RE: MRP question 4.05CD

["Damon, Mitch" <MDamon@xxxxxxxxxxxxxxxxx>]

Having encountered the same problem we are currently adjusting the shop
order quantity to match what is actually run, after the fact.  This removes
any component requirements but leaves the shop order open so that additional
issues to it or other adjustments can be made.

Mitch Damon, CPIM
Planning Systems Manager
Logistics - Rochester, NY
(716) 383-1070 ext.250


        -----Original Message-----
        From:   Zzbpcs@aol.com [SMTP:Zzbpcs@aol.com]
        Sent:   Thursday, January 11, 2001 8:36 AM
        To:     BPCS-L@midrange.com
        Subject:        MRP question 4.05CD

        Good day,
        We run BPCS 4.05 CD, full implementation ( all modules).
        Often, Shop Order Material Needed is not an exact qty.
        IE we expect to use 600 kg but actually issue 599.3 kg
        (the total qty rec'd on a lower level shop order).
        We have no intention of issuing the remainin 0.7 kg
        but, of course, since the shop order is still open (for as much as a
week for lab testing) MRP sees a requirement for the 0.3 kg and creates a
planned order
        for 600 kg (std lot size), and purchasing is triggered to but enough
raw material to make 600 kg.
        We used Minimum Planned Order % so we do not get an planned order
untill we need 1/2 a lot size ( 300 kg)
        but that simply delays the inevitable. That is, as soon as a
"legitimate" requirement arrives for a new planned order, we get one order
for 1200 kg ( new correct 600
        plus an additional 600 simply to satisfy the old remaining 0.3 from
the still open but basically completer shop order.
        We are going to try Order Policy "I" Incremental above the std lot
size with an increment qty of 3 or 7 or some "wierd" number so we easily
recognise it as a
        order qty simply to fulfill an 'unreal' demand.
        But, perhaps there is another way ??  
        We used to close out shop orders much more quickly.
        Now we added a routing step for the lab to do their testing and
report their time on that order, so the shop order is open much longer.
        Any suggestions ?

        Thanks
        Jim Barry
        ZZBPCS@AOL.COM
        413 - 283-2060
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