MRP Irregularities

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This week I had someone on our team report that every Friday night when MRP runs and every Monday night when MRP runs, the coverage groups using the Min/Max code end up having planned orders that suggest we produce enough inventory to bring the total to the min + the max. (i.e if the min is 40 and the max is 150, MRP wants to bring inventory to 190). Any other day of the week, it would cap it AT the max (150). This issue has apparently been happening for a long time and isn't a new occurrence.

We had a lean specialist who had set everything up and he has recently retired and I'm not very familiar with the Master Planning module. Has anyone else seen this behavior with the min and max being summed? Or ideas of which settings could be causing it?

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More or less I'm curious if there's ever a time when master planning should suggest that inventory for an item using a min./max. coverage group exceed the max quantity specified.

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jac_rod 39 Moderator on at

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It's bringing your suggested inventory to 190 at the end of the day? Is there any type of inventory transaction that's bringing the accumulated value lower?

If you select the planned order record in the overview section of the net requirements form, what's it pegged to? Is it showing anything other than safety stock?

-Jake

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Our print shop has altered the planned orders that had this issue on Monday night/Tuesday morning by now, but I will grab some screenshots when it happens again tomorrow night. Thanks for your reply!

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jac_rod 39 Moderator on at

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Can't wait to see it!

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Is there any chance that the batch schedule for Friday/Monday is running a different master plan than the Tues/Wed/Thurs schedules? That might be contributing to the different outcomes.

The other thing to check would be on the item coverage setting for the product. Look to the General tab, "fulfill minimum" policy setting. You might have something going on here where you're telling it to calculate using something like the item's leadtime, but where the leadtime is some bogus/low value and is also set to calendar days versus workdays. I'm not sure that would cause a Monday night anomaly, though, if you're running a standard M-F work week.

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Nope, it's the same master plan running each day.

I checked the "fulfill minimum" setting and it's set to coverage time fence. Here is an example of the item coverage for one item we're having the issue with:

I'll also be able to grab screencaps this afternoon/evening of what the pegging looks like when MRP suggests we plan an order for the min + max.

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jac_rod 39 Moderator on at

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Hey there,

Looks like there's some inconsistencies between the min/max and the min order quantity. In this case, if an order comes in that brings you down to 499 accumulated, AX will create a planned order at the min order quantity, or 750 pcs. This will bring the accumulated up to 1249 (which is higher than your max.)

You might think about adjusting one of those two to see if that helps.

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I will keep that in mind, but there are situations where it could satisfy the min order quantity without exceeding the maximum like below:

Notice the final accumulated is an exact sum of the min and the max. This is the case for MOST orders done on Friday night's run, but I did find a few that capped at the maximum like they were supposed to.

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Yeah, I think a few supply/demand (net requirements) screens will help with the details, not just the header summary you've clipped, possibly also some information on the routing details on this, like how many operations involved, whether there are any queues, and what calendar(s) the resources or resource groups are using. Given that funky Friday/Mon versus Tues-Thurs behavior, I'm beginning to think it smells more like a resource/routing type of problem rather than a coverage problem.

Also, you mentioned this was previously managed by a "lean specialist"--are these planned Kanban's you're referring to or regular planned production orders? I'm assuming not, but if the quantities you're referring to are Kanban quantities, not planned production order quantities, then those are configured in the Lean module, not item coverage.

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Those screen shots look a little suspicious, possibly some customizations in place? Normally for something with a coverage code of min//max. you would never see a safety stock line, even if there were a separately posted safety stock journal. Makes me wonder if that's not contributing to the issue--where what you're seeing is planned coverage of BOTH the min/max minimum AND a separate safety stock requirement, which is supposed to be either/or and never duplicated.

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