I need Clarification in Master Planning Module , Kindly Advise what would be the right Procedure to handle below scenario.
we are producing 5 Diff Products (Machine ) say A,B,C ,D,E .We have 70 % Items will be produced in house and 30 % will be Purchased Items for these FG.
All Above FG Codes, for in-House items will be produced in Common Warehouse called Production-Wh and Purchased items will be refilled from General-Wh to Concern Product Warehouse ( A-WH, B-WH...D-WH) .
We also Make to stock for Child Manufacturing Component (Not All ) in General-WH for 2 Machines, based on forecast .
Item Code Coverage Setup:
For in House Manufacturing item - WOB ( Work Order Based ).
For Purchase Items :ROL ( Re-order Level )
While we running the MRP based Machine FG Code ,it's creating Planned orders, Purchase orders and transfer orders with out any issue .
We are able to Firm only Purchase order to create Purchase orders .
we are not able to Firm production order's for child item ( Derived Production Order ) where it's allows only to firm FG code .
it's also not considering existing Stock On Hand from General warehouse where we make to stock .
Kindly advise , how to handle above .
1. Derived production orders are not real production orders, they are used to as a planning pegging tool. The planned production order that is derived will disappear when the parent planned order is firmed. In essence the elements in the plan for the derived elements are then included in the parent production order because of the configuration (phantoms etc.)
2. It will not consider stock on hand for many reasons, have you setup the transfer order refill, assuming you are planning at warehouse level? Why do you feel it should consider the stock where it is - show us the demand and supply rules etc.
Thanks for your update .
Our Product has more than 2000 Items to construct a machine (FG), Out 2000 Lines 1500 Items will be In house Manufacture items ( Pegged Supply) . some of the Pegged supply items will be Manufactured in advance based on forecast and kept in GENERAL WAREHOUSE.
When we ran MRP for FG, Let's say 200 Items(Pegged Supply) will be in stock on hand , we have tried Warehouse setup , Production warehouse refilling warehouse as General House , we expected to created Planned transfer order from General warehouse to Production House . But didn't happen .
Our Expectation is it should create only 1300 Planned Production orders as 200 Items already in general house stock . Please correct me if am wrong.
The warehouse setup you reference is unclear, I imagine you are in the wrong place. In the master planning section of the warehouse record is "refilling" activated with the refill warehouse set?
If you look at the item coverage of one of your items that is not transferring is the warehouse record for item coverage on the demand set to transfer from the general warehouse, or is it production or purchase. I know it is not transfer from what you say, but when you go and look you will see it is configured to do what is happening.
Ultimately MRP will suggest transfers and will reference stock, as long as you have configured it to do it.