There are a lot of ways of creating a production order picking list automatically in Dynamics AX 2012. You can create (and optional post) a production order picking list when you start a production order (forward flush); you can create and post a picking list automatically when you post a route card or a report as finish (back flush); and you have lots of options to create picking lists from your production order bill of material. Production control > Journals > Picking list > Picking list > Create lines:
But even with all those ways to avoid typing, every so often we get a support call where we find that the user has created a picking list manually and fallen into the trap for young players which the picking list form presents.
Let’s create a simple production order. In the demo data, item D0001 has a nice simple Bill of material of 5 components, so I’ve created a production order for 50 and started it. Now what seems to happen is that the forward/back flush process doesn’t go according to plan and the users need to adjust something. Let’s assume that we’re back flushing, and I’ve made my 50 of D0001 and consumed 50 of each of my components. Production control > Common > Production orders > All production orders > Production order > Production details > BOM:
The quantity tab is showing me that everything’s as normal as could be.
Now let’s try to adjust this and issue a few more M0001’s to the production order. Production order > View > Journals > Picking list shows me the existing journal:
And I succumb to temptation and click ‘Create new’:
Add the system’s created me a journal header, opened the lines form and it’s asking me for an Item number (that red wavy underline certainly catches the eye doesn’t it?)
So I’ll enter my item number and issue 10 more:
Click Post and everything looks hunky-dory:
But when I go back to the production order Bill of material I’ll notice something a little odd:
An extra line has appeared!
The quantities are correct – but the system isn’t really making it clear that we just over-issued one component – it looks like we’ve added another, unplanned, component:
Let’s try that again on another production order – right back a where we click ‘Create new’ and create a new picking list journal:
Don’t enter the item number!
Ignore the red wavy underline. Instead, click in the Lot Id field:
Now click the drop list arrow and you’ll get a list of the existing BOM components:
Select your item from this list:
And then enter your quantity and post:
Check your production order BOM:
No extra line, and the quantity tab makes more sense too:
In fact all of your production reporting is likely to make much more sense if you follow the process of selecting Lot Id (not Item number) when adding lines manually to a production order picking list (unless of course you are actually issuing a completely new unplanned component to the production order).