The Material Control module provides an effective means of controlling and tracking the delivery of component material and subassembly items from multiple warehouse stockrooms and locations to customer order configuration locations. A reorder point trigger controls just-in-time replenishment of component material to WIP stocking areas in an assembly operation and demand-pull replenishment of items picked from central stores locations during the manufacturing process.

To automate the control, and replenishment of inventory, the Material Control module uses shop floor stockrooms ("target" stockrooms), minimum and maximum levels for replenishment of these stockrooms, demand pull requisitions for the replenishment, inventory accounting control points, and real-time inventory status of work in process. The Material Control module uses pre-defined or calculated minimum and maximum inventory levels, and locations, to control the replenishment process automatically. A minimum and maximum inventory level is established for each item for each target stockroom. These values are used by the Material Control module to control both the inventory levels and the demand pull frequency from the source stockrooms(s). The Material Control module can calculate, automatically, the minimum and maximum inventory level values given user-specified and pre-defined determinant factors, Determinant factors can include the desired minimum and maximum number of days of floor stock to be maintained, the item type usage, the "ABC" part classification code, and any other site-specific parameters.

The Material Control module triggers the replenishment of target stockroom inventories as components are consumed and controls the on-hand inventory levels, maintaining them between the user-specified or system-calculated minimum and maximum levels. Replenishment of component material from a source stockroom is initiated automatically when the level of any component in a target stockroom reaches its minimum. When the inventory level at a work station falls below minimum, a demand pull request is generated by the Material Control module. (This request also can be issued manually by an authorized employee). A demand pull request initiates the printing of a ticket in the source stockroom. The Material Control module can communicate with and instruct automated storage and retrieval systems for control of inventory during the pick process.

The "pick" ticket indicates the item type and the quantity necessary to return the target stockroom inventory level to its established maximum. Each ticket is assigned a unique control number to distinguish among multiple requests originating from multiple target stockrooms for a given item type. When the material is issued to the target stockroom, the operator enters the quantity that has been moved via a CRT-based issue function. When the issue is complete, the Material Control module adjusts the respective inventories and deletes the requisition from the system. If the source stockroom inventory is not sufficient to satisfy a complete request, the partial quantity is issued to the target stockroom and the item type is flagged as short in the source stockroom. This process can be interfaced with a purchasing system such that the appropriate action can be initiated for the shortage.

The manufacturer can view and modify inventory balances at any time. The Material Control module status screens enable the manufacturer to view summary and detail information on the status and location of items in the manufacturing operations. Relevant information includes on hand balances, outstanding requisitions, current shortages, and established minimum and maximum levels.

In an assembly operation the Material Control module manages inventory levels and locations in any number of shop floor stock rooms. The Material Control module controls and tracks subassemblies and component material from source stockrooms (main stores or WIP areas) through the entire production process. The Material Control module uses pre-defined or calculated minimum/maximum inventory levels and main stores or factory floor locations of component material to control replenishment automatically. The Material Control module calculates the minimum and maximum values with user-specified and pre-defined determinant factors such as minimum and maximum number of days of floor stock to be maintained, part type usage, "ABC" part classification code, and any other site-specific parameters. Replenishes factory floor target stockrooms based on (1) actual consumption of parts at the operations and on (2) the operation specific bill of material (parts list) for the tracked work piece. The Material Control module initiates demand pull replenishment with electronic pick requests and/or printing of pick tickets in source stockrooms.

The Material Control module uses pre-defined points in the knowledge base to perform inventory record adjustments progressively after materials have been consumed, with no operator intervention. The Tracking module provides on-line displays of the status and location of component material in work-in-process. The Material Control module is often interfaced with MRP systems and automated storage and retrieval systems. The specifics of how and when relief is reported to the MRP system depends on the needs of the manufacturer.

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