produced and Packaging Labels are created, the product is moved to shipping.

Sales orders with just a single line item are moved toa conveyor for immediate UPS processing.

Sales Orders with multi-line items are consolidated on the shipping floor.

The shipping floor is an alpha numeric grid

Single Line Item Label

Single Line Item Labels are denoted by a series of ****** on the label.

If all items on a Sales Order ship but one, that line item becomes a Single Line Item.

Entering the DataShipping Transaction Menu

1. Request a New Sales Order Pick List

2. Pack A Sales Order

3. Receive into Staging

4. Resale

5. Release to Shipping

6. Ship / Invoice a Sales Order

7. Void a Sales Order

8. Change a Order Quantity on a Sales Order

9. Transfer Sales Order from Staging Location

10. Retry Ship / Invoice

0. Exit Shipping Menu

Consolidation

When the Sales Order is scanned from the Pack Label the Scanner will denote if there are other line items already staged.

In this case other line items are staged in Location H16. The only available Package ID to scan is 910972160543.

Consolidation

The Package ID is scanned. It states that the current Staging Location for this Sales Order is H16. Continue <Y/N>

The program will allow a different Staging Location if desired (filled up).

Otherwise, continue and place the part in the location.

Ready to ShipWhen all of the parts for a Sales Order are complete and Staged or a decision to ship is made, a Delivery Note is produced.

When the last part is Staged on a Sales Order, the Delivery Note will automatically print.

If the Sales Order is to ship incomplete, a Delivery Note is requested through ManBar.

Delivery Note Report

Entering the DataShipping Transaction Menu

1. Request a New Sales Order Pick List

2. Pack A Sales Order

3. Receive into Staging

4. Resale

5. Release to Shipping

6. Ship / Invoice a Sales Order

7. Void a Sales Order

8. Change a Order Quantity on a Sales Order

9. Transfer Sales Order from Staging Location

10. Retry Ship / Invoice

0. Exit Shipping Menu

Release to Shipping&

Ship and InvoiceRelease to Shipping Transaction

Scan to double check that insures all product is accounted for and ready to ship

Ship and Invoice

Consists of simply scanning the Sales Orderand answering the prompt Ready to Ship <Y / N>

Entering the DataShipping Transaction Menu

1. Request a New Sales Order Pick List

2. Pack A Sales Order

3. Receive into Staging

4. Resale

5. Release to Shipping

6. Ship / Invoice a Sales Order

7. Void a Sales Order

8. Change a Order Quantity on a Sales Order

9. Transfer Sales Order from Staging Location

10. Retry Ship / Invoice

0. Exit Shipping Menu

Other Shipping Menu ItemsRequest a Sales Order

Used when changes/adds are made to a S.O.Updates ManBar Database

ResaleSome product is Purchase for Resale. Follows same path except no Backflush

Void a Sales OrderUsed for S.O. CancellationsReverse Backflushes

Other Shipping Menu Items

Change a Order Quantity on a Sales Order

Transfer Sales Order from Staging LocationAllows Shipping to Change Staging Locations if necessary

Retry Ship / InvoiceAllows re-play of Ship/Invoice Transaction

Reports

ManBar is compatible with Crystal Reports

Daily Schedules

Staging Location Report

Transaction History Report

Package ID Report

Shipping Status Report

Elimination of Waste

Scan to Backflush No Data Entry Error

Scan to Consolidate PartsEliminates Manual System

Scan to Accumulate Parts for ShipmentInsures Parts are Available to Ship

Scan to ShipScan the Sales Order and Entire Order is Shipped / Invoiced

What Else

Receiving System

Creates labels and receives parts into either Stores or Inspection.

Cycle Count System

Will be using this week for Physical Inventory