Go to the planning data tab for the inventory part on the sub-assemblies you don’t want to build at that level.  Change the Planning Method to P for Phantom, this will bypass that level and effectively flatten the BOM.  You can do this at any or all levels except the top one obviously.  The routings are only required at the level you build.

Yes, this solution worked for many of our customers. We have been dealing with such solutions for years.

We followed this approach but now have an issue where a customer order line has been entered against one of the sub-assemblies we changed to planning method P. MRP is not recognising the demand to generate a shop order proposal.  Any suggestions on how we get around this?

Hi Shawn, is there any logic in IFS to handle the routing connected to the phantom or do you need to manually adjust the routing on the level to build with the operation connected to the phantom?

@Drausenhaus 

If you mean what happens if a routing already exists at one of the lower levels that is now phantom?

Routings on phantom items will be ignored because no shop orders will be created for those levels.

If you mean will the routings at the lower levels that have been changed to phantom be summed or rolled up to the upper level?

No, there is no intelligence or function to group all of the lower level routing time and move it to the top level.  All of those adjustments have to be made manually because there is no logical way to know how the top level is being assembled or how much time should be moved or removed from the routing.

Thanks Shawn, that was exactly my question. We will update the upper level routing manually.