Calling All Improvements - Libero/Adaxa LM

[redhuan d. oon]

Hi community,
I am reviewing Libero together with Adaxa Lite Mfg (LM) to publish any community work done to improve them collectively.
So far I been in discussion (will publish the relevant bits) with Steven Sackett of Adaxa for LM where Deepak Pansheriya is also involved. I am also reviewing bug reports and recommendations to Libero such as by Hiep LQ and Steven Yanzhi http://red1.org/adempiere/viewtopic.php?f=45&t=1775#p8512.
There is also the material provided by Chuck Boecking in his site:
http://www.chuckboecking.com/make-order-demonstration-adempiere-open-source-erp/ and
http://www.chuckboecking.com/light-manufacturing-demonstration-using-adempiere-idempiere/

Anyone who has further comments or improvements are welcome.

Kind regards
red1

[Chuck Boecking]

Hi Red1,

Thank you for posting this!

After having spent 2.5 years supporting Libero, I am not a fan. My recommendation is steer clear. I have included my libero summary thoughts at the bottom of this post.

I believe the future of manufacturing in iDempiere is a combination of Production and Project. It is not perfect yet; however, it represents much opportunity. This statement is especially true for manufacturing markets that are currently under served (MTO, HMLV, Custom, Capital Equipment, Outsourced, etc... manufacturing as well as construction). I am doing a project manufacturing series in the ERP Academy. Here are some publicly available training videos.

• http://www.chuckboecking.com/project-manufacturing-quick-demonstration-using-idempiere-open-source-erp/
  
• http://www.chuckboecking.com/project-manufacturing-explode-project-template-bom-components/
  

Here are some areas of improvement for Production and Projects:

• Prepare Doc Action for Physical Inventory and Inventory Move - https://idempiere.atlassian.net/browse/IDEMPIERE-2377
  
• Improved Project to Fixed Asset - https://idempiere.atlassian.net/browse/IDEMPIERE-2398
• Add Phase (and probably Task) parameters to processes that create documents from Projects
• https://idempiere.atlassian.net/browse/IDEMPIERE-2410
  
• https://idempiere.atlassian.net/browse/IDEMPIERE-2412
  
• https://idempiere.atlassian.net/browse/IDEMPIERE-2416
  
• Add Production Batch Process - https://idempiere.atlassian.net/browse/IDEMPIERE-2415
• Better BOM template management - https://idempiere.atlassian.net/browse/IDEMPIERE-2438

Here are some other ideas that do not have tickets/solutions yet:

• Project, Phase and Task references need to be more prevalent in the system, and they need to post to the GL. Currently only C_Orderline, M_InoutLIne, and C_InvoiceLine have a reverence to C_ProjectPhase and C_ProjectTask. One of the above tickets adds these fields to the Production Window.
• Replenish needs a complete rework. Thoughts include:
• The process of (1) creating the replenish records and (2) generating the documents from the replenish records should be two distinct steps. This gives the user the ability to generate some or all of the documents based on a review process.
• The results of a replenish run should not reside in a temporary table. Instead, there should be a M_Replenish and M_ReplenishLine table to represent the results. Documents that are created as a result...
• The custom replenishment class only iterates on existing T_Replenishment records one at a time. This is inefficient. Instead (or in addition to) I should be able to dynamically add a section (similar to the "//add production lines" bit of code) where you can update all records based on a type of "on order" or "reserve". Adding Project Lines as a source or demand is an example.
• The process should be able to iterate n-levels of Production until you reach the max BOM Depth - i.e. no more production records are created.
• Note: the first bullet (distinct steps) and this bullet oppose each other. I would be happy if all resulting documents had a "M_ReplenishmentRun_ID". That way I could review (and mass change) the records if a mistake was made.
• Currently, you have to manually execute Replenish for Production as many time as you need until no more Production records are created. (for each warehouse, etc....)
• The process should be able to create multiple types of documents in the same instance
• The process should be able to dictate the end document status of the documents it creates.
• You should be able to create multiple types of documents within the same run. In other words, I would be able to iterate across all production BOM levels then create the resulting Purchase Orders or Requisition documents.
• I would be nice if you could run replenishment for a given Project, Phase, or Task. The benefit is that the resulting documents are tagged with that project
• Project issue needs to be more versatile:
• You should be able to create a Project Issue for a Production and Vendor Invoice
• The Project Issue should post its Phase and Task.
• You should be able to configure a Vendor Invoice to automatically create a Project Issue to re-class project expenses without an extra manual issue step. The same is true when completing a Production document - it should be able to automatically create a Project Issue to issue the finished good back to the project.
• Project needs Project WIP or Project Asset balance monitoring reports/windows.
• Project needs the ability to take Project WIP or Project Asset balances (by Project, Phase, or Task) and create other documents that reduce the WIP/Asset balance. For example: create a Customer Invoice + GL Journal for a current WIP balance. This would be great for construction and service.
• Need a Project, Phase or Task Close option that expenses any WIP or Asset balance for that respective Project, Phase, Task. This feature would be great for Capital Equipment manufacturing.
• M_Product.isManufactured should be reviewed to make sure it is consistently used. The inclusion of Manufacturing Light created this field, and it makes sense to me. Just because a product has a BOM, does not mean it is manufactured. For example, a non-stocked product with a BOM will get automatically exploded into it BOM products when a Sales Order is completed. This is a cool feature when a BOM is not manufactured.

The above spends a lot of bullets discussing WIP. I believe this concept is critical for iDempiere to have any real manufacturing horsepower.

Here is an elaboration on my comments and concerns about libero:

• MRP is good
• The processes and concepts are not intuitive
• Manufacturing Order is not good. 
• The code tightly couples all the artifacts related to a MO - it ends up being a big spaghetti mess.
• There is no way to reverse correct a MO. You cannot even create a negative MO....
• Closed MOs will leave a WIP balance
• Variances are not calculated correctly (IMHO - and is very subjective). 
• CRP is is limited. You cannot schedule parallel workflow processes. It does not make use of Resource scheduling. Most of my class members end up using frepple for production planning.
• DRP is not good. It is overly complex and requires core code changes to fit most installations. Simply adding a prepared status (along with the current Inventory Move confirmation) supports most common inco freight term scenarios.
• The code style is not consistent with iDempiere. I find it much harder to read.
• There are many bugs - this one is either (1) true, (2) a result of my ignorance - therefore not bugs, and/or (3) a result of the difficulty to accurately read the code
• There is little documentation - I have lost hair scratching my head.

I hope this helps!!

Regards,

Chuck Boecking

www.chuckboecking.com

[armenrz]

Hi Red1,

For Adaxa LM, my wish list are :

1. to have BOM versioning in Production window (user can choose which BOM version to apply)
2. to be able to support costing for co-product/by-product (pro-rate or by percentage)

Best regards,

Armen

[nadrog]

Hi Ckuck, I have questions about bill of quantities (BOQ), is this posible attach into equipment maintenance workflow :
1. service request
2. if statement depends on working values (for work not under 1000 U$D need offer based on bill of quantities) 
2a for work < 1000 activities continue, and go to step 3.
3. material receipt 4. sales order
and in finish post analitics into accountiing.

regards
Gordan

[Tanmoy Prosun Dey]

I have done the following steps for Manufacturing with LiberoMFG.jar
1. Define Bill of Material and Formula;
2. Define Manufacturing work-flow and Resources;
3. Create Forecast and Sales Order for Demand;
4. Create Data Plan;
5. Run "Bill of Material and Formula Cost roll up" process for update product cost.
    (While running this process a massage is showing that "Not found Product Planning ID and product BOM ID"
6. Run "Work-flow cost roll up" process for update work flow cost.
    (While running this process a massage is showing that "Not found Product Planning ID and AD work-flow ID"
As this two processes  is not updating the cost of BOM and Work-flow for the Produced Product, so no costing record is created for Manufacturing order.

We have done the same process in ADempiere 370 and found the same problem. So we have checked "Bill of Material and Formula Cost roll up" and "Work-flow cost roll up" processes.
We found here the S_Resource_ID and M_Warehouse_ID is fixed to zero(0). We have added S_Resource_ID and M_Warehouse_ID in the process parameter. Then it works fine.

[redhuan d. oon]

Thank you Tanmoy, I am amending exactly as you described and will be posting all artifacts online.

[Michal Zilincar]

Hi Red1,

I liked complexity of Libero MFG but for my usecase was too much and after some analyzis I decided to use AdaxaLM at this momemt and extend it this way :


1) activated Forecast window , based on this I genarate production plan and production orders.
in Adaxa concept production = production orders, but this was not enough for me.

2) In production i added scrap qty and scrap locator where scrap is moved from production .

3) plan to add again BOM versioning

didn work on costing yet.

Best Regards
Michal

[redhuan d. oon]

Yes Michal, i have analysed both approaches side by side where Libero tackle many gaps that are suitable only for heavy manufacturing:
Replenish = MRP (with own processes)
Project = ProductPlanning+WF+Resources*
Production+*Time = MO
*Chuck's Project brilliant improvements still has lacking of 'Shopfloor scheduling'+ProductPlanning+Resource that Libero has. This includes many but little things such as material lead time and BOM versioning.

Now your costing need is another area that Libero tries and some says is a mess. If you can describe your costing requirements like u did with your 3 points it gives me important deduction of what remains.

Indeed Libero is too much code, too little guide, but it has come quite far, with the little tweaks along the way and i intend to finish the most important gap - a pretty good document guide for survival trials of it.

So in the end i am suggesting a minimalist approach:
1. Keep both approaches separate.
2. Make a simple converter for Production records to be migrated to MO records.

We should also finally remove the many evolution code and entities still in core. In fact they are the cause of model mistakes as they do not show red marks been redundant.

Originally when i first tackle this review in March 2011, there was no ownership feedback even after i duly inform the owner, Victor Perez of e-Evolution, that my review will continue his important work and increase his goodwill. I till date has maintained the community rule of respecting original ownership and only refactor naming schema to be more idempiere standard. But i am not forgiving when i find broken things or information hiding. I will objectively and academically report as such.

Nevertheless i think there is substantive following of Libero (perhaps due to the need for those gaps) and Libero was also the holy grail of the holy war before us - how to separate complexity into a mere plugin and stop fighting over trunk. A complete independent but fully working Libero plugin suite will mean complete victory of the iDempiere OSGi philosophy. Of course eventually a community will decide.

Thank you for your effort also.

[Carlos Antonio Ruiz Gomez]

On 25/02/15 a las 16:21, redhuan d. oon wrote:
> A complete independent but fully working Libero plugin suite will
mean complete victory of the iDempiere OSGi philosophy.

:-)

I think we don't need that to declare complete victory
Just look at
http://wiki.idempiere.org/en/Category:Available_Plugins
and take into account this is a partial list of all the plugins that
community is sharing.

You said long time ago - the war is over and there is a clear winner
(but we can discuss that better in your forums, as these forums are not
intended for political statements).

I definitely like your effort as we need quality plugins - not garbage
plugins just intended for marketing purposes. Just I'm not sure that
libero will be the best start, if you achieve it - great!
But also I like a lot Chuck's approach to use projects for mfg - of
course both can coexist with our amazing OSGi architecture.

Regards,

Carlos Ruiz

[Steven Sackett]

Some things that may be useful improvements in Manufacturing Light

added by TSPC

.. utilise the multiple Costing Elements rather than put all costs in Material

.. add a IsWIP flag to orders to make it easier to delete 'planning orders' before re-running Replenishment

.. process to delete planning Orders based on the condition of the IsWIP flag

.. scheduled task example to auto-run Replenishment multiple times

included in Adempiere 380 

.. adopt multiple BOMs for single Product

adaxa changes

.. add a flag to a parent product so that sale of the product auto-creates and completes a production order.

not done (or misplaced)

.. add a BOM importer

.. handle situation where a product is manufactured in warehouse1 but is a purchased part for warehouse2.

regards

steven

[Tanmoy Prosun Dey]

Dear Mr. Redhuan,

I have tested with your latest Libero Manufacturing jar. But i am facing the following error massage.

**Failed to create new process instance for org.eevolution process.RollupWorkflow

Please find the attached file also.

Thanks and Regards,

Tanmoy

[Steven Sackett]

missed above...

added by TSPC

... a form which is like a 'where used' for a product but which only displays where there is actual demand in the system.

added by adaxa

... an MRP Pegging Report (still to be tested) .. https://en.wikipedia.org/wiki/Pegging_report

[redhuan d. oon]

Hi Tamoy, this usually means you did not install or start the bundle_id. OR the new plugin extension has changed its value and you are still using the old setting < i think this is the actual case since i did make those changes (usually re Import fresh iDempiere solves that)
Now i uploaded an even newer bundle that changed the rest of all extensions to 'libero' namespace instead of 'eevolution'. Please download org.libero.manufacturing_3.0.0.201503051422.jar from https://sourceforge.net/projects/red1/files/p2/LiberoMFG/ 
You can email me privately if you have more issues.
At the moment i am going to create  Info Windows for ZK UI side as Libero only has Swing Forms Windows:
1. Manage MRP (to view the MRP records, selectively for process - Calculate Material Plan) this is more user oriented, visible or controllable than the present Calculate Material Plan as the newly improved iDempiere InfoWindow allows multi tabs and selective check boxes with multi-process classes to act on them.
2. Manage MO (production records) again as above to give more control and visibility to the user.
I am trying to make them as similar in model and process to avoid any sharp learning curve.

[Michal Zilincar]

Hi Red1,
sorry for delay,

for costing we want to use standart pricing. So each material will have fixed price.

And what actually will be more complex is controling of production.
We want to prepare concept of it within next weeks. I would be glad to share it, and get your opinion on it.

Thank you
Michal

[redhuan d. oon]

Michal Zilincar,
(Hope no more delays! :) I look forward to your model design. Otherwise i be around Praque in coming months and you have to buy me coffee so i can look at it in person or dinner if I take a long time to look at it! :) )
Meanwhile i am reviewing the entire code of CalculateMaterialPlan (MRP.java) already done as an Info Window process to resolve sub infos for its resulting Notices, MO (production orders), Distribution Orders, and Requisitions, as well as (with luck) its corresponding reference ProductPlanning window.

The idea is to allow a single InfoWindow reference for everything. I just committed a main Info Window work in progress without sub infos or testing which is tested on 3.0. It should also work on 2.1 but tell me if it does not. (Please see http://red1.org/adempiere/viewtopic.php?f=45&t=1775&p=8645#p8645)

You will note that the InfoWindow for MRP is selective for main CMP process as well Zoom individually into its MRP window created anew as a simple Window for individual MRP record checking.

Now the biggest user challenge is not about getting their features met in the code base (which i trust is 'over-killed' by Libero) but in understanding how to use it with the poor Libero documentation. So this time I have to resolve a better step by step tutorial. I hope to make just one tutorial at a time. For a start it be the MRP I (Material Requirements Planning) particularly pertaining to the MRP InfoWindow.

[Michal Zilincar]

Dear Redhuan,

regarding the concept it will take a little bit longer, some little more issues showed up.

But for sure, you are more than welcome here. I am actually located in Bratislava , but have some clients in Czech rep., so from time to time I am also around Prague. I can organize it to fit your timeschedule. And I would be honoured to invite you for a dinner or pay any "tribute" to Red1 :).

Michal

[redhuan d. oon]

It seems we have to pay you a small visit in Bratislava. Don't worry. I won't wear Prada. :) I will come with Norbert Bede.
Meanwhile i am working on something important http://red1.org/adempiere/viewtopic.php?f=45&t=1775&p=8648#p8648
I just welcome any feedback what can be a better naming schema at item 3 at the bottom.

[redhuan d. oon]

My big thanks to Hiep Le Quy for helping me solve a bug in the Libero Multi BOM Drop, thus completing a big step which is allowing variance setting of BOM Qtys for the drop! http://red1.org/adempiere/viewtopic.php?f=45&t=1775&p=8651#p8651

[HansAnton Riess]

Congratulations.

Do you also plan to enable this in web ui?

Regards

Hans

[redhuan d. oon]

Hi Hans, your congrats was really on time as i have just completed a Sales Order BOM Drop test successfully and recorded it here in a video https://youtu.be/YVJufthhXb4
Well, it should not be that difficult but let me finish off the InfoWindow (WebUI) version of the MRP processing among others, making it as versatile and friendly as can be knowing how complex this terrain is.

[HansAnton Riess]

When I compare the BOM Drop of Libero and current Production Module in Idempiere I see some way of enhancements:

- Alternate Group 1-9 is offered only by Production module

- Before dropping the BOM into Project, Order or invoice it would make sense to get an impression of the overall cost (displayed in a separate field). So you could compare the sum based on pricelist which is used for sales order and the costs which are defined in costing record of the bom componenents (e.g. standard cost). Some costing elements are usually indepenent of the amount, this is not considered when calculating the ovarall costs...

- If a component has no pricelist, the BOM drop usually fails (at least in standard BOM drop of idempiere). A potential enhancement would be that these products will not be dropped to the order. That means that the BOM can have more elements as in the final sales order, invoice or project. I think of internal steps, which are needed for production, but they should not appear on the sales order/proposal...

- another nice enhancement could be that we see the current stock amount in a separare field for each component within BOM before dropping.

- dropping to project phase/task instead of project line and get the price of the BOM elements automatically (current: you have to hit the button "get price" for each component.


Regards

Hans

[redhuan d. oon]

Hi Hans,
Thanks for the good feature descriptions. Yes, i now doing, done the QtyOnHand (with translation parsing) part as shown in the lower of http://red1.org/adempiere/viewtopic.php?f=45&t=1775&p=8652#p8652.

About dropping to Phase/Task, isn't that independent on predefining a Project with Phase/Task? As the drop will be onto the ProjectLine Tab. Explain more if I don't get it.

About the Roll Up Cost a a single figure, yes that is nice as a button on the main panel to calculate that as a single displayed cost. But i think that is dependent also on user control where production may be separate from Sales. Also there is already the RollupBillOfMaterial process that i presume is handling that. WDOT (what do others think?)

About no PriceList  or under limit, i double checked the code, it seems to workaround by your pricelist no enforce rule. Otherwise I wonder if such feature should be conventional.

About grouping 1-9, yes, i will look into it as Libero threw that out summarily.

[HansAnton Riess]

Regarding BOM drop to project:

We think about of project based production, where we will use the existing structure elements of project.

It could make sense to define individual production steps as a project phase or task. Example we get an order from web shop, which consist of more than one line (in our case customer orders a book, which should be printed as hardcover and within the same order he or she orders 100 visit cards, because they are offered for free). The project structure would help us to cover all the items of this webshop order).

Regards

Hans

[redhuan d. oon]

Hans,
I am thinking of making a simple but direct map of BOM structure to the Project/Phase/Task, i.e. there be a two layer schema (for Phase or Task) in the BOM and its ComponentType of such be set to 'Planning' . Then their descendants are dropped accordingly. WDYT? Otherwise one will need to use the Libero Workflow/Resource model which is already on its own and has no added value to a redundant Project structure.

Anyway also like to give some good news. ButtonGroups are working http://red1.org/adempiere/viewtopic.php?f=45&t=1775&p=8653#p8653

[HansAnton Riess]

HI Red1,

this is a great idea.

In some cases it would also make sense to add the whole BOM structure to only one element of the project phase or task.

regards

Hans

[redhuan d. oon]

I finally understood what you mean. Here it is! Please test. :) http://red1.org/adempiere/viewtopic.php?f=45&t=1775&p=8654#p8654. I will look at the WebUI version and Kanban Board integration to MOs next.

[HansAnton Riess]

Does this enhancement run on one of the following testsites?

• http://test.idempiere.org/  (development branch running zk7 - postgresql 9.3 - java7)

• http://experimental.idempiere.org/  (experimental branch running zk7 - postgresql 9.4 - java8)

• http://demo.globalqss.com/  (release-2.1 + updates + Localization Colombia LCO)

regards

Hans

[redhuan d. oon]

The base libero plugin i for server and i just applied it onto the test.idempiere.org site. The Swing UI is not for server as it is for Java Client. For server-side the only enhancement i made is in the form of MRP Info (ZK). You can select South warehouse location and refresh to see its MRP records.

[redhuan d. oon]

I have considered your suggestion for a display of costs but i make it pop up as a total header completed cost (including tax for Sales Order, and Planned Amt for Projects). The concept is quite proven as shown here http://red1.org/adempiere/viewtopic.php?f=45&t=1775&p=8655#p8655
and with the source i committed anyone can change or add any lines of info onto that box.

On Thursday, 9 April 2015 19:42:17 UTC+2, HansAnton Riess wrote:

[redhuan d. oon]

Hans,
The GetPrice routine is solved as shown attached. Thanks for contributing a good suggestion! :)

On Thursday, 9 April 2015 19:42:17 UTC+2, HansAnton Riess wrote:

[HansAnton Riess]

Thank you for your work.

In order to test this. Where should i download the code ?

I assume it is part of the libero plugin ?

regards

Hans

[redhuan d. oon]

You have to use this BOM Drop mechanism under the Swing UI, i.e. by launching adempiere-client.sh/bat. Plugins are at http://sf.net/projects/red1/files/p2/LiberoMFG, both org.libero.manufacturing and org.libero.manufacturing.swing. Start the first one and wait for its message that LIBERO MFG INSTALLED, then start the swing.

[redhuan d. oon]

Halo fra Danmark! Another very important gap patched up in Libero which is the Resources used during a production run are notified and assigned so that the next run will queue into what will become a Master Production Schedule. http://red1.org/adempiere/viewtopic.php?f=45&t=1775&p=8662#p8662
I also got the chance to refer to local Danish MFG system which finally has the MPS showing Gantt display with Resources Load Times.

[Flemming Birch]

Rart at hører lidt dansk i dette forum!  (Nice hearing Danish is this forum)

 

What Danish MFG system are we talking about? Is it iDempiere or is it one of the proprietary ERP’s!

BTW this feature is looking great! 

/Flemming

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[redhuan d. oon]

Of course the present ERP they are using is proprietary and they cannot stand it anymore the restriction to change it to their particular processes. And their willingness to become a trial user and provide me with ideas to improve is very important as Libero still has many unfinished code and i am not sure of much of the missing logic and still need real references to be sure that any improvements to it is useful and applicable to most and serious users.

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