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Storage Units and equipment can be configured with different lot handling modes that define how lots (or batches) of material are stored at equipment. To change these settings, click on the Production Item in the Production Model and select the Trace tab.

Mode 

Description

Single Lot

Only one lot can be stored at this location even if the location is not full.

Random Lot

You can put any lots in any order and pull them out in any order.

FIFO

This will cause the first lot stored at this location to be used first and the second lot to be used second and so on.

LIFO

This will cause the last lot stored at this location to be used first and the second to last lot to be used second and so on.

Same Lot

Material from the same lot that is received over multiple trucks or vessels can be added.

Blend Lot

Allows only one lot at a time in that tank. If you add another lot, it will cause a new lot to be created.





Zero Lot Threshold

The Zero Lot Threshold will cause the system to automatically zero the lot if not all of the lot was used from the silo. This cleans up a potentially large number of leftover lots with very small quantity remaining. The threshold value can be configured to be Unit Of Measure or Percentage

Note: In order to use Zero Lot Threshold functionality, set the Auto Lot Quantity Completion property of the Process Segment (or Operations Segment, if preferred) to Enabled (see Material Resource Property).






Single Lot Handling Mode

Description

Single Lot handling mode is for storage units and equipment that can only hold 1 lot of material at a time. After storing a lot to the storage unit or loading it into a piece of equipment that lot must be taken out before another can be added.

Example

In order to prep them for shipment, a factory that creates CNC milling machines stores each finished machine into a storage container. Each storage container can only hold one machine at a time. In order for another machine to be loaded into the storage the current machine must be removed from the storage container.

Figure 1: Single Lot Handling Mode Illustration

We are starting with a storage unit configured to Single Lot Handling Mode. We have 2 material lots: material lot 1 and material lot 2.

  1. We are starting with material lot 1 inside the storage unit. 
  2. We then remove material lot 1 from the storage unit.
  3. The storage unit is now empty and something else can be added to it.
  4. We are now free to add material lot 2 or any other material lot to the storage unit.

Figure 2: Single Lot Handling Mode Errors

Adding a lot to an already full storage unit or piece of equipment configured for Single Lot Handling is not a valid operation. If the user attempts this an exception will be thrown by the system.

Figure 1
Figure 2


Random Lot Handling Mode

Description

Random Lot Handling Mode is for a storage unit or piece of equipment where lots can be inserted or pulled out in any order. There are no restrictions on how lots are handled, any order is valid.

Example

A factory is installing tires onto a car. They have a storage bay where they keep all the tires. When the operator grabs 4 tires to put on the car, it does not matter what lot the grabbed tires are from.

Figure 3: Random Lot Handling Mode Illustration

In this example we have a storage unit that is configured to Random Lot Handling Mode. We also have 3 material lots: material lot 1, material lot 2, and material lot 3. With this mode you can choose any of the 3 lots in any order.


Random Lot Handling Mode Note

A common misconception is that with Random Lot Handling Mode the material lot is necessarily chosen for you. This is not the case, the user can either use the getMaterialLotNextAvailable() scripting function or choose the lot manually

Figure 3


 FIFO Lot Handling Mode

Description

FIFO Lot Handling Mode is for a storage unit or piece of equipment that is configured to follow the idea of 'First In First Out' meaning that the first lots added to the storage unit are the first lots used.

Example

A factory is packaging cupcakes into boxes to ship them out. In order to ensure that each of the finished product has the longest shelf-life possible they want to package the least recently baked cupcakes first.

Figure 4: FIFO Lot Handling Mode Usage

We have a storage unit that was configured to FIFO Lot Handling Mode. We also have 3 material lots: material lot 1, material lot 2, and material lot 3. The lots were added to the storage unit in the order, material lot 1, material lot 2, and lastly material lot 3. 

  1. To consume all the lots in the storage unit we must first consume material lot 1. 
  2. We then consume material lot 2
  3. Lastly we consume material lot 3

Figure 5: FIFO Lot Handling Mode Errors

When using the FIFO Lot Handling Mode when we request a lot using the getMaterialLotNextAvailable() scripting function it will always return the oldest lot. 


Overriding FIFO Lot Handling Mode

It is important to note that the restrictions put on a storage unit in FIFO Lot Handling Mode can be overridden by the user by simply selecting a different lot from the Storage Unit using scripting. No Exception will be thrown if you do this.


Figure 4
Figure 5


LIFO Lot Handling Mode

Description

LIFO Lot Handling Mode is for a storage unit or piece of equipment that is configured to follow the idea of 'Last In First Out' meaning that the last lots added to the equipment are the first lots used.

Example

A company has a storage bay for backstock of their product. They fill the bay up from the back of the bay to the front. Whenever they pull from the bay they pull from the front first.

Figure 6: LIFO Lot Handling Mode Usage

We have a storage unit that was configured to LIFO Lot Handling Mode. We also have 3 material lots: material lot 1, material lot 2, and material lot 3. The lots were added to the storage unit in the order, material lot 1, material lot 2, and lastly material lot 3. 


  1. To consume all the lots in the storage unit we must first consume material lot 3. 
  2. We then consume material lot 2
  3. Lastly we consume material lot 1

Figure 7: LIFO Lot Handling Mode Errors


When using the LIFO Lot Handling Mode when we request a lot using the getMaterialLotNextAvailable() scripting function it will always return the newest lot. 


Overriding LIFO Lot Handling Mode

It is important to note that the restrictions put on a storage unit in LIFO Lot Handling Mode can be overridden by the user by simply selecting a different lot from the Storage Unit using scripting. No Exception will be thrown if you do this.



Figure 6
Figure 7





Same Lot Handling Mode

Description

Same Lot Handling Mode is for a storage unit or piece of equipment that can have many lots inserted into it and all that is necessary is to track the overall quantity and not each lot added.

Example

A hardware distributor has a large storage bin that trucks all of the 1/4-20 X 3" bolts are put in the bin. In this case, it is not the quantities of each shipment of screws that matters but instead the overall quantity in the bin.

Figure 8: Same Lot Handling Mode Illustration

We have a storage unit set to Same Lot Handling Mode. We also have 4 input material lots: material lot 1, material lot 2, material lot 3, and material lot 4. We also have a output lot named Material Lot Sum 

    1. We are going to add material lot 1 to the storage unit. 

    2. material lot 1's quantity has now been added to Material Lot Sum 

  1.  

    1. We are going to add material lot 2 to the storage unit. 

    2. material lot 2's quantity has now been added to Material Lot Sum 

    1. We are going to add material lot 3 to the storage unit. 

    2. material lot 3's quantity has now been added to Material Lot Sum 

    1. We are going to add material lot 4 to the storage unit. 

    2. material lot 4's quantity has now been added to Material Lot Sum 

    1. We have Material Lot Sum which has the summed quantity of all 4 of the added material lots 

    2. When we take from Material Lot Sum we create a new lot called material lot sum.



Adding Lots to Same Lot Storage Unit

It is important to note that when material lots are added to a piece of Storage Unit that is set to Same Lot Handling Mode the material lots themselves are not stored to the Storage Unit but instead their quantities are stored to a singular immutable lot inside the Storage Unit.



Figure 8


Blend Lot Handling Mode

Description

Blend Lot Handling Mode type is useful for situations when material added to a storage unit or piece of equipment is mixed with the current material and cannot be separated into distinct lots. 

Blend Lot vs. Same Lot

An important distinction between a Blend Lot and a Same Lot is that with a blend lot every time that material is added to the equipment a new lot is created. This allows for historical tracking of the storage unit. With a Same Lot the material is always added to the same lot.


Example

An ice cream factory has a storage tank in which they store their cream. While the cream is mixed when it is in the tank they want to keep historical data when cream was either added or taken from the tank. 

Figure 9: Blend Lot Mode Material Addition Illustration

We have a storage unit set to Blend Lot Handling Mode. This storage unit already has material in it named starting quantity and an input lot of material called material lot in.

  1. The storage unit starts off containing Lot 1 with a starting quantity
  2. We add to the storage unit material lot in
  3. The starting quantity and the quantity of material lot in are summed together and a new lot is created called Lot 2

Figure 10a: Using a Subset of the Available Quantity

We have our storage unit that is set to Blend Lot Handling Mode with some available quantity. We also have an output lot called material blend lot out.

  1. We are going to take some of the material from the storage unit and put it into material blend lot out.
  2. There is still some remaining quantity in the storage unit 


Important

Notice that since we did not use all of the available material the lot is still Lot 2.

Figure 10b: Using All of the Available Quantity

We have our storage unit that is set to Blend Lot Handling Mode with some available quantity. We also have an output lot called material blend lot out.

  1. We are going to take all of the available material from the storage unit and put it into material blend lot out.
  2. The storage unit is now empty

Important

After removing all the material from the storage unit it is empty. When we add material to it a new lot will be created

Figure 9

Figure 10a
Figure 10b




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