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Implementing Consignment Inventory (Part 2 of 3)

In the previous blog post, we covered the definition, initial setup and advantages of managing consignment inventory using Epicor ERP v9 or v10.

Below are the steps that must be done to implement a new consignment customer with a new consignment part, assuming that you already have a consignment plant (in v9) or site (in v10) set up in the system.

  1. New consignment agreement is placed by the customer
    • Create a “Consignment Warehouse” for this new customer (one time for each customer).
    • Define minimum stocking levels in the consignment plant/site; i.e., if your contract says you are to always have 100 on hand, then set 100 as the minimum on hand for the consignment plant/site.
    • Define minimum stocking level at the manufacturer’s local plant. This would be any inventory that you want to keep on hand to fulfill any rush requirements. Typically, this is less than or equal to the minimum consignment level above.
    • In the consignment plant/site, specify that this item is a “Transfer” item, and that the “Supply Plant/Site” is your main manufacturing plant. Also specify the transfer lead time (the number of days that the item will be in transit).
    • Create the MRP forecast for this customer part in the consignment plant (i.e., you are forecasting that the inventory will be consumed from consignment, not from your local stores).
    • Note: at this point, you do not have to have any firm Sales order entered… MRP Forecasting + minimum on-hand will drive the first fulfillment of consignment inventory.
  2. Run MRP
    • MRP will see that you are currently below the minimum in the consignment plant, and will generate suggested transfer order requirements from the manufacturer’s plant to consignment.
    • MRP will then add these requirements to the minimum on hand specified in the manufacturer’s plant, and will generate “unfirm jobs” to fill these demands (even without a firm sales order).
  3. Firm Job, and Make Product
    • This is a normal job in your local plant.
    • When complete, the product is received to stock.
    • Once in stock, it will show on the suggested transfer order shipments.
  4. Ship Transfer Order from the manufacturer’s plant
    • Transfer orders generate Transfer Order Packslips. These packslips show the address of the demand (the consignment plant). It is your paperwork that goes to the customer.
    • Note that this is not a customer shipment…it is a transfer, because you are not transferring ownership, only moving inventory locations.
  5. Receive Transfer Order into Consignment
    • This is done once you receive confirmation from the customer that they have received the shipment.
    • This function actually takes the inventory out of “In transit” and puts it into the consignment plant.
  6. Consumption of Consignment Inventory
    • In most cases, your customers give a report showing what items were consumed. When this happens, an order needs to be entered, shipped and invoiced.
    • There are several ways that this can be done, but easiest is to create a new “counter sale” sales order. Counter sales allow for an order to be entered, “shipped” and immediately invoiced without all the extra processing.
    • When you create the counter sales order, you tell the system that you are selling it from the “consignment warehouse” location. This then automatically reduces the quantity on hand in consignment.
    • If there are a large number of parts consumed each day, then this could be automated with a Service Connect process to create and ship the orders. Alternately, an Excel spreadsheet could be copied and pasted into the counter sale section on the sales order.
  7. Replenishing consignment locations (basically, Go to Step 2 above)
    • If the customer’s consumption above did not reduce inventory below the “minimum” on hand in the consignment plant, then nothing will happen.
    • But, if it does reduce the on hand below minimum, then when MRP has its nightly run (see step 2 above), it will create another transfer order suggestion to move more inventory from your main stock to consignment.

Consignment Summary
While there are “urban legends” that Epicor ERP v9 and v10 cannot do consignment inventory because there is not a consignment module, this is not true, and as shown above, the actual steps are not difficult. In fact, once set up, the system will self-fulfill as the customer consumes the inventory. The manufacturer may need some help from an Epicor consultant in setting this up the first time, but once the model is complete, it can be easily replicated.

In the last part of this series, we will discuss how to verify the quantities and finish the contract for consignment inventory.

Posted by Tim Shoemaker, Senior Principal Consultant, Epicor Professional Services

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