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Requisition worksheet not respecting Fixed Reorder Qty

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Posted on by MaddieGreen

Hi! We have a weird issue with our Requisition Worksheet not respecting the set Fixed Reorder Qty.

I've run the requisition worksheet, and this is one of the items that is not respecting parameters:

We have a product with 18 in inventory. You can see that it has 12 on the Purchase Order (we actioned the requisition worksheet items already and added 12 to the PO).

But when I check the planning parameters on the Stockkeeping Unit Card it shows that it should only order when the inventory hits 8 items, and should only order 6.

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Ben Baxter 6,575 Super User 2025 Season 2 on at

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First, I think you should test this in a Sandbox environment before making changes to your Production Environment.

If your inventory is 18, why did it suggest a PO in the first place?

Its actually easier to troubleshoot without the PO present. I would suggest deleting your PO and re-running using the Planning Worksheet. It is easier to audit the suggestion in the Planning Worksheet. Click inside the "Warning" field, even if it is blank (there is a small link). This will give you visibility to the planning parameters it is using. Verify it is pulling the Reorder Point and Quantity correctly.

Next check the supply and demand for the Item again. If you have demand that will deplete your inventory below 2, it could trigger two purchases of 6, in order to get beyond your Reorder Point, which would give you a PO suggestion for 12.

Is your product Item Tracked with an Expiration Date? Maybe inventory is no longer usable.

Could be any number of things, but let us know what you find out. If you get stuck, I would suggest reaching out to your BC Partner to help you track this down.

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Alfredo_Iorio 1,262 on at

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With a reorder point and a fixed reorder Qty the order quantity will be equal to the reorder quantity at a minimum, meaning the order cannot be less that the reorder qty. But the order quantity can increase to meet demand or the desired inventory level like safety stock.

A common reasons for higher quantity in the requisition worksheet is excess demand like sales orders, transfer orders to another location, items as components on assembly or production orders or if you use a demand forecast when you run the calculation.

You must have demand that is causing your projected inventory (not your inventory!) to go below the reorder point.

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MaddieGreen 35 on at

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Thanks for your help. We've done some digging but we can't figure out what is going wrong.

We don't use demand forecasting

We don't have open sales orders

We have multiple products that only have an SKU for one location, and we only do the Requisition worksheet for that location.

We are still getting products in the Requisition Worksheet that are recommend to be bought. An example is:

Calculate Plan:

Comes up in the Requisition Worksheet:

We still have 7 in stock:

We only have 1 stock keeping unit for this item:

Reorder point is set to 2, and we have no expiry date for this product:

We have no demand:

Sales orders are empty:

I get the same if I use the Planning Worksheet:

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Alfredo_Iorio 1,262 on at

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Check the unit of measure. Inventory is displayed as a base unit of measure while planning is based on purchasing UoM

Also, do you have order tracking policy enabled for action messages for the item?

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MaddieGreen 35 on at

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Thanks Alfredo for helping us out here.

I'm not sure if we have set it up correctly, but for the particular item above we have:

Base unit of measure: EA (1)
Sale unit of measure: EA (1)
Purchase unit of measure: CTN (6)
We have all our planning parameters set on EA (we had used CTN before but that was wrong apparently).

So Reorder point is 2 (EA) and reorder qty is 6 (equals 1 CTN).

We have the order tracking policy for all our items set to NONE.

I have noticed that for items where it is working we have the following selected (I haven't had time to cross reference this to all of our products):

We have an Item Tracking code and Lot No set for those items. Could that maybe interfere with it?

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Alfredo_Iorio 1,262 on at

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The setup looks correct.

You do need to set up your planning parameters in the base UoM. Still, the reorder quantity is always in the purchase unit of measure. Furthermore, BC uses the same purchase unit of measure in the requisition worksheet.

Therefore, with your setup, BC will plan for an order of 6 CTN every time your availability goes below 2 EA.

The planning suggestion you see in the planning worksheet is for one CTN (6 EA). In essence, BC is trying to get your item SKU inventory above reordering point of 2 EA telling you to purchase the minimum quantity of 1 CTN.

This make me think that the entire quantity of 7 EA of your SKU is not available.

Reasons might be:

- Lot No. is blocked. Go see in if the field blocked in the Lot No. information card is on. If the full lot is blocked, you will get a planning suggestion.

- Check that the SKU is not in a bin where blocked momevent is on.

- Check any reservations for transfer orders or assembly orders.

I believe we are getting close.

Out of curiosity. Why do you use SKUs? If you have only one location that you use for planning you don't really need an SKU.

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MaddieGreen 35 on at

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Thanks Alfredo.

- Lot No. is blocked. Go see in if the field blocked in the Lot No. information card is on. If the full lot is blocked, you will get a planning suggestion.

We have no Lot No. assigned:

- Check that the SKU is not in a bin where blocked momevent is on.

Both the base item card and the SKU don't have any bin contents (we don't use bins):

- Check any reservations for transfer orders or assembly orders.

We don't use transfer or assembly orders:

As for the SKU's we use them because we couldn't get the Requisition Worksheet to work without SKU's (products won't show up in the req. worksheet if they didn't have an SKU).

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Alfredo_Iorio 1,262 on at

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I run out of options.

The fact that you need to use SKUs to get the planning to work is suspicious.

BC planning works fine without SKUs. You only use SKUs if you have variable planning parameters by location.

I suggest getting your MS partner to login into your system and see what else is affecting the demand.

Clearly, something is consuming the supply of your item but I cannot help further without login into your DB.

Best of luck.

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