Crossdock Planning & Execution

Documentation

Release 12

White Paper Jan 29th 2007

Page 1 of 95

Main Objectives: The main objective of this document is to show basic setups required for cross docking (Release 12) and has examples of some flows that will give any user an head start in using the functionality. Primary Author: John Changaramangalam The information contained in this document is subject to change without notice. If you find any problems in the documentation, please report them by e-mailing john.chankaramangalam@oracle.com. Special Thanks to Harry Herman (Support Manager), Madhu Punugati (Product Management) , Anand Nallaalaghu (QA Manager), Gopal Rao (Development), Lydia Chen (Program Management) , Support team & Development team.

Page 2 of 95

Table of Contents

Overview Of Crossdocking...................................................................................................................... 4 Planned Crossdocking:........................................................................................................................ 5 Planned Cross Docking With PO as Supply and SO as Demand: ......................................................... 6 Planned Cross Docking With ASN as Supply and SO as Demand: ..................................................... 27 Planned Crossdocking: ........................................................................................................................ 28 Opportunistic Crossdocking: ............................................................................................................ 52 Opportunistic Crossdocking with Sales Order as Demand & PO as Supply: ...................................... 53 Opportunistic Crossdocking with WIP Component Demand: .............................................................. 72 Cross dock exceptions: ...................................................................................................................... 89 Planned & Opportunistic Cross Docking: .............................................................................................. 91 Crossdocking and Change Management :........................................................................................ 92 Debugging Issues:............................................................................................................................... 95

Page 3 of 95

Crossdock Planning & Execution Overview Of Crossdocking Crossdocking allows warehouses to increase its operational efficiency by transferring inbound material directly to an outbound area. It bypasses the inventory-holding function of a warehouse while still allowing it to serve its consolidation and shipping functions. With this feature, crossdocking can be planned in the warehouse. The system can identify crossdocking opportunities in the warehouse by comparing expected receipts and outbound shipments. When a crossdocking opportunity is identified, the scheduled inbound receipt(supply) is pegged to the outbound shipment(demand) using crossdock criteria. A specific inbound receipt is identified based on whether the warehouse wants to maximize crossdocking or minimize wait time or minimize fragmentation. In case of Planned crossdocking the pre-allocation is done during Pick Release. In opportunistic crossdocking dynamic allocation is done during material putaway.

Page 4 of 95

Planned Crossdocking: Step Planned Cross Docking Setup PreReqs Prerequisites Required WMS should be

setup up. PCross 1 Define a Planned Crossdock Criteria PCross 2 Define Item PCross 3 Setup Crossdock criteria assignment PCross 4 Create Crossdock Opreation Plan PCross 5 Order Management & Shipping Parameter Setup PCross 6 Create Purchase Order and Sales Order PCross 7 Run Pick Release PCross 8 View Reservations PCross 10 View Sales Order From Shipping Transactions PCross 11 Perform PO Receipt PCross 12 Verify Planned Cross Dock task PCross 13 Execute Cross Docking Scenario: In this example we will show how Planned Crossdocking happens for a PO as supply and Sales Order as Demand. We will define an item and assign it to organization W1. Then we will create a PO for the item for qty 20. Create a Sales Order for the item for qty10. Run pick release with allocation method as Cross Dock Only. Then we review the reservations created. Then we execute the cross docking.

Page 5 of 95

Planned Cross Docking With PO as Supply and SO as Demand:

PREREQS Prerequisites Required Complete all WMS setups. PCross 1 Define a Planned Crossdock Criteria Responsibility: Warehouse Manager Navigation: Setup Warehouse Configuration Rules Warehouse Execution Crossdock Criteria

Planned Crossdock is demand driven and prior to arrival of the material, demand is planned to be fulfilled using incoming supply. In the above example we are creating a planned crossdock criteria by the name CJP CROSS DOCK PLANNED. Crossdocking Time fences - Identify eligible supply sources (for planned crossdocking) or eligible demand sources (for opportunistic crossdocking)

Crossdock Window (CW) : Wait Time Order Processing Time (OPT) : Load/unload/move Time Buffer Time (BT) : Safety margin Past Due Supply Cut-off (PDS) : To exclude uncertain supplies

Page 6 of 95

Crossdocking Goal - Choose one or more supply (or demand) sources from the pool of eligible supply (or demand) sources

Maximize Crossdock (FIFO) Minimize Wait (LIFO) Custom

Determine expected arrival time for supply Dock appointment time Planned arrival date Expected receipt date Shipped date + Transit time Promise date Need by date

Determine expected departure time for demand Dock appointment time Planned departure date Schedule ship date Promise date

Planned Crossdock Backward scheduling Current Time - 11:00

Scheduled Ship time for demand 16:00 Order Processing Time = 1 Hr

Buffer Time = 1 Hr Crossdock Window = 2 Hrs Past Due Supply Cutoff = 0.5 Hrs

Latest arrival time for a supply to be crossdocked = Scheduled Ship time for demand ( Order Processing Time + Buffer Time) = 16:00 (1+1) = 14:00 Earliest arrival time for a supply to be crossdocked = Latest ar rival time for a supply to be crossdocked - Crossdock Window = 14:00 2 = 12:00 PDS Cross Dock Window BT OPT 10:30 11:00 12:00 13:00 14:00 15:00 16:00 17:00

Page 7 of 95

Eligible supplies for planned crossdock PO, ASN, Internal Requisition, In-transit shipment, Receiving Eligible demands for planned crossdock Sales Order, Internal sales order

Page 8 of 95

PCross 2 Define Item

Responsibility: Warehouse Manager Business Approach: Navigation: Setup Material Setup Master Items

Define an Item and assign it to child organization where you will be doing the transaction. In our example we have defined item testplnxdocitem.

Page 9 of 95

PCross 3 Setup Crossdock criteria assignment Responsibility: Warehouse Manager Business Approach: Navigation: Setup Warehouse Configuration Rules Warehouse Execution Rules Workbench

Two new Rule Types are introduced in R12. Planned Crossdock & Opportunistic Crossdock. In out planned cross dock test we will select Planned Crossdock type. We create a new assignment with a sequence number. Lower the sequence higher the precedence. In our case we have assigned sequence 5 . Then we have selected the cross dock criteria we had defined (CJP CROSS DOCK PLANNED). We select organization (W1) and select the crossdock planned item (testplnxdocitem). Select Always in the Date Type column. Check Enabled. Note: Always remember to run Generate All Rules Concurrent program after you have defined any new rule or made changes to existing rule.

Page 10 of 95

Navigation: Other Requests Requests Run

Page 11 of 95

PCross 4 Create Crossdock Operation Plan Responsibility: Warehouse Manager Navigation: Setup Warehouse Configuration Warehouses Operation Plan

On operation select Cross dock. In cross dock method select appropriate cross dock method. In our example we select (Default) LPN based consolidation in staging lane within delivery. The other options are:

Locator based consolidation in consolidation locator, within delivery in staging lane LPN based consolidation in consolidation locator, within delivery in staging lane Direct consolidation in staging lane within delivery LPN based consolidation in staging lane across deliveries Direct consolidation in staging lane across deliveries LPN based consolidation in consolidation locator, across deliveries in staging lane Locator based consolidation in consolidation locator, across deliveries in staging lane

Page 12 of 95

PCross 5 Order Management & Shipping Parameter Setup

Responsibility: Order Management Business Approach: Navigation: Setup System Parameters Values

Set a value of 0 for Reservation Time Fence parameter. Note: This setting will ensure that no high level reservations are created when the sales orders are booked. This is necessary because system will not try to crossdock for the demand lines with any reservations.

Page 13 of 95

Navigation: Setup Shipping Global Parameters

For Delivery Date Calculation Method field select Scheduled Date, Requested Date value. Note: This will ensure that the Deliverys initial pickup data is correctly set as per the scheduled ship date.

Page 14 of 95

PCross 6 Create Purchase Order and Sales Order Responsibility: Purchasing Business Approach: Navigation: Purchase Orders Purchase Orders

Create a Standard PO(In our case created PO 6117). Set Ship-to and Bill-to to your organization (W1). Create a line for crossdock planned item (testplnxdocitem) for qty (20) and enter promise date with time details (10-Nov-2006 16:00:00). Once can change the receipt routing to Standard Receipt.

Page 15 of 95

Responsibility: Order Management Business Approach: Navigation: Orders, Returns Order Organizer

In our test case we created order 65333 for item testplnxdocitem for qty 10.

Page 16 of 95

PCross 7 Run Pick Release Responsibility: Order Management Navigation: Shipping Release Sales Orders Release Sales Orders

Two new allocation methods are available Cross Dock Only and Prioritize Cross Dock. We select Cross Dock Only for allocation method.

Page 17 of 95

Page 18 of 95

PCross 8 View Reservations Responsibility: Warehouse Manager Navigation: Inquiry View Reservations

We enter organization (W1) and item (testplnxdocitem). A new filed is added to reservation inquiry Include Crossdock. We check that field. Now we select Find button.

Page 19 of 95

You can see the Demand & Supply and the planned reservation for crossdock. The crossdock field shows Yes.

Page 20 of 95

PCross 9 View Sales Order From Shipping Transactions Responsibility: Warehouse Manager Navigation: Outbound logistics Shipping Planning & Transactions.

When you query up the sales order you will see that the line status is Planned For Crossdocking.

Page 21 of 95

PCross 9 Perform PO Receipt Responsibility: Whse Mgmt Navigation: Inbound Inbound Receive PO

Page 22 of 95

PCross 10 Verify Planned Cross Dock task Responsibility: Warehouse Manager Navigation: Inquiry Material Workbench

Select Inbound in source and select the various statuses.

Page 23 of 95

Under Inbound Plan select Plan Type Cross-docking.

Under Inbound tab select the purchase order (6117). Select Find button.

Page 24 of 95

You will now be able to see the crossdock plan task.

Page 25 of 95

PCross 11 Execute Cross Docking Responsibility: Whse Mgmt You can use Navigation: Tasks Directed Tasks Directed Move Move any LPN Or Navigation: Tasks Manual Tasks Manual load/Manual drop.

You will see that system directly suggests the staging subinventory/Locator , thus doing cross docking.

Page 26 of 95

Planned Cross Docking With ASN as Supply and SO as Demand: In this scenario we are going to have Supply as ASN, Demand as Sales Order Scheduled, Allocation Method= Priortize Inventory, ensuring remaining lines are allocated from cross dock supply Step Planned Cross Docking Setup PreReqs Prerequisites Required WMS should

be setup up. PACross 1 Define a Planned Crossdock Criteria for ASN PACross 2 Define Item PACross 3 Setup Crossdock criteria assignment PACross 4 Create Crossdock Operation Plan PACross 5 Order Management & Shipping Parameter Setup PACross 6 Create Supplier & Supplier Sites PACross 7 Create Supplier User & Register User PACross 8 Create Purchase Order PACross 9 Create ASN PACross 10 Create Sales Order PACross 11 Perform Alias Receipt PACross 12 Run Pick Release PACross 13 View Reservation PACross 14 View Sales Order From Shipping Transactions PACross 15 Perform Receipt for ASN PACross 16 Verify Task In Control Board PACross 17 Execute Cross Docking PACross 18 View Sales Order From Shipping Transactions Scenario: In this example we will show how Planned Crossdocking happens for an ASN as supply and Sales Order as Demand. We will define an item and assign it to organization W1. Then we will create a PO for the item for qty 10. Create an ASN for the PO. Create a Sales Order for the item for qty10. Do Miscellaneous Alias receipt for qty 7. Run pick release with allocation method as Prioritize Inventory. Then we review the reservations created. You will see that there are 2 reservations created. One for quantity 7, for the quantity available in inventory. The second for quantity 3 against the ASN. Then we execute the cross docking.

Page 27 of 95

Planned Crossdocking:

PREREQS Prerequisites Required Complete all WMS setups. PACross 1 Define a Planned Crossdock Criteria for ASN Responsibility: Warehouse Manager Navigation: Setup Warehouse Configuration Rules Warehouse Execution Crossdock Criteria

Page 28 of 95

We have selected ASN as the supply.

Page 29 of 95

PACross 2 Define Item Responsibility: Warehouse Manager Business Approach: Navigation: Setup Material Setup Master Items

Define an Item and assign it to child organization where you will be doing the transaction. In our example we have defined item testitem.

Page 30 of 95

PACross 3 Setup Crossdock criteria assignment Responsibility: Warehouse Manager Business Approach: Navigation: Setup Warehouse Configuration Rules Warehouse Execution Rules Workbench

Navigation: Other Requests Requests Run

Page 31 of 95

PACross 4 Create Crossdock Operation Plan

Responsibility: Warehouse Manager Business Approach: Navigation: Setup Warehouse Configuration Warehouses Operation Plan

Page 32 of 95

PACross 5 Order Management & Shipping Parameter Setup Responsibility: Order Management Navigation: Setup System Parameters Values

Set a value of 0 for Reservation Time Fence parameter. Note: This setting will ensure that no high level reservations are created when the sales orders are booked. This is necessary because system will not try to crossdock for the demand lines with any reservations.

Page 33 of 95

Navigation: Setup Shipping Global Parameters

For Delivery Date Calculation Method field select Scheduled Date, Requested Date value. Note: This will ensure that the Deliverys initial pickup data is correctly set as per the scheduled ship date.

Page 34 of 95

PACross 6 Create Supplier & Supplier Sites Responsibility: Purchasing Super User Navigation: Supply base Suppliers In our case we have defined General Electric as the supplier. We define a new site W1.

Complete the supplier site creation for W1 for ship to and bill to location.

Page 35 of 95

PACross 7 Create Supplier User & Register User Responsibility: Purchasing Super User Navigation: Supply base Supplier User Management Supplier User Creation Register Supplier User We register supplier user cjohnp@gmail.com. We assign all responsibilities to the user. The main responsibility is iSupplier Portal Full Access

Page 36 of 95

Responsibility: Sysadmin Navigation: Security User Define

When the user is registered through Isupplier Portal a user is created and you can check it from sysadmin /security/user and you can change the password. Note: One needs to log in using this user id to create ASNs.

Page 37 of 95

PACross 8 Create Purchase Order Responsibility: Purchasing Navigation: Purchase Orders Purchase Orders

Create a Standard PO(In our case created PO5416). Set Ship-to and Bill-to to your organization (W1). Create a line for crossdock planned item (testitem) for qty (10) .One can change the receipt routing to Standard Receipt.

Page 38 of 95

PACross 9 Create ASN Responsibility: Isupplier Portal Full Access Navigation: Isupplier Portal Full Access

We go to shipments tab and query our purchase order that we created.

Page 39 of 95

We select Create Advance Shipment Notice and create ASN. In our case we defined cjptest1.

Page 40 of 95

PACross 10 Create Sales Order Responsibility: Order Management Navigation: Orders, Returns Order Organizer

In our test case we created order 63714 for item testitem for qty 10.

Page 41 of 95

PACross 11 Perform Alias Receipt Responsibility: Whse Mgmt Navigation: Warehousing Inventory Receipts Alias Receipt.

Responsibility: Warehouse Manager Navigation: Inquiry Material Workbench

Verify the material received through material workbench.

Page 42 of 95

PACross 12 Run Pick Release Responsibility: Order Management Navigation: Shipping Release Sales Orders Release Sales Orders

We are using allocation method Prioritize Inventory.

Page 43 of 95

Pick slip report output.

Page 44 of 95

PACross 13 View Reservation Responsibility: Warehouse Manager Navigation: Inquiry View Reservations We enter organization (W1) and item (testitem). A new field is added to reservation inquiry Include Crossdock. We check that field. Now we select Find button.

Page 45 of 95

You will see 2 reservation records. One for quantity 7, against the quantity present in inventory. Second against the ASN for quantity 3. You will see that the crossdock flag is set to Yes for this record.

Page 46 of 95

PACross 14 View Sales Order From Shipping Transactions Responsibility: Warehouse Manager Navigation: Outbound logistics Shipping Planning & Transactions.

When you query up the sales order you will see that the line status is Planned For Crossdocking.

Page 47 of 95

PACross 15 Perform Receipt for ASN Responsibility: Whse Mgmt Navigation: Inbound Inbound Receive ASN

We do the receipt against the ASN (cjptest1).

Page 48 of 95

PACross 16 Verify Task In Control Board Responsibility: Warehouse Manager Navigation: Inquiry Warehouse Control Board Select Crossdock in source and select the various statuses.

Under Inbound Plan select Plan Type Cross-docking.

You will now be able to see the crossdock planned task.

Page 49 of 95

PACross 17 Execute Cross Docking Responsibility: Whse Mgmt You can use Navigation: Tasks Directed Tasks Directed Move Move any LPN Or Navigation: Tasks Manual Tasks Manual load/Manual drop.

Now when we try to do the putaway the system suggest the staging subinventory and locator and suggest that the material can be crossdocked. We execute the cross docking.

Page 50 of 95

PACross 18 View Sales Order From Shipping Transactions Responsibility: Warehouse Manager Navigation: Outbound logistics Shipping Planning & Transactions.

You will see that the line status is changed to Staged/Pick Confirmed.

Page 51 of 95

Opportunistic Crossdocking: Opportunistic Crossdock Supply driven - Supply of inbound material is dynamically crossdocked on arrival to fulfill a demand. The newly received material can be crossdocked directly to backordered component requirements. Supply from purchase order receipts and LPN-based completions will be considered. Both push and pull component requirements will be considered for demand. A push requirement would be crossdocked directly to the job, while a pull requirement would be crossdocked to the supply subinventory and locator.

Page 52 of 95

Opportunistic Crossdocking with Sales Order as Demand & PO as Supply:

Step Opportunistic Cross Docking Setup PreReqs Prerequisites Required WMS should be

setup up. OCross 1 Define a Opportunistic Crossdock Criteria OCross 2 Define Item OCross 3 Setup Crossdock criteria assignment OCross 4 Setup Organization Parameters OCross 5 Create Crossdock Operation Plan OCross 6 Shipping Parameter Setup OCross 7 Create Purchase Order OCross 8 Create Sales Order OCross 9 Execute PO Receipt OCross 10 View Reservation OCross 11 Execute Cross Docking OCross 12 View Sales Order From Shipping Transactions OCross 13 View Reservation Scenario: In this example we will show how Opportunistic Crossdocking happens for a PO as Supply and Sales Order as Demand. We will define an item and assign it to organization W1. Then we will create a PO for the item for qty 10. Then we create a Sales Order for the item for qty10. Now we do PO receipt for quantity of 10. When you try to do put away system will prompt you that crossdocking opportunity exists. Execute cross docking.

Page 53 of 95

OCross 1 Define a Opportunistic Crossdock Criteria

Responsibility: Warehouse Manager Business Approach: Navigation: Setup Warehouse Configuration Rules Warehouse Execution Crossdock Criteria

Page 54 of 95

Eligible demands for opportunistic crossdock Sales Order, Internal Order, WIP components (Discrete, Repetitive, and lot based jobs) Eligible supplies for opportunistic crossdock Receipts : PO, ASN, Internal requisition, Internal shipment, Manufacturing completions : Discrete job, Flow schedule

Opportunistic Crossdock Forward scheduling Current Time - 11:00

Supply arrives at 11:00 Order Processing Time = 1 Hr

Buffer Time = 1 Hr Crossdock Window = 2 Hrs

Earliest departure time for crossdocking to a demand = Current Time + (Order Processing Time + Buffer Time) = 11:00 + (1+1) = 13:00 Latest departure time for crossdocking to a demand = Earliest departure time for crossdocking to a demand + Crossdock Window = 13:00 + 2 = 15:00

OPT BT Cross Dock Window 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00

Page 55 of 95

OCross 2 Define Item Responsibility: Warehouse Manager Business Approach: Navigation: Setup Material Setup Master Items

We create item testoprxdocitem and assign it to organization W1.

Page 56 of 95

OCross 3 Setup Crossdock criteria assignment Responsibility: Warehouse Manager Business Approach: Navigation: Setup Warehouse Configuration Rules Warehouse Execution Rules Workbench

Two new Rule Types are introduced in R12. Planned Crossdock & Opportunistic Crossdock. In our Opportunistic Cross dock test we will select Opportunistic Crossdock type. We create a new assignment with a sequence number. Lower the sequence higher the precedence.

Page 57 of 95

In our case we have assigned sequence 30 . Then we have selected the crossdock criteria we had defined (CJP CROSS DOCK OPPORTUNISTIC). We select organization (W1) and select the crossdock planned item (testoprxdocitem). Select Always in the Date Type column. Check Enabled. Note: Always remember to run Generate All Rules Concurrent program after you have defined any new rule or made changes to existing rule.

Page 58 of 95

OCross 4 Setup Organization Parameters

Responsibility: Warehouse Manager Business Approach: Navigation: Setup Warehouse Configuration Warehouses Warehouse Parameters

Enable Opportunistic Crossdocking. Select default Crossdock criteria (CJP CROSS DOCK OPPORTUNISITC).

Page 59 of 95

OCross 5 Create Crossdock Operation Plan

Responsibility: Warehouse Manager Business Approach: Navigation: Setup Warehouse Configuration Warehouses Operation Plan

On operation select Cross dock. In cross dock method select appropriate cross dock method. In our example we select (Default) LPN based consolidation in staging lane within delivery. The other options are:

Locator based consolidation in consolidation locator, within delivery in staging lane LPN based consolidation in consolidation locator, within delivery in staging lane Direct consolidation in staging lane within delivery LPN based consolidation in staging lane across deliveries Direct consolidation in staging lane across deliveries LPN based consolidation in consolidation locator, across deliveries in staging lane Locator based consolidation in consolidation locator, across deliveries in staging lane

Page 60 of 95

OCross 6 Shipping Parameter Setup Responsibility: Order Management Business Approach: Navigation: Setup Shipping Shipping parameters.

You can define default Staging Subinventory and Locator.

Page 61 of 95

OCross 7 Create Purchase Order Responsibility: Purchasing Business Approach: Navigation: Purchase Orders Purchase Orders

We create a purchase order 7046.

Page 62 of 95

OCross 8 Create Sales Order Responsibility: Order Management Business Approach: Navigation: Orders, Returns Order Organizer We create on Order (70747) for item testoprxdocitem for qty 10.

Page 63 of 95

Page 64 of 95

OCross 9 Execute PO Receipt Responsibility: Whse Mgmt Navigation: Inbound Inbound Receive PO We receive against the purchase order (7046). We receive the item into the receiving subinvenory locator and into LPN LPN863A.

Page 65 of 95

OCross 10 View Reservation Responsibility: Warehouse Manager Navigation: Inquiry View Reservations Enter the organization name (In our case W1) and then enter the item (In our case testoprxdocitem) and then check Include Crossdock and then click Find . You will see that a crossdock reservation exists. It mentions Pending Crossdock and you will see in the supply type that the item is in receiving.

Page 66 of 95

Page 67 of 95

OCross 11 Execute Cross Docking

Responsibility: Whse Mgmt Navigation: Tasks Directed Tasks Directed Move Move Any LPN We enter the LPN number(In our case LPN863A). As we confirm the subinventory we get the message Crossdock material exists. Crossdock will be performed. Press any key to continue. Then we enter the locator information and select Drop Full LPN.

Page 68 of 95

OCross 12 View Sales Order From Shipping Transactions

Responsibility: Warehouse Manager Navigation: Outbound Logistics Shipment Planning & Transactions. Select Lines and LPNs from the query window and then put in the order number. In our case the order number was 70747. You will see that line status is Staged/Pick Confirmed.

Page 69 of 95

OCross 13 View Reservation

Responsibility: Warehouse Manager Navigation: Inquiry View Reservations. Once you have done the putaway of the material to staging (though crossdocking) the crossdock flag changes to No as crossdocking has already happened and the supply type shows Inventory as the material is already in inventory.

Page 70 of 95

Page 71 of 95

Opportunistic Crossdocking with WIP Component Demand: Step Opportunistic Cross Docking Setup PreReqs Prerequisites Required WMS should be

setup up. OWCross 1 Define a Opportunistic Crossdock Criteria OWCross 2 Define Item OWCross 3 Setup Crossdock criteria assignment OWCross 4 Setup Organization Parameters OWCross 5 Create Crossdock Operation Plan OWCross 6 Create BOM OWCross 7 Create Routing OWCross 8 Create Job OWCross 9 Run Component Pick release OWCross 10 Create Purchase Order OWCross 11 Execute PO Receipt OWCross 12 Move Assembly OWCross 13 Execute Cross Docking OWCross 14 Verify Job Scenario: In this example we will show how Opportunistic Crossdocking happens for a PO as Supply and backordered WIP component as Demand. We will define an item and assign it to organization W1. Then we will create a BOM & Routing for the assembly including the component. We run Component Pick Release. Then we create a Purchase Order for the item. Now we do PO receipt. When you try to put away, system will prompt you to do the cross docking by suggesting the job. Execute cross docking.

Page 72 of 95

OWCross 1 Define a Opportunistic Crossdock Criteria Responsibility: Warehouse Manager Business Approach: Navigation: Setup Warehouse Configuration Rules Warehouse Execution Crossdock Criteria

We define cross dock criteria CJP CROSS DOCK OPPORTUNISTIC. Make sure you have selected WIP Component Demand (Backordered) in your Demand tab.

Page 73 of 95

OWCross 2 Define Item

Responsibility: Warehouse Manager Business Approach: We define 2 items a. cjpfinishedgood b. cjpcomp Navigation: Setup Material Setup Master Items

Page 74 of 95

OWCross 3 Setup Crossdock criteria assignment Responsibility: Warehouse Manager Business Approach: Navigation: Setup Warehouse Configuration Rules Warehouse Execution Rules Workbench

We select Opportunistic Cross dock .

Page 75 of 95

OWCross 4 Setup Organization Parameters

Responsibility: Warehouse Manager Business Approach: Navigation: Setup Warehouse Configuration Warehouses Warehouse Parameters

Enable Opportunistic Crossdocking. Select default Crossdock criteria (CJP CROSS DOCK OPPORTUNISITC).

Page 76 of 95

OWCross 5 Create Crossdock Operation Plan Responsibility: Warehouse Manager Business Approach: Navigation: Setup Warehouse Configuration Warehouses Operation Plan

Make sure that Crossdock to WIP is checked.

Page 77 of 95

OWCross 6 Create BOM

Responsibility: Manufacturing & Distribution Manager Navigation: Bills Of Materials Bills Bills

Page 78 of 95

Page 79 of 95

OWCross 7 Create Routing Responsibility: Manufacturing & Distribution Manager Navigation: Bills Of Materials Routings Routings

Page 80 of 95

OWCross 8 Create Job Responsibility: Manufacturing & Distribution Manager Navigation: WIP Discrete Discrete Jobs

Page 81 of 95

Page 82 of 95

OWCross 9 Run Component Pick release

Responsibility: Manufacturing & Distribution Manager Navigation: WIP Discrete Component Pick Release Component Pick Release

A record gets populated in table wip_material_shortages_v.

Page 83 of 95

OWCross 10 Create Purchase Order Responsibility: Purchasing Navigation: Purchase Orders Purchase Orders

Page 84 of 95

OWCross 11 Execute PO Receipt

Responsibility: Whse Mgmt Navigation: Inbound Inbound Receive PO We receive against the purchase order (7047). We receive the item into the receiving subinvenory locator and into LPN LPN864A.

Page 85 of 95

OWCross 12 Move Assembly

Responsibility: Whse Mgmt Navigation: Manufacturing Assy & Material Txn Move Assy

We do the Assembly move from seq 10 Queue to seq 10 Run.

Page 86 of 95

OWCross 13 Execute Cross Docking

Responsibility: Whse Mgmt Navigation: Tasks Directed Tasks Directed Move Move Any LPN Enter the LPN(LPN864A). Select Drop. You will see that immediately it shows to Job, to dept and to op seq. Now the cross docking has happened. Material is moved from receiving to job.

Page 87 of 95

OWCross 14 Verify Job

Responsibility: Manufacturing & Distribution Manager Navigation: WIP Discrete Discrete Jobs

When you query up the job you will see in the issued column that the material was issued to the job.

Page 88 of 95

Cross dock exceptions: (Please refer to R12 WMS User Guide Pg 6-12) Crossdocking exceptions can occur if: The supply source is delayed and the document is not modified The supply source is delayed and the document is modified The supply source is canceled or reduced The supply source fails inspection The material is not available for crossdocking The system generates the following types of crossdocking exceptions: Note: Time initiated exceptions are more severe than schedule initiated exceptions. Time-initiated exceptions Schedule initiated exceptions

Oracle Warehouse Management uses a concurrent program to check for exceptions and assign an exception code to each exception. It uses the parameter Look-Ahead Time to check whether incoming supply is available for crossdocking. The concurrent program checks for all supply scheduled to arrive in the warehouse within the exception look-ahead time window. It considers the past-due supply and assumes the supply-scheduled receipt date and time is the current system date and time. It uses the supply source and the crossdocking reservation and determines the corresponding demand source. The concurrent program divides the future time window for the supply into four zones. The concurrent program uses these zones to categorize the different exception types. If crossdocked demand lies in zone one, then the remaining time for crossdocking is less than the order processing time. The system cannot perform a crossdock and records an error. If the supply source is late, then the system records a late exception. If the supply is not late, then the system records a schedule exception. If crossdocked demand lies within zone two, the remaining crossdock time is more than

Page 89 of 95

the order processing time, but less than the order processing time + buffer time. Though the system can still perform crossdocking, you may need to manually expedite the supply. In this case, the system records a warning exception code. If the supply source is past due, then the system records a late exception. If the supply is not late, then it records a schedule exception. If crossdocked demand lies within zone three, the remaining crossdock time is more than the order processing time + buffer time, but less than the order processing time + buffer time + crossdock window. This implies that crossdocking is possible without manual expedite, and the system does not record an exception. If crossdocked demand lies within zone four, the remaining crossdock time is more than the order processing time + buffer time + crossdock window. Though crossdocking is possible, an unnecessary wait time is required for the inbound material before you can ship the order; therefore, the system records a scheduled exception with the code warning. The following table shows the exception codes: Exception Code Severity Description LE Error Late Exception LW Warning Late Exception SE Error Schedule Exception SW Warning Schedule Exception Time Initiated Exceptions A concurrent program tracks crossdocked receipts and generates exceptions. The concurrent program checks for all past-due supply, and determines whether the material will arrive in time. A late exception occurs when incoming supply does not arrive on schedule. The system generates a warning if the time remaining for the planned crossdock is more than the buffer time, but less than the latest crossdock time. It generates an error exception if the time remaining to fulfill is greater than the buffer time. Schedule Initiated Exception The system generates a system exception if the crossdock window is violated. A schedule exception occurs if the time remaining to fulfill the demand is more than the buffer time + order processing time + Crossdock window. Exceptions Corrective Action Once the system records a crossdocking exception, it triggers one of the following corrective actions: Reschedule supply and demand: To change the supply and demand, you change either the document, or the dock door appointment. Delete reservation: You can manually delete the reservation and sever the link between the supply and demand.

Page 90 of 95

Planned & Opportunistic Cross Docking:

The Planned depiction of crossdock window(CW), Buffer Time (BT), and Order Processing Time (OPT) will be used in Planned Crossdocking process for backward scheduling. Similarly Opportunistic depiction will be used for Opportunistic Crossdocking process for forward scheduling.

Page 91 of 95

Crossdocking and Change Management : (Please Refer to R12 User Guide Pg 6-8) You can make changes to supply and demand sources after the system links the supply and demand. The following tables display the changes the system makes if you modify supply and demand sources.

Page 92 of 95

Page 93 of 95

Page 94 of 95

Debugging Issues: The following are the requirements from support for logging a tar.

Screen shots of the issue along with a good scenario. Pick release log files : Set profile options

OM: Debug set to level 5 OM: Debug log directory = INV: Debug Trace = YES

INV: Debug File = [directory value from above query]/logfilename.log (make sure that you have write permission for this file and directory)]

INV: Debug Level = 9 While running pick release please select Tools from Tool bar and Check debug. Upload the pick release log file and the inventory debug log file. In case there are issues with completing the cross dock transaction on mobile that please also

upload the mobile log files. 1. set mwa.cfg to trace level. To do this go to the mwa server config file,

/mwa/secure/mwa.cfg, and modify log level to trace 2. restart the mobile server and hit ctrl-X, see what directory is for the logging 3. perform the transaction again and get the following log files from that log directory

[port].INV.log [port]WMS.log

[port].system.log Inventory Debug log from the directory set in profile 'INV: Debug File

Page 95 of 95

Overview Of CrossdockingPlanned Crossdocking:

Planned Cross Docking With PO as Supply and SO as Demand:Planned Cross Docking With ASN as Supply and SO as Demand:Planned Crossdocking:Opportunistic Crossdocking:

Opportunistic Crossdocking with Sales Order as Demand & PO Opportunistic Crossdocking with WIP Component Demand:Cross dock exceptions:

Planned & Opportunistic Cross Docking:Crossdocking and Change Management :Debugging Issues: