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MRP - Planned Production Orders

  • 1.  MRP - Planned Production Orders

    Posted Feb 19, 2020 08:11 PM
    Edited by Jake Milford Feb 19, 2020 08:13 PM

    Hi Everyone,

    It seems like Master Planning is almost always an interesting topic.  We have made a fair amount of progress but have some challenges that I am unsure of how to address.  We utilize BOMs and a fixed batch size per item.  We are not using formulas.

    Example our quantity on a production order is 1,000 pcs.  But we always have sampling and retention that reduce the final sellable quantity.  The amount will vary by finished item.  In the example noted our quantity is removed for sampling and retention is 63 pcs.  We also tend to have some additional quantity (5-15) that reduce our quantity further.  With planned production orders and MRP it doesn't seem like there is a good way of managing the quantity that is removed/error from our sellable quantity to where it is factored into MRP (to where it knows that we actually need to produce more production orders because of what is taken out).  I know we could handle this quantity with quality orders but those are reflected with planned production orders.  Right now, the quantity is removed via the route card as error quantity.  

    Thanks - Jake
    AX 2012 R3 CU 10
    #AX2012 #Manufacturing, #MasterPlanning​​​​​

  • 2.  RE: MRP - Planned Production Orders

    Posted Feb 20, 2020 06:41 PM

    In the example where your Production order quantity is 1,000 pcs, are you saying that you will physically make and consume raw materials for about 1,078 pcs, but will only RAF 1,000 pcs. And the trick is you want MRP to plan production orders for 1,000, but consumption of 1,078 pcs worth of raw materials?


    Did you mean that MRP is planning production orders for 1,000, but you only make about 922 good ones, so really you'd rather MRP consider that for each planned order of 1,000, only 922 will become available?

    Guy Terry
    Application Consultant

  • 3.  RE: MRP - Planned Production Orders

    Posted Feb 24, 2020 12:22 PM
    ​I also have a silly question.  What problem is caused by using the error factor on the route operation?

    Kevin McLean
    Strategic Solutions NW, LLC
    Beaverton OR

  • 4.  RE: MRP - Planned Production Orders

    Posted Feb 20, 2020 06:57 PM
    Good clarification, the second option.  We consume raw material for mainly 1,000 pcs and sellable quantity is around the 922.  There's a variety of reasons why we can't setup the production order/BOM to be the first way.  Thanks! - Jake

    AX 2012 R3 CU 10

  • 5.  RE: MRP - Planned Production Orders

    Posted Feb 21, 2020 08:23 AM
    so just catching this conversation, silly question, have you looked at scrap, if you know that you will scrap 10 per 1000, then you could put in a scrap factor that would assume you would remove this much in the order, actually it will show the additional materials  required to allow complete production and the scrapped materials

    Paul Martin
    Production Program Manager
    Elite Comfort Solutions, LLC
    Rutherfordton NC

  • 6.  RE: MRP - Planned Production Orders

    Posted Feb 21, 2020 08:46 AM
    I thought you could only have scrap in two places on the BOM (raw materials and components) and on the Route (hours and components) and in my narrow thinking (not wanting to have multiple PPOs) you wouldn't have your finished item listed as a component.  I'm happy if I'm missing something obvious.

    AX 2012 R3 CU 10

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