Assembly Order Processing-Duplicate Planned / Prod. Orders getting created.

[Former Member]

Hi All,

I have an issue with Assembly Order processing for a MTO.

I have a Parent production order for the Finished Good and corresponding Child production orders for the sub-assemblies that make up the Finished Good.

Production Orders for FG and Sub-Assemblies get created only when we receive a Sales Order.

The issue am facing is, Even after a Sub-Assembly production order is GR'd and Confirmed also, MRP is creating a duplicate planned order eventually converted to a production order for the same sub-assembly eventhough it is not required.

MRP is not creating a duplicate planned order (eventually converted to production order) if the Original production order for the sub-assembly is still not delivered (i.e GR'd).

Wondering, if there is some config setting am missing in Assembly Order processing such that MRP doesn't create any duplicate planned orders for the sub-assemblies.

Any clue or direction would be really helpful.

THANKS FOR YOUR HELP.

Regards,

Bharat.

[former_member196398]

Bharat,

Your question is not clear? Can you explain with some quantities for us to understand more clearly? Also let me know if the Planned orders of sub assembly is created with Sales order account assignment or not? I mean after making GR for sub assembly does the quantity go to sales order stock or Unrestricted stock?

Also let me know the data you are seeing in Yield/Varience field in the subassembly order header general tab.

Regards,

Prasobh

[Former Member]

Hi Prasobh,

here is the scenario in the following sequence.

1. Sales Order of Qty-1 Created for Material say...FG1.

2. Production Order say PROD1 for FG1 automatically gets created (No MRP Run required) when Sales Order gets created i.e Assembly Order Processing.

3. MRP is Run.

4. Planned Orders of Qty-1 for Sub-Assemblies say SA2 and SA3 get created.

5. Planned Orders converted to Production Orders say PROD2 for SA2 of Qty-1, PROD3 for SA3 of Qty-1.

6. PROD2 is GR'd with Qty-1 and PROD3 is still in processing i.e Not GR'd.

7. when i run MRP again for SA2, One more planned order for SA2 is getting created which is not required as i already have stock for SA2. Planned Orders are not getting created for SA3.

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Yes, Stock for Sub-Assemblies go to Sales Order Stock. It is not unrestricted stock.

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I received the complete GR of Qty-1 for the Production order PROD2, ExpectedYieldVariance is 0 in Header General tab.

Planned Orders / Production Orders that get created for Sub-Assemblies are created with Sales Order Assignment.

Please let me know if i am still not clear enough.

Regards,

Bharat.

Edited by: BRN on Jun 16, 2009 9:05 PM