Skip to main content

Good morning community!  We have a scenario where we have a sub assembly on our PS.  We would like to flatten the PS to move the sub assembly components to direct components of the finished good eliminating the need to transact the sub assembly.  This sub assembly that we want to remove from the PS is used in multiple finished goods (it is a blend of materials).  We want the ability to see demand for the blend (sub assembly) but not actually schedule it or produce it unless we need to put it in barrels to be store in inventory (lot controlled).

We have tried phantom parts, but they only seem to explode the materials in the shop order as opposed to the operations.  We want both to be part of the finished good.

We have tried putting the blend in our PS as a zero QPA, but had to set the component to ‘allow as not consumed’ to get it to work.  This created an error because it is lot controlled (which it needs to be).

And we cannot put both the sub assembly and raw components on the shop order because it would skew the cost.

How do others deal with this type of scenario?

Thank you for your help!

Robin  

You were on the right track with setting the blend as a phantom, and by using Planning Method 'P' for this you will be able to produce the blend when required for inventory.

Yes, the operations for the blend do not transfer to the parent shop order. Because of this, the operations for the blend should be on the routings for its parent part(s).

And you should have a buildable Product Structure and a buildable Routing Alternate for the blend to use when you want to produce the subassembly for inventory. Keep in mind that the manufacturing (i.e., routing) costs of 'P' parts do not roll-up to the parent part cost. Material costs roll up from the lower levels, but operation costs do not. So there should be no concern of Shop Order operation costs being skewed due to the operations for the blend appearing on both its routing and its parents' routings.

Also, you should have a routing alternate for the parent part that excludes the operations to produce the blend for when you have a shop order that will consume the blend from your inventory. The costs of those operations are already sitting in inventory with the blend and you would not be performing them again.

Finally, there will be no visibility to demand for the blend in the IPAP/MRP Part Info pages, but in the Shop Order Materials page (and the Materials tab of a Shop Order) you can see the phantom parts (Phantom Part No field) that have been replaced by their components. One of the messages from MRP is 'Phantom Orders', which means that there is an order for a phantom part, but I cannot get this message to generate for my parts. But this could be helpful if you have this message in your MRP Action Proposals.

​@matt.watters Thank you.

Reply


Terms & ConditionsCookie settings