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Sporadic reservation issues - Planned to Firmed Production orders

  • 1.  Sporadic reservation issues - Planned to Firmed Production orders

    SILVER CONTRIBUTOR
    Posted Aug 13, 2019 05:48 AM
    So this is a weird one and could use some help looking for where the issue may be.

    We're firming planned production orders for item # 1 and Item # 2. Now item number 1 is a component on item # 2 production order.
    Lets say that I have 5 production orders of each item and that all 10 were firmed at the same time.

    This is where the issue sometimes is created. There are some usually only 1 or 2 of the production orders for item # 2 that create a reservation for item # 1, but it's not the correct batch and it's never for the whole amount.

    When we go into post for one of the orders that does not have any reservation but is for a specific batch we can't post the pick list since it is reserved on another production order.

    Note when the planned production orders are firmed they are firmed into estimated production orders.

    Where can I turn off this aggravating reservation.
    Any help will be greatly appreciated.
    ​​​​​Ted Jillett
    #AX2012
    #Functional​​​

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    Ted Jillett
    Business Systems Analyst, Manufacturing AX
    Insulet Corporation
    Acton MA
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    Conference-AXUG_200x200


  • 2.  RE: Sporadic reservation issues - Planned to Firmed Production orders

    TOP CONTRIBUTOR
    Posted Aug 13, 2019 12:23 PM
    Hi Ted,
    Two places you can look. In Production module, under Parameters, there is a Reservation parameter for when material should be reserved. If you don't want to use reservations, set this to "Manual." Otherwise, it will try to reserve inventory based on the Production status specified in the parameter.

    There is also the concept of "Ordered reservations" which mean you can reserve inventory that is not in stock, i.e. reserve against an incoming PO. This setting is a checkbox and is under the Inventory management parameters and it's called "Reserve ordered items."

    Take a look there first and see if it resolves your issues.

    Thanks
    Drew

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    Andrew Lencsak
    Solution Architect
    DXC
    GA
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    Conference-AXUG_200x200


  • 3.  RE: Sporadic reservation issues - Planned to Firmed Production orders

    SILVER CONTRIBUTOR
    Posted Aug 13, 2019 01:13 PM
    Andrew;
        Thank you for the suggestions, I did verify that we already had the two parameter settings previously set.
    I'm going to keep a close watch on when the production manager firms the next set of orders and see if something jumps out.
    As mentioned previously this is a strange sporadic issue that doesn't affect the entire group of planned production orders when firming.

    If and when I find the root cause I'll be sure to post what we found so that if there are others they can refer to this post.

    Best Regards,
    Ted Jillett

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    Ted Jillett
    Business Systems Analyst, Manufacturing AX
    Insulet Corporation
    Acton MA
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    Conference-AXUG_200x200


  • 4.  RE: Sporadic reservation issues - Planned to Firmed Production orders

    GOLD CONTRIBUTOR
    Posted Aug 14, 2019 05:28 PM
    ​We've dealt with that at one of my clients.  It occurs when you have the marking setting on the firming window set to  Standard or Enhanced.  You might want to do this to mark the production output to a sales order, but there are consequences beyond your control.  Also note: there is a master planning parameter that controls the default for that marking setting, but it only works when a user has no personal default.  The user's personal default is set based on the last time they firmed orders, and will remain until they clear usage data.

    The consequences of the marking are that it marks component lines on the production BOM to open orders, even if there is inventory available of the component item.  Once it does that, the system expects the inventory from that order to be used for the component line.  We use warehouse management, and it will not create the raw material picking work until the inventory produced by that order is available, even if there is plenty of the item in the warehouse.  It's not pretty.

    We created a batch job that uses the methods from the marking form to clear marking from production order BOM lines.  We scheduled it, and let run several times per day.  It worked well, until we implemented the use of quality orders for the inspection of purchase receipts.

    Quality order create inbound and outbound stock blocking transactions.  The new behavior we are seeing is that the production BOM transactions are being marked to the inbound stock blocking transaction.  The standard AX functionality will not clear the marking from a stock blocking transaction.  Fortunately, the marking goes away when the quality order is passed, so we have not been affected by it yet.

    I'd love to hear if anyone has found a good way around this.

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    Kevin McLean
    Strategic Solutions NW, LLC
    Beaverton OR
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    Conference-AXUG_200x200


  • 5.  RE: Sporadic reservation issues - Planned to Firmed Production orders

    TOP CONTRIBUTOR
    Posted Aug 14, 2019 08:41 PM
    Kevin has another great point. I did not point to that one first because I would generally not recommend a company has Automatic marking turned on if they are not make to order/engineer to order or where every order is custom. It causes a lot of headaches when it's putting in reservations that a company does not need. You'll spend more time de-allocating and reallocating inventory to orders than is worth it.

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    Andrew Lencsak
    Solution Architect
    DXC
    GA
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    Conference-AXUG_200x200


  • 6.  RE: Sporadic reservation issues - Planned to Firmed Production orders

    GOLD CONTRIBUTOR
    Posted Aug 15, 2019 01:20 PM
    Agreed.  I try to avoid marking where possible.  That being said, it is sometimes handy to be able to establish a relationship between the customer order and the production order that will fulfill the customer order.  ​There may be changes in the production process that are triggered by the customer for whom the product is being built.  It's nice to be able to do those without creating new item numbers.  It would be nice if the marking function called by the order firming process did not include BOM components.  I've talked about it with the support line, and it does not appear to be something that Microsoft plans to change.

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    Kevin McLean
    Strategic Solutions NW, LLC
    Beaverton OR
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    Conference-AXUG_200x200


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