Problem with overproduction

@Savtsuk let me see if I correctly understood your scenario.

You have a finished product - FG1 that needs to be assembled from WIP1 (produced inhouse) and PUR1 (part supplied by your external supplier).

I assume now you have different Shop Orders for producing the WIP part and another Shop Order for the Assembly. And that might be the reason why your production planning maybe is losing track of this.

One suggestion could be use just one Shop Order with 2 different operations

• internal WIP production
• assembly

Then, whatever is produced in operation 1 must be consumed in operation 2. You could setup the routing that the 2 operations can run in parralel and then your production planners will see that the assembly is stuck and could communicate to the shopfloor to stop operation 1 from overproducing. Just an idea.

Hello, 

Thank you for the quick reply. you understood the problem correctly, but I am afraid that this would not be doable for us. for example the final assembly consists of 100 different manufactured parts and 100 purchased parts. and we print out a shop order for each batch of subparts. the assembly line is designed by the required capacity. for example the line can produce 10 final assemblies in one day. the line storage is built to fit the subparts for 30 assemblies so we have a manufacturing lead time of 3 days for the subparts. but if the subparts and the final assembly would be on the same shop order then the finals assembly cannot start until all the subparts are done also we would need to remodel the way we create shop orders, because each operation has to be started and ended by scanning the barcode on a physical printed shop order, and this cannot be in 100 different stations. that is why I was hoping to build the system so it would react to the quantity of the subparts on the final assembly line. when the quantity goes under a threshold, the system would give a suggestion to start producing more subparts.

Thank you,

Sten

@Savtsuk  Sten then why not simply use Order Proposals for the WIP part (method B or C). You setup your order point / lot size / safety stock and then the system will ignore the open demands for that part and just create an order proposal based on the  order point / lot size / safety stock. Then you process the Order Proposal and convert it to Shop Order so that you could start your production.

You could read more on this at the below page:

https://docs.ifs.com/ifsclouddocs/24r1/MaintainInventory/ActivityInvOrdProposalOrdOrReq.htm?StandAlone=true

Hey,

Thanks for the suggestion, I tried this in the test environment but with planning method B for the WIP part we lose the MRP planned demand for raw material.

With best regards!

Sten

Hi Sten,

I was testing Kanban circuits recently and managed to achieve something similar by master scheduling my top level part and creating a Kanban circuit for a manufactured sub assembly. The supply for the raw material was then based on my forecast for the top level manufactured part, but the supply for the intemediate sub-assembly was controlled by the Kanban circuit:

Finished Good:

Shop Order Reqs generated from MS:

Intermediate Sub Assembly:

Demand flows through, but supply (2 shop orders) has come from the Kanban electronic request (the data’s a bit out of date as I did the demo back in July). I.e. Reqs not generated by MRP, but you still get action messages, which is helpful.

Raw material for Sub Assembly:

Demand flows through from MS forecast & actual Shop Order raised in Kanban - supplies are generated by MRP at this level.