Create and use a Packout step

KB ARTICLE

Overview

Packout is a special step type in an operation that allows process engineers to define packing list items to be placed into pre-defined boxes in inventory. A packing list can consist of completed assemblies from production as well as additional materials or items from inventory. Packout guides operators step-by-step through box selection and item packing, and can validate that assemblies have no open defect indictments and have completed all defined route steps. Items not tracked in the FactoryLogix inventory system can also be included if needed.

Prerequisites

• Access to FactoryLogix Office with Process Engineering permissions.

• The target assembly and process revision must exist in FactoryLogix Office.

• The process must be released to production before packout can be used on the shop floor.

Create a box type in FactoryLogix Office

1. Log in to FactoryLogix Office.

2. Select Materials Management > Containers, then select Boxes on the left side of the window.

3. Select the Add button to create a new box.

4. Enter a Name, set the Max Capacity (the maximum number of items the box can hold when fully packed), then select OK.

5. Scan or manually enter a barcode if one was previously created for this box. If no barcode exists, select Auto Generate Barcode to create UIDs automatically.

6. Select Add to add the box as an inventory type, then select Submit in the lower-right corner of the window.
   
   A confirmation message indicates the box was saved successfully.

Create box instances in inventory

1. Select the box type you just created, then select the Add button (each selection creates one new instance of the box).

2. Select Submit in the lower-right corner of the window.
   
   A new box of the selected type is created and a UID is generated for each instance.
   

3. Use the fields on the right side of the window to add details for each instance, such as Lot, Supplier, Supplier Part Number, and Goods Receipt ID.

4. Select View Inventory on the right side of the window to view all box instances. Select any field to enter additional details such as Quantity or Vendor, then select OK to return to the Containers window.

Add a packout step to an operation

1. In FactoryLogix Office, select Process Engineering and open the assembly and process revision you want to modify.

2. Create an operation named Packout and set its Operation Mode to Full Tracking, then select OK.

3. Double-click the Packout operation to open it for editing.

4. Select the Add button, then select Packout Step.

5. Double-click the Packout step to open it for editing.

Configure packout step settings

1. Select the Packout Settings tab.

2. Select the desired box from the Box Type drop-down.

3. Select Add Packing Items to search for inventory items to include in the packing list. (To remove an item, select Remove Packing Items.)

4. Search for the assemblies to be packed, select each item using the checkboxes in the Select column, then select OK.
   
   Two activities are created under the Packout step: one to retrieve the box from inventory, and one detailing the assembly to be packed.
   

5. If multiple revisions of the selected assembly exist, use the Revision drop-down to select the valid revisions. Use Revision Mode to specify how revisions are evaluated.

6. Enter a Quantity to be packed per box.

7. Use the Verification Mode drop-down to specify what the operator must enter or scan to confirm each packing item: Acknowledge (check box confirmation), No Action (no acknowledgement required), Scan UID (enables all validation options), or Scan Lot (operator scans or enters any alphanumeric lot ID with no validation).

8. Select Has No Unresolved Defects to check for any open defects on items being packed.

9. Select Has No Unresolved Symptoms to check for any open symptoms on items being packed.

10. Select Pack Items Individually for each item that must be packed separately.

11. Select Label Template, select a shipping label from the drop-down, then select OK.

12. Select Force Complete Boxes to require that the box be filled to capacity before an operator can mark it complete.

13. Use Batch Restrictions if you want to restrict which items can be packed together.

14. Select Allow Supervisory Override for Incomplete Boxes to require supervisor approval for any incomplete box.

15. Select Export Completed Boxes as XML to generate an XML file of completed box contents.

16. Select Validate Entry Conditions of this operation for each item added to enforce that all entry conditions for the Packout operation are met for each packing list item.

17. Select any desired Analytics reports for packout-specific alarms and reporting.

18. Select OK to save the Packout step settings, then select Save and Close Operation to return to the Process Definition window.

Use packout in FactoryLogix Operations

1. Release the process to production, create a new batch, then process a unit through the process flow until it reaches the Packout operation.

2. At the Packout operation, the Activity Work Area gadget displays instructions to the shop floor operator. The first instruction is to retrieve the appropriate box type from inventory and scan its UID.

3. Follow the instructions to satisfy each item in the packing list.

4. When all packing list items are satisfied, select Complete to mark the box as complete.