Master Scheduling proposes planned purchase despite enough in inventory

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Posted on by Rolly Rulona

Hi,

I have raw materials A,B,C and finished good D. I have enough on-hand inventory of the raw materials. Raw materials A and B have a subcontractor warehouse stated in their respective BOM Line in item D-BOM. I created a sales order where I run the master scheduling in the sales order line through Inquiries>Net Requirements>Update>Master Scheduling.

When I look at the planned order details form, I get a planned production order for item D (which is good), planned transfer and planned purchase orders for items A and B, and planned purchase order for item C. Keep in mind that I have A LOT in inventory to cover the requirement, yet master scheduling proposed to buy the given maximum on-hand quantity plus the requirement quantity - which is absurd. The same thing happens even if I run master scheduling through Master Scheduling>Periodic>master scheduling>Item D

Now, I completely deleted the plan. I went to Item Details form, looked up items A, B and C where I go to Inquiries>Net Requirements and it doesn't show the available on-hand quantity. I then updated the net requirements through Update>Master Scheduling where the result shows the on-hand inventory. I did that for all raw material items.

Now, when I run the master scheduling again in the sales order and the result planned order details from shows me what I wanted it to i.e. planned production order of item D and two planned transfer orders for items A and B. There were no planned purchase order which is great.

It's as if AX does not look at on-hand (in that matter the BOM of item D).

Anybody can help?

Best regards,

Rolly

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guk1964 10,888 on at

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BOM set ups e.g. use of phantoms or references to sub assemblies typically assume make to roder rather than use stock on hand

orders outside positive days will also ignore on hand - i.e. the window in which you want to keep stock on had to meet new short term demand

etc

try running action and future messages those often give a clue.

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Rolly Rulona 60 on at

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Thanks for the reply.

I do not have phantoms on my BOM lines and I have tried running finished good D with items A and B both as BOM line type and item. It did not help. The four items mentioned are all newly created for the sole purpose of testing, so no records of previous transactions other than adding on-hand inventory through profit & loss.

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guk1964 10,888 on at

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Did you check positive days setting? if it s at zero then the system has to plan new orders. To consider actual on-hand for any demand, the positive days have to be at least as long as the coverage fence.

The MRP logic would think like this:

“Demand that I have not covered. Should I create a planned order with a date equal to that demand date?

Look ahead as far as the negative days. Is there an existing supply to cover the new demand? This includes On-hand inventory. Am I allowed to use that existing supply?

How close, in calendar days, do I have to be to projected positive inventory to be allowed to use it? If, positive days = 0. then mrp will create a new planned order NO matter whether there is stock available on-hand, mrp can’t use it.

Have you tried looking at the MRP Explanation tab?

Also turn on Action and Future messages for a test run for maybe a month ahead and see what messages you get - the way Ax logic works you may get a planned order and then a message to cancel it.

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Weaveriski 23,620 Moderator on at

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"Where" is the inventory and and what level of dimension do you control it?

Can you show the net requirements screen for one of the raw material items showing the inventory on hand, the production demand and the level?

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Rolly Rulona 60 on at

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Hi magic1949,

Thanks for the reply.

The following are stated for the raw materials' coverage group:

The positive days = 730 and negative days = 5

There are no other demand except the sales order I specifically created to test master scheduling which means that there is more than enough supply to fulfill the sales order.

Action and Future messages are turned on.

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Rolly Rulona 60 on at

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Hi Steven,

Thanks for the reply.

I control the raw materials only by storage dimensions where warehouse and batch number are active. As mentioned earlier, A and B are to be transferred to subcontractor warehouse which means that I additionally checked the "Coverage plan by dimension" for warehouse which is one of the prerequisite parameter for generating planned transfer order of these materials. Item C is not checked on "coverage plan by dimension". I presume that it has nothing to do with this because, MRP still generates planned purchase orders for these three raw materials despite having more than enough on-hand.

The inventory on-hand of the raw materials are in the main company warehouse.

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Rolly Rulona 60 on at

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Hi again Steven,

This one is taken from the Item Details>Inquiries>Net Requirements (as a result of running master scheduling on the sales order I created). As we can see, it doesn't show the inventory on-hand.

This one is from Master Planning>Common Forms>Planned Order Details. Items IS17393 and IS17398 are the raw materials (A and B from my initial post) that have to be transferred. Item IS17399 is the raw material item C in the initial post.

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Weaveriski 23,620 Moderator on at

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In the first screen you have 0 on hand, you have a minimum of 50,000, you have a trigger of the 100 from the TO and it is ordering up to the maximum as you are using Min/Max (You would have to tell me why as I see no point). AX is reacting to the demand and Min/Max setting. Why are you not holding the defined 50,000 minimum at the warehouse, why do you want a 500,000 maxiumum?

I presume the TO is to move it into the sub-con warehouse? You are moving stock you dont have in the configured setup. Where is the stock?

The second screen is the generated planned orders filtered, not sure what you are showing me ecept the highlighted one, and the pegging is the TO with the modifiers applied to get the replenishment.

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Rolly Rulona 60 on at

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In the first screen, yes I do have on-hand inventory it just doesn't show. That is the whole problem. It doesn't show the on-hand unless I update the "net requirements" from the Item details>Inquiries>Update>Master Scheduling.

My intention regarding the second screenshot is to simply to show what I meant by MRP suggesting both how to fulfill the sales order plus the filling up of given maximum inventory value (which is the problem since I do have more than enough on-hand)

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Weaveriski 23,620 Moderator on at

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By Item details you mean the item record itself or does Item details mean somewhere else?

Are you a single or multi-plan business? If multi which plans are you looking at in which screen and are they configured differently? Looks like you are looking at the same plan but I cannot be sure.

The stock will always be the first point, so either it is configured out, there is an old bug which there is probably a hotfix for but it is a long time ago so I suggest asking your partner or there is something in the data, batch expiry for example.

So other things to look at are your dimension group setup for the item, and compare this to the actual on-hand dimension by dimension for coverage group.

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