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We have the need to keep a secondary item in our BOM for quality reason, so that we can switch over to the other item if needed. We do this by including the second item in the BOM as zero qty, then if we need to switch to it, Quality has what they need and we then consume the item used. Obviously, for MRP this doesn't help us plan for the second item, but that's OK.
The probably is that if there is a zero qty line in the BOM, it doesn't carry over to the production BOM when a new production order is created. Is there a way to include zero qty items from the BOM to the Production BOM? Is there a setting or is there a line of code that allows us to include zero qty items?
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One option we are going to test is setting the BOM line to a flushing principle of "Manual". This seems to bring over the line without causing a problem since it's a zero qty item. Do you see any problems with this method?
There are three options:
Use BOM versions
Use the substitute item as a phantom made out of the main item - the demand will blow through to the phantom component but you can always issue the phantom parent if need be.
The third option typically used for tools and changeparts is to add a second BOM line for the substitute part as a negative value i.e. one with a positive quantity with flushing principle set to start and another with negative quantity with flushing principle set to Finish. However for this situation its not a good choice because it will see allocation to issue the item with a future receipt and its more work for mrp also
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