Hi All,
I have set up a MPS for a production company. I will try to be as detailed as possible. Hopefully someone can point me towards the right direction.
Man Setup:
Dynamic Low level Code: Yes
Combined MPS/MRP calculation: Yes
Use Forecast on Location: Yes
Combined MRP/MPS: Yes
SKUs are used. There are two production locations and one sales location and multiple stock locations for components.
The way this is setup is that there is a sales forecast that is used for the one sales location
The sales location has only items that have a replenishment system of transfer, which they get from production location finished Goods. Alls SKUs in the sales location are setup as lot-for-lot with a lot accumulation period filled in.
The Finished Goods location gets their finished products with a replenishment system of Prod. Order. and the components are also there with a replenishment system of Transfer. The transfer from location is either one of the multiple stock locations for components or the second production location which produces semi-finished goods that get used as components into the finished goods. As Prod. Order SKUs regardless of it being a semi-finished good or transfer item, use the lot-for-lot system with accumulation periods filled in.
With the Semi-finished goods, there are prod order SKUs and transfer SKUs. (Replenishment system: Prod Order or Transfer). For all of these SKUs again a lot-for-lot planning is used with corresponding lot accumulation period stated.
At last but not least, the stock locations which consist of multiple locations use SKUs as well with either fixed Reorder Qty. or Lot-for-lot.
Problem:
When testing the MPS I do get calculations for all components at all low-level codes. My issue is that the suggestions does not behave in the way I would expect it to.
The main problem here being: when we are calculating the need for a low level component which gets used in multiple products, we do not get the expected output.
Example:
We have a product that is used within 10 semi-finished goods. which themselves are used within 16 finished goods. So there is is one to many relationship from component to semi-finished good. And them again for semi-finished good to Finished Good.
The only item forecasted are the finished Goods. SO when calculating MPS for all the finished Goods that use the semi-fnished goods and then in turn the component, we do not get the expected results for the component. The finished Good and semi finished Good get suggested as expected, but because of the amount of semi finished goods that get produced we would expect a transfer order suggestion for getting the component to the semi-finished production location. This however does not happen. We do see a suggestion to purchase the component for a large qty at the items storage location.
I do want to mention that we have not set any production capacities. So this would mean that anything we need gets there within the same day. The first goal with MPS was to be able to calculate how much we need. The second phase would be to know when.
Any suggestions or extra information needed i will gladly provide. Thank you in advance for any suggestions.
