PRODUCTION. This guide will introduce you to the concepts, basics and main processes of Orchestrated Production. Let s get Brewing!

Transcription

1 PRODUCTION This guide will introduce you to the concepts, basics and main processes of Orchestrated Production. Let s get Brewing! SB

2 Table of Contents Production Concepts Overview... 3 Process Flow... 4 Terminology... 5 Production Basics Production Flow... 6 Bill of Materials... 7 Finding a BoM... 8 BoM Editing a BoM Production Order Finding a PdO PdO Worksheets Finding a Worksheet Worksheet Brewing Worksheet Cellar Worksheet Packaging Worksheet Express Screen Production Process Planning vs. Expressing PdO Wizards & Planning Plan Production Run Plan Packaging for the future Worksheets & Expressing Express Wort Express Green Beer Express Additional Steps Express Brite Beer Plan Packaging based on Brite Beer in the tank Express Packaging Continued on next page 1

3 Table of Contents Additional Scenarios Close Production Orders Empty Tanks Disassemble an incorrectly expressed PdO Troubleshooting Production Blend 2 Batches of Beer together Inventory Transfer Warehouse Assignment Wizard Useful Production Reports Reports by Persona

4 Production Concepts Overview The production process is when making your Beer happens! OBEER will be there by your side as you plan what needs to be brewed, and execute on that plan. The software follows your day to day on the floor, so you know what stage your liquid product is at, where your liquid is located, and the next steps to take. OBEER is an inventory management system. This means that inventory has to be consumed, in order to make more inventory: For Example: during brewing, raw materials such as malts and hops are consumed by wort. During fermentation, wort is consumed by green beer. During filtration, green beer is consumed by a dry hop, and then the dry hop is consumed by Brite beer. Eventually, Brite beer will be consumed by packaging. And finally, finished product will be enjoyably consumed by your Customers! Wort W1001 Consumes RH1001 Green GB1001 Consumes W1001 Dry Hop DH1001 Consumes GB1001 Brite BB1001 Consumes DH1001 Pack - aged PG1001 Consumes BB1001 Why Produce through OBEER? Gives your business visibility into the components used to create beer, retains your tried and true recipes, impacts inventory, captures TTB information, ties heavily into the financial impact your produced goods have on your business. 3

5 Production Concepts Process Flow How will OBEER capture our production process? OBEER Production is broken out into two main processes: Planning & Expressing EXPRESS (CREATE) Reads and then creates the plan PLAN Standing instructions to create your end product at each step Includes when it needs to be made (how long it will take) Includes what components/ingredients will be used Physical consumption of previous step Inventory is moved between Warehouses Issues-out and receives-in components/ingredients Impacts inventory Impacts financials Does NOT impact inventory 4

6 Production Concepts Terminology PROCESS Method in which you re trying to create an item (liquid) Brewing Fermentation Optional Steps Filtration Packaging COMPONENTS Materials being used during each process Raw Materials Wort Green Beer Optional Step Brite Beer Packaging Materials WAREHOUSE Location of components Brew House Fermenter Barrels Brite Tank Main Warehouse PRODUCT The end item being produced Wort Green Beer Dry Hopped Beer Brite Beer Finished Beer 5

7 Production Basics Production Flow What do we use in OBEER to make Production happen? Great question! There will be 3 main functions that impact each process & product! Express Worksheets Brewing Cellar Cellar Cellar Packaging Plan Production Order Wort Green Beer Optional Step Brite Beer Packaged Goods Plan Bill of Materials Wort Green Beer Optional Step Brite Beer Packaged Goods Let s get a grasp on each of these functions: 6

8 Production Basics Bill of Materials A RECIPE! What is it? Created from item master data Guides how to make each step of beer BoM What does it do? Informs OBEER what and how many components to take out of inventory to make an end product Incorporates the product produced in the previous step (consumption) Why use it? Begins the planning process Can be edited Can save versions of recipes Product that will be made The Ingredients that will be consumed 7

9 Production Basics Bill of Materials Finding a BoM Item Master Data > Find Item (i.e. Wort) > Right Click > Bill of Materials Navigation Tip! You can also drag and drop the Bill of Materials function into your Common Functions box: Modules > Production > Bill of Materials Real Life! Bruno wants to double check his recipe for Amber Ale Wort (W1001) Let s take a closer look with Bruno 8

10 Production Basics Bill of Materials BoM 411 Product that will be made How many BBLS are made with this recipe? Where will my product reside? Ingredients (can drill into individual item codes) Quantity of ingredients needed to make product above Unit of Measure for Quantity Warehouse (where do ingredients reside?) Price per Unit Update all open PdOs (carbon copies of this BoM) with any ingredient changes View versions of recipe View built-in procedures on how to make product listed above Real Life! Sweet!!! The Amber Ale is good to go! Let s review the BoMs for Bruno s IPA #1003, from wort to Brite beer, and see how they fit in to one another. 9

11 Product that will be made Production Basics Bill of Materials BoM 411 How many BBLS are made with this recipe? Where will my product reside? Recipe Ingredients that will be consumed Take Note! Any BoM after Wort (i.e. Dry Hop & Packaging) should consume the liquid as the very first item. 10

12 Production Basics Bill of Materials Editing a BoM Real Life! Bruno notices his recipe for his IPA needs to be changed. He ll no longer be using Fuggle hops, but rather German Tradition hops. Let s take a look at how he goes about editing his BoM! Bruno begins by opening his BoM for W1003 (Wort IPA) Bruno s next step is to add his new hop variety (German Tradition hops) He searches by item code to bring up his list of items, and once item is found, selects <Choose> Now that the German Tradition hops are added to his BoM, he needs to remove the Fuggle hops 11

13 Production Basics Bill of Materials Editing a BoM Bruno right clicks on the item he needs to remove, and selects Delete Row To save his changes, Bruno clicks <Update> and is prompted with the BoM Version system message Bruno selects a name to save his version as for future reference 12

14 Production Basics Bill of Materials Editing a BoM Bruno would now like to update open Production Orders (the PLAN(s)) with changes to the recipe. He selects <Update PdOs> Then highlights the PdO(s) that need to be updated, and clicks <Process> Bruno is prompted with a System Message about overwriting selected Production Orders, to which is clicks <Proceed> Real Life! Sweet! Bruno just made some edits to his BoM and is ready to find out about the PLAN of action! 13

15 Production Basics Production Order What is it? The PLAN! A carbon copy of a BoM PdO What does it do? Communicates production plans Quantifies how much end product to make, and when Does NOT impact inventory Why use it? Provides visibility into upcoming Production needs Can be edited if change is needed Product you re planning to make Ingredients that will be consumed 14

16 Production Basics Production Order Finding a PdO Modules >Production > Production Order > Find Mode > Search for PdO Navigation Tip! You can also drag and drop the Production Order function into your Common Functions box: Real Life! Bill is planning out Production for his team on the floor. He s going to review some important fields on an individual PdO for Wort IPA. Let s take a closer look with Bill 15

17 Production Basics Production Order PdO 411 PdO Number Status: Set to Planned Released Closed Product you are planning to make Quantity of end-product Date of PdO creation Unit of Measure for quantity Master Production Number: Links multiple production orders into a single run Where will my product reside? Date of PdO Production (when does it need to occur?) PdO Batch # Copy of BoM! Express = to Create! Make this Plan Real Life! Bill likes what he sees. This plan for IPA wort is looking pretty good, and he s ready to get the actual Express process going! 16

18 Production Basics Worksheets What are they? The ACTION! Physical manifestation of the Production Order WORKSHEETS What do they do? Expresses (Creates) end product Decrements and Increments inventory as Production occurs Reflects inventory location, cost and loss in real time Note! There are 3 Worksheets Why use them? Affects TTB Impacts financials Modules > Production > Production Forms > Brewing Cellar Packaging Worksheet Brewing Worksheet: Where you go to Express (Create) Wort* *and/or Green Beer if you choose Cellar Worksheet: Where you go to Express (Create) Green Beer/Additional Steps/Brite Beer Packaging Worksheet: Where you go to Express (Create) Packaged Goods 17

19 Production Basics Worksheets Worksheet 411 Real Life! Dan wants to check on the outstanding plans for the production of IPA so he knows how to plan out his week Let s take a closer look at each worksheet with Dan Brewing Worksheet Modules > Production > Production Forms > Brewing Worksheet Wort Green Beer Choose correct Tab Location of Production Production Start & End Dates (as indicated on PdO) Refresh Matrix to update data Choose PdO status to always show Planned/ Released Express! Takes you to CREATE the wort Production Orders (PdOs) for Wort The Plan(s) Ingredients that will be consumed 18

20 Production Basics Worksheets Worksheet 411 Cellar Worksheet Modules > Production > Production Forms > Cellar Worksheet Green Beer Brite Beer Hopped Beer Choose correct Tab Location of Production Production Start & End Dates (as indicated on PdO) Choose PdO status to always show Planned/ Released Shows tanks and their current liquid volumes! Refresh Matrix to update data Express! Takes you to CREATE the Green Beer/Add l Steps/ Brite Beer Ingredients that will be consumed Production Orders (PdOs) for Green Beer/Add l Steps/Brite Beer The Plan(s) 19

21 Packaging Worksheet Production Basics Worksheets Worksheet 411 Modules > Production > Production Forms > Packaging Worksheet Finished Beer Location of Production Production Start & End Dates (as indicated on PdO) Choose PdO status to always show Planned/ Released Refresh Matrix to update data Shows tanks and their current liquid volumes! Express! Takes you to CREATE the Packaged goods Ingredients that will be consumed Production Orders (PdOs) for Packaged goods 20

22 Production Basics Worksheets Worksheet 411 Express Screen Modules > Production > Production Forms > Worksheet <Express Button> Product being made and quantity received Ingredients and amounts that are ACTUALLY consumed Real Life! Aha! Dan is ready to start brewing some beer now that he knows which functions to utilize within OBEER! Worksheet Production Order Bill of Materials 21

23 Production Process Planning vs. Expressing As Bruno, Bill and Dan found out during Production Basics, there are 2 main processes within Production. Planning and Expressing. Bill of Materials (BoMs) and Production Orders (PdOs) take care of the planning stages, and Worksheets (Brewing, Cellar & Packaging) handle the execution/creation of those plans. Express Worksheets Brewing Cellar Cellar Cellar Packaging Plan Production Order Wort Green Beer Optional Step Brite Beer Packaged Goods Plan Bill of Materials Wort Green Beer Optional Step Brite Beer Packaged Goods Remember! Each step in production consumes the previous. 22

24 Production Process PdO Wizards & Planning What are they? A production RUN assistant PdO Wizards What do they do? Creates multiple PdOs in one step Can also create single PdOs with ease Leads you through the defined steps of planning your product! Why use one? Saves time! Can focus on a few fields instead of many. You will be utilizing PdO Wizards to do the following: Plan Production Run 23

25 Production Process Plan Production Run Plan Production Run Modules > Production > Automation > PdO Creation Wizard 1. Open PdO Creation Wizard 2. Click <Build Production Run> 24

26 Production Process Plan Production Run continued 3. Select Starting Point item a. Beginning = wort 4. Click Build Direction dropdown 5. Select Forward a. Forward (from wort to Brite beer) 6. Enter QTY (i.e. how many turns in the Brewhouse?) 7. Enter Prod Date a. When do you want/need this to be made (can be backdated) 8. Click <Outline Production Run> Batch # will autopopulate based on last batch used for this item Optional: add text to Suffix field (no special characters alphanumeric only) 9. Click <Select> 25

27 Production Process Plan Production Run continued 10. Entire production run should be outlined Confirm Quantities i. Wort 1. Turns = # of turns in the Brewhouse (i.e. 2) 2. Quantity = # of BBLS in Brewhouse (i.e. 30) ii. All other steps (i.e. Green Beer/Add l Steps/Brite Beer) 1. Turns = 1 2. Quantity = Total BBLS after Brewhouse step(s) (i.e. 60) Update dates for Wort, Green, Add l Steps, Brite Beer) i. Production Date = start date ii. Due Date = completion date 26

28 Production Process Plan Production Run continued Update Warehouses i. Wort = comes from A1 and goes into BH01 ii. Green Beer = comes from BH01 and goes into FVxx (choose your Fermenter) iii. Brite Beer = comes from FVxx and goes into BTxx (chose your Brite Tank) iv. Additional Steps? 1. Barrel Aged moves into BA01/OAK01 2. Dry Hop/Dry Spice stays in FVxx 11. Click <Write to PdO Wizard> 27

29 Production Process Plan Production Run continued Use Set All Status To dropdown to choose Released 12. Click <Preview> 13. Click <Create> Wait until ALL Production Orders disappear from the screen DO NOT click Create again 14. Click <Cancel> to close the PdO Creation Wizard function 28

30 Production Process Plan Packaging for the future Plan Packaging for the future Modules > Production > Automation > Packaging Run c 1. Open Packaging Run 2. Enter the Source Item code Ex. BB

31 Production Process Plan Packaging for the future continued 3. Enter the Production Date (top right-hand of form) 4. Click <Add PdO> 5. Select the row (PdO) This is a PdO for Brite Beer, so it represents the volume of liquid to be packaged 6. Double check the Warehouse information in the bottom grid 7. Enter in the QTY of finished goods to be produced (racked) This can be for one or all the items shown in the bottom grid Notice the volume consumed updates in the row, and in the header. Use this real-time calculation to split your volume as needed 30

32 Production Process Plan Packaging for the future continued 8. Click <Add> You have now created Production Orders for your splits, all in one function! Using the Production Run is the easiest way to handle planning our packaging splits! 31

33 Production Process Worksheets & Expressing What are they? The ACTION! Physical manifestation of the Production Order WORKSHEETS What do they do? Expresses (Creates) end product Decrements and Increments inventory as Production occurs Reflects inventory location, cost and loss in real time Why use them? Affects TTB Impacts financials Express (Create) Wort Express (Create) Green You will be utilizing the 3 Worksheets to do the following: Express (Create) Brite Beer Express (Create) Packaging Beer/Add l Steps 32

34 Production Process Express Wort Express (Create) Wort Modules > Production > Production Forms > Brewing Worksheet 1. Open Brewing Worksheet 33

35 Production Process Express Wort continued 2. Select Location 3. Select Start Date & End Date for the production orders you are ready to Express 4. Ensure Status dropdown is set to Released 5. Click <Refresh Matrix> 6. Highlight the PdO for Wort you re ready to made by clicking the row 7. Click <Express> 34

36 Production Process Express Wort continued UPPER SECTION: What you re making! 8. Enter Receive Qty 9. Enter Initials 10. Confirm Production Date 11. In lower section (materials consumed) confirm quantity used of each individual item The far right ActQty column is where you will enter actual quantities you want taken out of inventory 12. Click <Process> LOWER SECTION: What you ll be consuming during Production 35

37 Production Process Express Wort continued PdO for 1 turn (30 BBLS) of Wort has been expressed on Brewing Worksheet Both Issued & Receipt boxes should be checked Wort down, now on to Green Beer! 36

38 Production Process Express Green Beer Express (Create) Green Beer Modules > Production > Production Forms > Cellar Worksheet > Green Beer tab or Modules > Production > Production Forms > Brewing Worksheet > Green Beer tab 1. Open Cellar Worksheet > Green Beer tab 37

39 Production Process Express Green Beer continued 2. Select Location 3. Select Start Date & End Date for the Production Orders you are ready to Express 4. Ensure Status dropdown is set to Released 5. Click <Refresh Matrix> 6. Highlight to PdO for Green Beer you re ready to make by clicking the row 7. Click <Express> 38

40 Production Process Express Green Beer continued 8. Enter Receive Qty 9. Enter Initials 10. Confirm Production Date 11. In lower section (materials consumed) confirm quantity of Wort in the Brewhouse Be sure to consume all of it so no residual is left in your tank (ActQty needs to equal true, in-stock amount of Wort) 12. Click <Process> UPPER SECTION: What you re making! LOWER SECTION: What you ll be consuming during Production 39

41 Production Process Express Green Beer continued PdO for Green Beer has now been expressed on the Cellar Worksheet > Green Beer tab Both Issued & Receipt boxes should be checked 13. Current Tank Status Should now reflect Green Beer sitting in the correct Warehouse (Fermenter) Green Beer down! Now on to Additional Steps! 40

42 Production Process Express Additional Steps Express (Create) Additional Steps* Modules > Production > Production Forms > Cellar Worksheet > Cellar tab *Any additional steps (i.e. Dry Hop, Fruited, Barrel Aged) will be Expressed in the exact same manner as Green Beer & Brite Beer. Follow the previous or following instructions for your additional step! You will begin from the Cellar tab of the Cellar Worksheet. Got it! Now on to Expressing Brite Beer! 41

43 Production Process Express Brite Beer Express (Create) Brite Beer Modules > Production > Production Forms > Cellar Worksheet > Cellar tab 1. Open Cellar Worksheet > Cellar tab 42

44 Production Process Express Brite Beer continued 2. Select Location 3. Select Start Date & End Date for the Production Orders you are ready to Express 4. Ensure Status dropdown is set to Released 5. Click <Refresh Matrix> 6. Highlight the PdO for Brite Beer you re ready to make by clicking the row 7. Click <Express> 43

45 Production Process Express Brite Beer continued 8. Enter Receive Qty 9. Enter Initials 10. Confirm Production Date 11. In lower section (materials consumed) confirm quantity of Green Beer/Additional Step in the Fermenter Be sure to consume all of it so no residual is left in your tank (ActQty needs to equal true, in-stock amount of Green Beer/Additional Step) 12. Click <Process> LOWER SECTION: What you ll be consuming during Production 44

46 Production Process Express Brite Beer continued PdO for Brite Beer has now been expressed on Cellar Worksheet Both Issued & Receipt boxes should be checked 13. Current Tank Status Should now reflect Brite Beer sitting in the correct Warehouse (Brite Tank) Cool! Expressing works the same way for each step! Now, how about Packaging? 45

47 Production Process Plan Packaging based on Brite Beer in the tank Modules > Production > Production Forms > Packaging Worksheet 1. From the Current Tank Status table, highlight the tank (batch of brite beer) that you want to pack 2. Right Click > Create Packaging Run 3. Enter the Production Date (top right of form) 4. Verify the To Whs column 5. Enter in the QTY of finished goods to be produced This can be for one or all the items shown in the bottom grid Notice the volume consumed updates in the row, and in the header. Use this real-time calculation to split your volume as needed 6. Click <Add> 46

48 Production Process Express Packaging Express (Create) Packaging Modules > Production > Production Forms > Packaging Worksheet 3. Open Packaging Worksheet 47

49 Production Process Express Packaging continued 4. Select Location 5. Select Start Date & End Date for the Production Orders you are ready to Express 6. Ensure Status dropdown is set to Released 7. Click <Refresh Matrix> 8. Highlight the PdO for Packaged Goods you re ready to fulfill by clicking the row 9. Click <Express> 48

50 Production Process Express Packaging continued 10. Enter Receive Qty 11. Enter Initials 12. Confirm Production Date 13. In lower section (materials consumed) confirm quantity of Brite Beer in the Brite Tank Be sure to consume all of it so no residual is left in your tank (ActQty needs to equal true, instock amount of Brite Beer) 14. Click <Process> **If packaging multiple items, express the next PdO that needs to be 49

51 Production Process Express Packaging continued PdO(s) for Packaged Goods have now been expressed on Packaging Worksheet Both Issued & Receipt boxes should be checked 15. Current Tank Status Should now reflect Brite Beer removed/decremented from previous Warehouse (Brite Tank) Nice! Expressing Pro-Status! 50

52 Additional Scenarios Close Production Orders Close Production Orders Modules > Production > Automation > PdO Close Wizard 1. Open PdO Close Wizard 2. Select Status dropdown and choose Received 3. Select Start Date & End Date for the Production Orders you are ready to close 4. Click <Search> 5. In the left-hand column, checkmark the Production Orders you would like to close 6. Click <Close> <Yes> <Cancel> 51

53 Additional Scenarios Empty Tanks Modules > Production > Production Forms > Packaging Worksheet 1. Open Packaging Worksheet 2. Select Location 3. Verify leftover amount in Warehouse Under Current Tank Status table 4. Click in the top left dropdown <Goods Issue> click <Create New> 5. Select date liquid was lost 6. Fill out item that needs to be issued out/emptied (i.e. BB1001) 7. Enter quantity that was lost (typically matches quantity in Warehouse) Empty Tank 8. Input Warehouse where liquid is located (i.e. BT01) 9. Variance Reason dropdown > choose specific reason 10. Click <Add> <Auto-Select All> <OK> <Add> <Yes> <Cancel> 11. On the Packaging Worksheet click <Refresh Matrix> to verify removal of liquid 52

54 Additional Scenarios Disassemble an incorrectly expressed PdO Modules > Production > Production Forms > Brewing/Cellar/Packaging Worksheet 1. Open the worksheet associated with the production order that was incorrectly expressed (i.e. Wort on the Brewing Worksheet, Green/Brite Beer on the Cellar Worksheet) If the item you need to disassemble has been consumed (i.e. Wort was already consumed by Green Beer), you will need to disassemble what consumed it (i.e. Green Beer), and work backwards 2. Select Location 3. Select Start Date & End Date for the Production Orders you need to disassemble 4. Ensure Status dropdown is set to Released 5. Click Refresh Matrix 6. Select the Production Order (both issued and receipt boxes should be checked) 7. Drill into the Production Order # (Prod#) via the yellow arrow Opens up the single Production Order 8. Right Click <Disassemble> <Yes> <Okay> Disassemble an incorrectly expressed Production Order 53

55 Additional Scenarios Troubleshooting Production If you see RED BARS during Expressing, this means you are out of inventory or your Production Order is trying to pull inventory from the wrong warehouse. Drill into the PdO to fix. Once updates/corrections are made. Click <Refresh> 54

56 Additional Scenarios Blend 2 Batches of Beer together Modules > Production > Production Forms > Cellar Worksheet 1. Highlight the tank in the Current Tank Status window (this will be the tank that contains 2 different batches 2. <Right Click> choose Blend Tank 3. Verify the combination of different batches being combined 4. Change the batch number (if you so choose) 5. Click <Add> 55

57 Additional Scenarios Blend 2 Batches of Beer together continued 6. Click <Refresh Matrix> 7. Verify the new batch of combined liquid 56

58 Additional Scenarios Inventory Transfer Modules > Inventory > Inventory Transactions > Inventory Transfer 1. Enter the Date you need transfer to take place 2. Fill out the From & To Warehouse 3. Fill out the item that will be transferred 4. Fill out the quantity that needs to be transferred 5. Click <Add> 57

59 Additional Scenarios Inventory Transfer continued 6. Select the correct batch(es) and amounts that will be moved Auto-Select All will just pull amounts from the oldest batch first <Update> <Okay> <Add> <Yes> 58

60 Additional Scenarios Warehouse Assignment Wizard Modules > Administration > Setup > Inventory > Warehouses 1. Add new Warehouse Code 2. Add new Warehouse Name/Description 3. Go to View (Main Menu Bar) > User Defined Fields 59

61 Additional Scenarios Warehouse Assignment Wizard continued 4. Under Warehouse Type, add correct type of Warehouse 5. Click <Add> 6. Go to Modules > Inventory > Warehouse Assignment Wizard (to assign inventory that can be in this new Warehouse) 7. Type in new code 8. Click <Search> 9. Select all items that may be added to the new Warehouse (i.e. Raw Malts, Hops, Adjuncts etc.) 10. Click <OK> 60

62 Additional Scenarios Warehouse Assignment Wizard continued 11. To verify the Warehouse was correctly added: Via Item Master Data, find an item that was added to the new Warehouse Verify Warehouse has successfully been added under the Inventory tab 61

63 Useful Production Reports Reports by Persona Production > Production Reports > TTB BRO Reporting Production > Production Reports >Orchestrated Reports > QC Reports Production > Production Reports >Orchestrated Reports > Production Dashboard Daily production for brewing and packaging Capacity utilization Raw Material Status Current Production Orders (past due partially completed scheduled today, tomorrow, future) Production > Production Reports >Orchestrated Reports > Inventory Item Trace Aka Where Used Packaging Volumes Filtration by Batch Brewing Data by Batch Air Tet Batch QC Production > Backtrace Batches Production > Production Reports >Orchestrated Reports > Indented Costed BOM Production > Production Reports >Orchestrated Reports > Production Cost Analysis by Item Helpful for setting up and troubleshooting BoMs and BoM costs Know your production costs! 62