Planned vs. Allocated Inventory & Scheduling Customer Orders -- BPCS-L

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Jenny - We are on BPCS 6.04 and had the same issues.  Our Cost Accountant
read Goldratt's book "Necessary but not Sufficient" and recommended we
look for a TOC based APS.  We found one and had a demo.  We liked what we
saw, but the implementation looked like it would be prohibitive.  We
looked for another solution and uncovered a product called OTTO (On Time
Orders).  While they did not advertise TOC features, we felt it would
address our immediate concerns.  The implementation was minimal and our
"on time order performance" has improved dramatically in just a few
months.

Mark Shank
IS Manager
Shenandoah Manufacturing

----- Forwarded by Mark Shank/Shenmfg on 03/26/2002 12:53 PM -----


"Jenny Carr" <jgcarr@durhamcompany.com>
Sent by: bpcs-l-admin@midrange.com
03/01/2002 04:32 PM
Please respond to bpcs-l


        To:     <bpcs-l@midrange.com>
        cc:
        Subject:        Planned vs. Allocated Inventory & Scheduling Customer 
Orders

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We repeatedly have problems with the scheduling of customer orders (i.e.
don't have purchase parts when we need them).  Unfortunately, you have to
schedule items and wait for MRP to run (in our case, nightly) before you
know whether you can meet the scheduled date.  Although we use reports
that notify our buyers that they need to expedite purchase parts, we have
not found an effective way to easily identify those customer orders.  I
"think" this is because of the volume of orders, common purchase parts,
and the difficulty associated with pegging through 4-8 levels of the bill.
 I got excited when I saw the SFC350 program; until I recently discovered
that it only includes allocations of orders already released (not the ones
that are still planned).  For us, that is where most of our inventory is.
Does anybody have any good ideas?

I saw on a flowchart that SFC350 is typically used before releasing
orders.  Now I know why.  Assuming that there isn't an easy way to pull in
the planned quantities into SFC350, what is a good procedure for to
reschedule the orders at that point without affecting capacity issues,
etc.?

Even if we solve this problem, the other problem still exists.  We still
need to figure a way out to figure out a realistic schedule date based on
1) allocations (released to shop), 2) planned, 3) on order and what is
required on the customer's order request.  We at one time looked at some
APS systems to accomplish this, but it doesn't seem like it should be that
difficult.  I've considered building a database that pulls the necessary
data from BPCS.

I'm open for suggestions, but please remember, we are only on 3.7 with
Nexgen Y2K mods.

TIA,

Jenny Carr

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