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Mar 17, 2009 at 09:04 PM

Rounding components in planned orders

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Looking for a solution for this issue:

We produce semifinished goods which can be components for several finished goods. The semis are produced in case quantities, and are only handled in case quantities. The BOMs for the finished goods are set up in each.

Since MRP adds up all the requirements coming from finished goods BOMs first, we run into shortages all the time.

For example, say our semifinished good is produce in case quantities of 200 (which, again, can not be split up).

Now we have the following FG requiring the following quantities:

A - 2500

B - 1300

C - 700

So MRP adds them up to 4500, adds 100 to tell us to produce 23 cases.

We do that, and now distribute them to the various FG. A gets 13 cases, B gets 7 cases, and C needs 4 but OMG only 3 are left!

There must be a way to fix that one, so we get exactly the number of cases that we need. Is there a way to configure BOMs or planned orders to round up to full case quantities for their components?

Any help is appreciated.