The following is a list of standard NAV features utilized to improve their overall workflow and day-to-day operations:
1. Supply Planning
Supply Planning was a major pain point. With multiple warehouses under its umbrella, each providing parts and services to the other, creating and maintaining accurate internal supply orders was a logistical nightmare. Supply planning in Dynamics NAV is a comprehensive tool that helps to plan the production schedule, as well as material requirements. Supply planning keeps supply in line with demand and stocking parameters.
Planning Features Utilized:
- Create production orders and corresponding supply orders from their other production facilities simultaneously as part of their planning process.
- Integrate and plan disassembly production orders as part of the overall materials requirements planning.
- Consolidate purchase requirements by vendor and expected receipt date.
- Track updates of the demand/supply in real time (pegging), automatically linking demand to the available supply, including on-hand inventory as well as in-bound receipts from purchase or production orders.
- Adjust production plans and related orders automatically depending on adjustments made to purchase orders or expected delivery dates.
By implementing several production-based features on Microsoft Dynamics NAV, they were able to improve accuracy while simultaneously minimizing data entry, both of which served to reduce cost and increase productivity.
Production Features Utilized:
- Manage multiple versions of BOMs maintained per item, with the option of using a different version in planning.
- Streamline made-to-order requests and simplify make-or-buy decisions.
- Modify components and operations as needed, even on released production orders.
- Manage subcontracted operations with outside suppliers.
3. Warehouse Management
Perhaps the biggest frustration that they had with their previous system was the inefficiency and inventory accuracy (or lack thereof) in its warehouse management and inventory control. Under the old system, paperwork was generated when a part was needed, but the transaction could be recorded later or not all. Because of this, actual inventory was frequently at odds with reported inventory, resulting in production delays, inventory adjustments and profit loss.
NAV Warehouse Management Systems (WMS) is designed to help reduce costs through effective warehouse processes. It is appropriate for companies thatreceive, manufacture and ship goods, while maintaining an optimum utilization of space while knowing specifically where all goods are stored at any given time.
Warehouse Management Features Utilized:
- Implemented bin management and mandatory warehouse transactions, drastically reducing inventory discrepancies and, of course, loss.
- Deployed wireless hand held scanners to improve accuracy and update inventory in real time.
- Implemented rules-based directed warehouse activities, helping to ensure that material is picked from and placed into bin locations for optimum efficiency and accuracy.
- Generate a daily cycle count for dedicated workers, providing an ongoing inventory calculation that increases accuracy and efficiency simultaneously.
Integration with other applications was also a high priority. As a primary requirement, the chosen ERP system must provide the tools and flexibility to integrate with other applications and interfaces. Microsoft Dynamics NAV features seamless integration with other standard software packages, including EDI, which was implemented to enhance the business relationships with their customers and suppliers, by improving the accuracy and timeliness of processing orders, shipment advice, and invoicing.
- Mapped their data to their trading partner data.
- Define and map various EDI sales and purchase documents with customers and suppliers.
- Standard workflows for processing EDI transactions.
Enhancements (the really good stuff)
While Microsoft Dynamics NAV provides rich ERP functionality, it does not include features to meet all of the major unique requirements of the remanufacturing industry. By leveraging the customizability of Microsoft Dynamics NAV, and workingwith the customer to incorporate the required remanufacturing functionality,
Level Seven developed a set of remanufacturing features fully integrated into Microsoft Dynamics NAV, creating what we believe to be the only modern-day ERP solution built specifically for remanufacturing.
The “Microsoft Dynamics NAV For Reman” solution from Level Seven seamlessly incorporates these new, custom built features in Microsoft Dynamics NAV:
- Core Tracking: This functionality tracks the “core” inside the remanufactured product, beginning at the point in time the item entered your inventory, regardless of whether it was manufactured or purchased, and is tracked outbound to your customer when the product is shipped.
- Customer & Vendor Core Terms: This feature maintains the core invoicing terms, including whether or not a core charge applies, core charge amount, return eligibility period, etc. Similar to standard sales pricing, core terms are defined by item by customer, thereby providing flexibility to define terms.
- Core Charge Invoice: As part of the standard sales order fulfillment process, the core charge, if applicable, can be included on the product invoice, or invoiced separately.
- Core Ledger: Central to tracking cores, the Core Ledger is updated by normal posting and is where tracking details are maintained. Various screens and reports provide access to the core tracking details.
- Core Returns: A return order process provides a method for receiving core returns from customers, and manages the application against owed cores, and the core credit due back to the customer.
- Core Cross-reference: A cross-reference table is provided to allow core items to be cross-referenced. This is intended primarily to allow a credit to be given on core return of a specific item not owed, but that is essentially the same core, such as with slight model variations or revisions.
- Disassembly Bill of Material (BOM): Sometimes referred to as a reverse bill of material, and not available in most ERP systems, the disassembly BOM defines the components that are yielded when an item is disassembled.
- Disassembly Production Order: Again, not common in ERP systems, this feature adds a new production order type to support the teardown of a (core) assembly. The assembly item is consumed from inventory and the reusable components, as defined by the Disassembly BOM and certified by the shop personnel, are yielded into inventory.