How to handle revision changes on a product with master planning, production orders and stock levels?

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Hi,

We have a discussion here about what to do with revisions on our products. We have product 1 and product 2. Both have revision A (inventsizeid) and all MRP is setup. We start purchasing and manufacturing. After a while R&D decides the drawing becomes revision B of product 1 and revision C of product 2.

Now we have an administrative change in AX. First of all we cannot stop the revisions, nor the MRP understands (like SAP/ Oracle) to change this in all further planning. So as a work around we now have the discussion if we actually:

1. Should use revisions since A becomes B and is usable. Should we not stop with them? How then to indicate to vendors and in our service BOM that we need B?

2. We should change the item coverage and demand so that the item B is purchased, manufactured etc. But how to coop with running transactions like production orders going by 100 and now the revision is changed. If you have large BOMs and a lot of changes this is a lot of work and no BOM version will correctly have the right amount of product 1 and 2 in it.

3. We should remove all reservation on the revisions and then use a count/ transfer journal to move from revision A to B we basically are changing our inventory and all inventory reports are wrong, like recounting journals, FIFO, etc.

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guk1964 10,886 on at

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RE: How to handle revision changes on a product with master planning, production orders and stock levels?

If the fit form and function are not the same then you need at least a new variant, if not a new product id. Particularly if cost, warranty, traceability is required

Similarly it will need at least a bom version change.

MRO needs to see the change or will still want to use the old components for open/palnned orders orders

On an open production order you can always issue a new item and not issue an old item so you will get a plus and minus variance. However your end item code will not change in that case so you would at least need a batch number change and possibly a plus an minus stock adjustment later.

A potential work around is to have a batch number that signifies the revision and change the batch id with each new revision.

Its the old story, if you want the control. then you have to do the admin. The actual business requirement should be the determinant of what that means in practise.

Most tricky is to get use up strategy agreed ie. is the change instantaneous or only when the old supply runs out? You may no know when that will be and without changes mrp will continue to order the old part.

Consider creating a fictitious stocked item with no cost that is a change control document for each time. The description is item name plus version-use a configuration to record each new version. that way you can create a bill of changes , by adding the item and those can be just extra lines or put into a sub assembly/phantom and disable mrp explosion for that sub assembly etc. Attach a document go the bill of change to explain the detail of each change.

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JoeGr 360 on at

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RE: How to handle revision changes on a product with master planning, production orders and stock levels?

you can look for product engineering solutions like the one from To-Increase.

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Tim Schofield on at

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RE: How to handle revision changes on a product with master planning, production orders and stock levels?

This is a great question. IMHO AX doesn't really have the concept of an item revision - only a BOM version/revision. So if your item is a component you have one solution In that its 'where-used' BOM lines will call for Revision A up to some cut-off date in the future, then the new BOM lines start to call for Revision B. But then there is no concept of use up all of A and then start to issue B - you have to manage that manually. If your item's finished goods manufactured item - well basically that the same case, since the item is defined by its BOM. But if you buy the finished goods I guess your demand forecast says that you're going to sell Revision A up to a date, then start selling Revision B. There was an 'Engineering change order' ISV solution I saw somewhere that tries to answer all of your issues. erpsolutions.biz/engineering-change-management

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