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Dynamics 365 Community / Forums / Microsoft Dynamics GP (Archived) / MRP Calculations Incor...
Microsoft Dynamics GP (Archived)

MRP Calculations Incorrect

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Posted on by MichaelC 1,761

When I run Request Resolution in GP, I get recommendations to create Purchase Orders for Items that are already on a Purchase Order. That being the case, all of our open purchase orders are being ignored within the MRP calculations.

We have run the Checklinks and Reconcile utilities, Regeneration, and rerun the Requisition Resolution process, but GP still does not recognize that there are Open POs for items in the system and recommend that we create additional POs for items.

Example:

Demand from Open MOs        2,500 Units
Open PO                                     2,500 Units

Net effect                                    0 Units

However, MRP is recommending that a PO for another 2,500 units be created. So we have no problem getting POs created. Our problem is getting system to create POs when appropriate based on Open MO Demand and Open PO Supply.

Any assistance would be greatly appreciated.

Thanks,

Michael

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  • Verified answer
    MichaelC Profile Picture
    MichaelC 1,761 on at
    RE: MRP Calculations Incorrect

    Ok...the answer was that in the MRP System setup the default setting was set to 0 for "Quantities to Include - Include Past Due for Prior "0" days.

    We had to change this to at least 60 to pickup the outstanding Purchase Orders.

    That was the trick. Thanks for all the help in trying to troubleshoot this issue!

  • Bron Profile Picture
    Bron 2 on at
    Re: MRP Calculations Incorrect

    David has some great comments and suggestions.

    I've seen this before when folks are not using Lead Times and the dates are a certain data condition.

    Example - Item A has a zero lead time and MRP is not using any fence time.

    Item A has zero on hand. Item A has Order Point Qty = '50' and a PO with a future expected delivery of 100.

    MRP is ran and suggests a PO for 50 with an expected delivery date of today, even though a have released and Open PO - and you say Why?

    MRP logic - since the item has zero lead time - MRP figures it's faster to order and receive delivery (because no lead time) than it is to move in the released PO.

    Look at PO dates, your lead Times, your Picklist required date - MRP could be doing exactly what it is programmed to do......(I don't agree with the logic - but I've seen this many times).........

    Good Luck............

  • GPDavid Profile Picture
    GPDavid 2,250 on at
    Re: MRP Calculations Incorrect

    Running low on ideas over here!  :)

    How about the Item Resource Planning window for the component item at the selected site: what do you have set for Order Policy?  Do you have Move In/Move Out/Cancel suggestion checked?  Is your Order Policy set to Lot for Lot or some other type of policy that might be preventing existing supply from meeting the requirement?  Do you have a Planning Time Fence set for the item-site combination?

    David

  • MichaelC Profile Picture
    MichaelC 1,761 on at
    Re: MRP Calculations Incorrect

    No the POs do not fall outside. I checked to make sure. All POs are falling inside the MRP calculation range.

    We have tried changing the dates so that they are in or out of the MRP range to see if we can "jog" the system and get it to work, but no go.

    Any additional thoughts are greatly appreciated,

    Thanks!

    Michael

  • GPDavid Profile Picture
    GPDavid 2,250 on at
    Re: MRP Calculations Incorrect

    What is the relationship between the Vendor Promised Date on the PO Line and when the Demand is actually required?  Could the Vendor Promised Date on the PO line item be falling outside of the MRP calculation range?  This could happen if you do not set the "Run For" value to extend far enough out to include both the demand and supply dates or if you have set the "Past Due Number of Days" too low to pick up the PO shipment (assuming the Vendor Promised Date is earlier than the system date minus Past Due Number of Days).

    David

  • MichaelC Profile Picture
    MichaelC 1,761 on at
    Re: MRP Calculations Incorrect

    Thanks for your reply. I checked on both of those.

    >  The PO’s are printed = released (Thanks for the note regarding Planned Order Receipts).

    > The demand site and the PO site are both the same site.

    I am checking, but at the moment, the item site is the same on all related transactions and system is still suggested that we order more.

    I also looked at the pegging report – it also has the same inventory site and is not picking up the open purchase orders.

    Any additional feedback is appreciated,

    Michael

  • GPDavid Profile Picture
    GPDavid 2,250 on at
    Re: MRP Calculations Incorrect

    Hi, are the POs in a Released Status (printed) or Open?  Additionally, are you sure the Demand site is the same as the Site on the PO line?  If the two are not the same, then MRP would suggest a new PO to replenish the demand at the site and would likely suggest an oversupply of the PO at the PO receipt site.

    David

    Edit: Just tested quickly and regardless of whether or not the PO is Released or Open, it should still show as a Planned Order Receipt.  I would start with checking the Sites to ensure the Supply Site is aligned with the Demand site.

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