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Patrick Am Posted: 2013-1-9 2:50

Hi, I am running AX 2012 FP where my inventory model is FIFO with no negative inventory physical 

I receive the raw item in inventory warehouse location (10) and on-hand shows that it is sitting in the correct location 

that's the only part on a BoM, the production will place the finished good at location 30 

automatic BoM and route consumption When I post the picklist it is correctly showing the amount in WIP. 

after posting the pick-list, when I report as finished I am getting the following error. 

Have anyone come across this scenario (when I allow pick negative from Inv model it is working fine). 

The quantity cannot be reduced. The number of inventory transactions on order is too low because the quantity or part of it is referenced by an output order or a production order or is marked against other transactions.
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AdamRoue replied on 2013-1-9 8:30

Your BOM Consumption on the RAF parameters is set to "Always" or "flushing method" and there is no stock, it is trying to double consume as you are telling it to do this.

“Any fool can know. The point is to understand.”
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Patrick Am replied on 2013-1-9 8:48

On the start stage (of production parameters for MES), i set auto-consumption to always for both pick and route 

on operation and RAF stage, i set the auto-consumption for both Pick and route to never.  With these settings, I am able to post both pick and RAF journals. However, when I post the route card, I am getting a warning message as below. Is there a reason why? 

Posting Route card Journal 

Journal has been posted. 

Posting picklist journal 

item number xxxx 

physical on-hand 

site '10' warehouse 'abc' location '1'

1 quantity cannot be picked because '0' quantity available 

***  Looks like it tries to post the

pick-list journal again (while posting RAF). why?  I posted the pick-list at the start of the production operation. After that, I report as finished and then am trying to post the route card with actual hours (operational scheduling). 

Is there anything that need to consider to disable 'pick-list journal' from being posted again during the RAF stage. 

many thanks for your help. 

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Patrick Am replied on 2013-1-9 8:50

Hi Adam, thank you for clarifying it. You are absolutely correct. I set the 'auto consumption' to never for RAF and it worked fine. However, while posting the route card journal, it gives me a warning - I think I am double posting the pick-list during the RAF stage. please let me know where I am going wrong. thank you 

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AdamRoue replied on 2013-1-9 8:55

When are you posting the route journal - there is a posting for this on RAF and Start as well. In addition you can link BOM lines to routing operations, check your routing and BOM links as well.

“Any fool can know. The point is to understand.”
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Patrick Am replied on 2013-1-9 9:02

Hi Adam, I am posting route card after RAF. I set the route 'auto-consumption' to always at the Start and in the RAF, i set the auto-consumption for Route card journal to 'never'. 

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Patrick Am replied on 2013-1-9 9:20

Hi Adam, I have a very simple routing with 1 route for the Parent BoM and 1 for the sub-BoM.  In fact, In this example, I have one item associated to the BoM that has 1 route operation. 

While Posting picklist, i noticed that  auto-consumption is selected for the route card/journal section of the set up tab (of the picklist journal). I unchecked, but it still is giving me the error? 

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AdamRoue replied on 2013-1-9 10:19

You will need to step through this but by bit

Post route at start as ALWAYS, ensure post route card is checked. Post Pick at start. The remaining status of teh order should then be RAF. Post pick journal.

Then ensure on RAF Route and Pick are NEVER

Is your Sub-BOM an item or is it a referenced production order? If referenced ensure this is all closed off before processing the parent.

“Any fool can know. The point is to understand.”
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Patrick Am replied on 2013-1-9 17:21

Hi Adam, thank you. I step through this as you from start to RAF. Everything works fine. But when I post the route, it is throwing a warning - as it tries to post the pick list again and it couldn't find quantity

At start, I have both Pick and Route consumption as "Always" 

Then I post the Pick-list.

Post the RAF - I set both Pick and Route consumption is "Never". 

Finally I post the Route - The route card journal is posted. However, the info log shows me that Pick-list journal couldn't be posted as there is 0 quantity.  I am not sure why AX giving me this warning. 

 

 

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AdamRoue replied on 2013-1-9 18:06

In the Production Control Parameters on teh Journals tab and Route card/Job Card Journal do you have "Automatic BOM Consumption" ticked?

In the BOM on the general tab is the operation number populated?

Is your picking end marked?

“Any fool can know. The point is to understand.”
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Patrick Am replied on 2013-1-9 19:14

Hi Adam, I checked the production control parameters and yes I have selected 'Automatic boM consumption' as "always" for the route card/pick journal. However, I didn't select the "Automatic BoM consumption for route card journal" 

Automatic update section, I have auto bom consumption 'always' and route consumption never for the Automatic execution; For auto-report as finished, I have auto bom consumption as 'Never' and route consumption 'Always' 

I ensured that the operation number is populated on the BoM line. 

Also I selected 'End mark' for picklist at the Start and RAF stage.  

I noticed that when I select 'end mark' for route card at the RAF stage, it posts the route card. When I don't end-mark the route, during RAF stage, the route card journal is posted.

after that, when I try to post the route card, the route card journal is posted However, it also posts the picklist (that double my material consumption.  

Any idea if I am missing anything. 

 

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Patrick Am replied on 2013-1-9 20:20

Hi Adam. I found one thing that's quite interesting. probably I may need to do this.

While posting the route card (after RAF), i notice in the journal line the BOM consumption is checked.  When I unchecked that, it route card journal posted without any hitch. (and it didn't post the pick-list journal again this time).   Does it mean that, i need to uncheck this option every time I post the route card journal?  

also when is the best time to post the route card. Is it after RAF or prior in general? 

many thanks  

 

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AdamRoue replied on 2013-1-9 21:07

You were at the wrong parameter Big Smile

Journals tab and Route card/Job Card Journal "Automatic BOM Consumption" I presume this is ticked? Un tick it. This will impact on the route card journal as it will not tick BOM consumption on creation.

Also remove the operation from the BOM line in a test.

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Patrick Am replied on 2013-1-9 21:48

Hi Adam, yes. that did the trick. Thanks again for the great help. 

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AdamRoue replied on 2013-1-9 21:50

No problem, glad you are having fun Big Smile

“Any fool can know. The point is to understand.”
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Patrick Am replied on 2013-1-31 18:23

hello Adam, I noticed an issue with production orders where the material consumption costs  show almost 50% less as report as finished (with no labor/indirect) - We use FIFO.  I looked at the Production price calculation - almost all components with exception 1 component, where the realized consumption cost shows 50% less than the estimate. 

Few observations: From inventory transactions for one of the raw material item, one purchase order line show as purchased but there is no cost amount. Could that explain the drop in the running average cost?.  we brought some items through inventory movement journal and some quantity by purchase orders.   So when I sum the cost amount  and divide by total quantity there is some deviation to the running average as shown by AX as well. Perhaps running average calculation is different. 

From what I understand, the AX calculates based on  running average and then settles to receipt at the time of inventory close. 

We an raw item is received, it goes to site1-warehouse1-location 1;   The finished good is placed in Site1-WareHour1-Location2;

I also noticed that  when the material is consumed (in the production order), the raw materials are going to location 2. So when I look at the on-hand for that item, it show two lines -- one line showing the quantity (say 50) for that location and the cost price for e.g. 100;   Another line that show the quantity deducted (per production order) but show the different location with -ive quantity available and with different cost price in that location. 

Appreciate your input. thank you 

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AdamRoue replied on 2013-1-31 23:15

Brining in cost at zero will impact on average and when financially consumed it will consume it correctly at zero cost.

If you do not control physical stock by location and allow negative stock this will happen and will cause you issues, the close procedure cannot match this cost until the inventory is zero and therefore skips it in teh calculation (I believe).

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Patrick Am replied on 2013-1-31 23:39

Thanks Adam. How could we rectify this now? Why AX doesn't deduct the quantity from location A but instead deduct from Location B where is no quantity on-hand.  In the FIFO model, I didn't allow negative.  But then how AX is able to deduct from a location where there is no quantity is what baffles me?  In the production order, I can see that the locations for all BoM line (raw materials) are populated as Location B. 

When I create a Production order - I set Site, WH and Location B.  Could that be the reason? 

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AdamRoue replied on 2013-2-1 1:13

You are not physically tracking at location so it does not care as you told it not to. Will not check negative, but I believe the costing cares. To correct it move teh stock from A to B. You cannot as standard define the location on a BOM line, you must have modified this, it is only warehouse. If on the warehouse you define B this will "probably" backflush to B - try it without and see where it takes stock from - my guess would be the default location if you have set it up, but it will reserve as well but the issue will come back to you not physically tracking at location which is your main issue I believe.

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Patrick Am replied on 2013-2-7 23:50

Hi Adam, so if I am not tracking the item at specific location, but tracking is set at Site and Warehouse level, it seems AX allow the negative quantity at location level. 

I set the location for the production order to "B" and I see that by default all production bom components have this dimension. 

What I notice is that, at the warehouse level, the total quantity is correct and also the financial amount - the way it would calculate the running average. 

It also seems to be that I need to set up the warehouse item location for each item which i think will default on the production order. 

When I manually change the dimension for the Raw matl,  i see that AX has consumed correctly from that location.  Does it mean, that we need to update the inventory location every time I run the production order? 

many thanks  

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AdamRoue replied on 2013-2-8 8:43

Patrick Am:

When I manually change the dimension for the Raw matl,  i see that AX has consumed correctly from that location.  Does it mean, that we need to update the inventory location every time I run the production order? 

Essentially you have turned on location control but do not care about the physical stock in the location, which I feel is wrong. When using locations if you are producing into one location I would want the journal to consume from the correct mixed locations - reservation would do this if you controlled the location dimension, however if you are autoconsuming it takes the location on the production order (or I beleive the one on teh resource for operation stepped consumption) in these instances you have to ensure you plan the system to remove from one location (like production withdraw) that you always move stock into and control any negative elements. Ultimately it depends upon the process and what you are trying to achieve.

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Patrick Am replied on 2013-2-8 17:15

Hi Adam, you are absolutely correct on this. I turned the location as one of the storage dimension but i didn't tick the physical and financial for that location. Since we are auto-consuming, it takes the location from the production order location.  

1) So how could I control the location dimension going forward? 

For now, I am going to manually change the consumption location for components (in the production order) so at least the consumption is taking place correctly, since we are auto-consuming it. 

2) For the transaction already done, could we move the positive stock from Location A (where it should have consumed origionally) to the Location B (where the negative stock is)? 

Thank you 

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Patrick Am replied on 2013-2-8 17:20

AdamRoue:
If on the warehouse you define B this will "probably" backflush to B - try it without and see where it takes stock from - my guess would be the default location if you have set it up, but it will reserve as well but the issue will come back to you not physically tracking at location which is your main issue I believe.

Hi adam, yes on the warehouse, I set the location "A" for the raw material, but i am auto-consuming so will it still back-flush this location, even though production is consuming from location B (because it is picking up from the production order location default). 

otherwise, you as recommended, I need to control at the location level. Appreciate if you could advise how I can do that. 

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Patrick Am replied on 2013-2-8 18:37

Actually, I noticed that when I set the warehouse item location at the component level, AX automatically default to that location in the production material consumption so I didn't have to manually change in the production bom everytime.  This would work for us and the material is taken from the correct location. 

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AdamRoue replied on 2013-2-8 22:12

I would go for option 2. and I would ensure that in the future there is a process to move stock into the production area where it is being made (location) to ensure the stock is consumed from the correct location.

“Any fool can know. The point is to understand.”
Albert Einstein

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