Ralcorp Frozen Expire LogicSeptember, 2013

Agenda

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Sections Presenter

Background David Friedli

Picking Functions

Expiration Functions

Distressing Functions

Hawk (If time permits)

Q & A Discussion

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Who is Ralcorp Frozen?

• A $1.1B Leader in Private Label Frozen Bakery• Products

– Cookies (#1)– Pancake / Waffle (#1)– Refrigerated Dough (#1)– Bread / Biscuits

Environment Overview

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Lodi

Seattle

Delta

Ogden

Louisville 1 & 2

Chicago/Downer

s

FridleyBrantford

Grand Rapids

Forest Park

Carrollton

Environment Overview

• MfgPro eb2.1 service pack 5• .Net 2011• MSW/PSW vs 3.2.2.1• Eagle Barcoding since 2009• Both Lot/Serial and Reference number is

populated for FG and RM pallets

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Personal Overview

• My Experience– 12 years in Automotive with QAD– 4 years in Food with QAD– 30 years with ERP systems

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Picking Function

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• We are having Customers reject shipments due to insufficient remaining shelf life

• Each customer can have different requirements

• Can’t rely on fork lift drivers to pick qualified pallets and memorize all the rules

• Customer Service being impacted

Picking Function

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• Very first thing, smart lot numbers– YYJJJSPLN (132101A01)– Production Reporting application modified

Picking Function

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• Next modified Eagles PPK pallet pick option– Gen Codes Generated to restrict age of

product being shipped• By ship-to/product line• By ship-to/marketing group• By part number

Picking Function

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– Modified PPK so the find function would only show pallets that qualify for the customer

– Modified PPK so the find function by Lot– Also added warnings

Expiration Functions

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So we have individual customers satisfied now

How do we prevent shipping out of date product? We have:

• Dated Lot Code• Shelf life in a custom table

Want to use as much standard QAD logic as possible (item status, inventory status)

Expiration Functions

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Two New Applications

• Run Nightly• Looks at all ld_det records that are

missing an Expire or Distress Date• For Expire dates, we turn the Lot

number into a date and add the shelf life.

• FYI, for distress dates, go thru the logic in the Eagle pick program and add the lowest MaxLife value to the Lot number.

Expire Functions

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• Run Nightly after Expire Date Calc• Setup in batch for each site’s

needs• Able to update the status of the

inventory based upon a horizon (e.g. Expire all material with an expire date within the next 7 days)

• Able to enter a Reason Code and Comment into the ld_det table so can see why it is on Hold. 3.1.1 also updated so QA can manage reason code and comment for QA reasons.

• Ran for inventory with a Current status and changes ld_det to the new status (RCT-CHL created) (Runs thru CIM).

Expire Function

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Plant has two primary ways to look at inventory

Expire Function

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Distress Function

Distress Function is for the material that can no longer be shipped to a standard customer

• Handle two ways– Have Distress date in the ld_det table, run Auto

Expire Utility on this date (GOOD > HOLD-DIS)– Have Expire date, run Auto Expire Utility for all items

that do not have a distress date (e.g. 30 days before expire)

Interface - DS1 (Data Source One)

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• Purpose– Home-grown tool for centralized maintenance of

Raw, WIP, and Packaging items (QAD BPM handles FG items)

– Centralized maintenance of Customers/Suppliers– Data flows from QAD thru Pro2SQL to SQL Data

Warehouse to DS1 application back to QAD– CIM loads into QAD with auto-emailing and

auto-reprocessing of errors• Frequency

– Every 30 minutes• Mechanism

– SQL ODBC’s to custom staging table in QAD along with an automated Cron job to load into QAD

HAWK

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• Purpose– Home-grown efficiency tool used for FG reporting

and inventory transactions to avoid manual QAD data entry and other slow processes

– Data flows from QAD thru Pro2SQL to SQL Data Warehouse to HAWK application back to QAD

– CIM loads into QAD with mass auto-emailing and auto-reprocessing of errors

– To date, 5.0 million loads completed in QAD (now averaging 170k QAD loads per month)

– 9 transaction types: BKF (backflush), WOR (work order receipt), PDL (pallet delete), PMV (pallet move), POR (purchase order receipt), CYC (cycle count)

HAWK

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• Production Reporting– Hawk (7 Plants)

• Runs regionally on SQL servers• Reports Sub Assemblies and Finished Goods

– Can be used with Repetitive and Discrete Orders– Collects/Uploads production within seconds to QAD– Creates Pallet Labels for Eagle/Inventory

• If QAD is down, still collects production and prints

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Hawk – Front End

Hawk – Back End

• Back End is in QAD• Custom Table and Utilities• Upto 10 transactions/second capability• Sends Emails on errors• Serves as interface to multiple external

applications– Hawk– PO receipts at external sites– Cycle Counts by external sites

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Hawk – Back End

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Hawk – Back End

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• Used in batch for each site• Each site has its own processing queue• Runs every 20 seconds• Can setup to run all transaction types, or only specific ones if needed• Each transaction type has a pre-cim validation

• If an issue, do not want to submit thru CIM, it will just delay 20 seconds• Each transaction creates an email (can be setup for P or E)

Hawk – Back End

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Hawk – Back End

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Hawk – Back End

• Reprocesses Errors• Runs every hour• Can run manually • Can run for a single record• Can run for entire site• Can cancel a single record

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Hawk – Back End

• Runs every 8 hours• Does send out email that errors still exist• Purges old records based upon GenCode settings

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Questions?

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