MFS Testing strategy for smooth transition and reliable performance

It is crucial to test the MFS solution thoroughly before Go Live to ensure a smooth transition and reliable performance. Different projects require different test strategies. Below, I share some general approaches I followed in various MFS implementation projects.

During the build phase, we usually use an ABAP program (SCWM/MFS_TEST_MFS_RECEIVE2 or a custom program) to test our solution. However, this does not provide visibility into how the PLC would react to different situations. Therefore, we use emulation software where the warehouse automation layout is modelled and all possible logic is implemented. In SIT, we typically use this emulation software to test the MFS solution.

Many cases, existing PLC logic is changed to ensure it can work with MFS solution. Even sometimes a master PLC is introduced which communicate with lower-level PLC or hardware’s & then communicate with MFS with telegram messages. So, it is important to test these PLC changes. For this we usually place the new version of PLC software in place of the existing Legacy PLC & do the test with MFS. These kind of test needs warehouse down time.

Many warehouses run 24/7 & getting a down time is a big challenge. So, it is very crucial to plan these kinds of tests in detail so we can utilize this downtime to the fullest. This is also a great opportunity to test all your warehouse automation & integration with other software’s.

We usually try to replicate a day after Go Live in the testing environment which gives us a very good visibility & confidence how the EWM/MFS solution would work in production environment.

Operational test Planning:

We need to ensure following key items are addressed before we start operational testing for Warehouse Automation with MFS.

Master data: Need to ensure all the master data such as products, packaging specifications, any other data entries are in place in test system so you can use these production data for these tests. These test data also need to be available in other software test system. You may need to block bins not part of the agreed test scope so to ensure testing process does not mess up current legacy production inventory.

Network issues: Network team need to set up the firewall rules so Test MFS system can communicate with Test PLC without any issues. Similarly, connection between Test EWM/MFS system, Test Fleet management software which controls the AGV & any other application which we would like to test as part of end to end operational test needs to be in place.

Resources: It is crucial to have resources from business teams and all other applications available during planning & execution of operational test. All warehouse key resources should be trained on the new MFS processes so they can participate actively and appreciate the test results..

Test Scenarios: You need to have test cases covering both happy paths and all exception scenarios. Decide how to recreate exception scenarios. For example, to simulate a "No Read" scenario from a scanner, you might need to cover the scanners so the PLC sends telegrams accordingly.

Test Cases/Pallets: Ensure you have enough cases and pallets with all possible data variations. For partial pallet scenarios, have partial pallets ready. Also, include oversize pallets, mixed pallets, etc. Decide the entry and exit points of these pallets, Cases for each test. For instance, in the Goods Receipt process, determine where pallets should enter and where they should be stored. If cases are used to build pallets, decide where cases need to enter the system and where pallets should come out.

Rollback Approach: It is critical to have a solid roll back plan so after the test everything is brought back to BAU status. 

Operational Test Execution:

During the test, all the test results, observations need to recorded correctly. Not everything goes as planned, so need to be able to change the approach on the fly with due consideration to overall design architecture.

After Test execution:

During the test, things move very fast & so many transaction data gets posted. So after the completion of the test, it is important to analyze the data to see of anything has any abnormal posting. Log all defects & track for its closure.

It is very critical to complete the rollback steps before handing over to business. Such as replacing the test PLC with current production PLC, changing the IP address at MFS. Network team reverting the Firewall rules. If any test EWM labels are used, it is necessary to replace with actual labels. If any BAU labels are damaged, ensure to reprint them in current legacy software. Do a stock count & ensure they are in right places. Sometimes you need to bring back the pallets, cases to its original positions or manually adjust the new position of these stock in legacy WMS application.