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Levelled production and delivery schedules

Hi,

We are trying to run a levelled production, the same quantity produced each week, and we want to send equally leveled delivery schedules to our suppliers. The MRP gives us uneven requirements which directly reflects in uneven delivery schedules which we manually correct. As we show in the example below, if we have a material that has a fixed lot size set to 12 and deliver on specific weekday, the MRP will produce schedule lines (receipts) containing a mixture of 0, 12 and 24 pieces. Obviously we must have some zero lines but we don’t want any 24-piece lines.

We have tried using the coverage profile as an “elastic band” with no success. An unlucky choice of minimum coverage in relation to the requirement seems to group the receipts even more. Any ideas on how to solve our issue/requirement? Is there a way to only procure in blocks of 12 and if we need more 12 to keep our safety stock to procure on an earlier date?

Example

Period Plnd ind req Requiremnt Recieipts Available quantity

W 49/2012 0,00 11,00- 12,00 41,00

W 50/2012 0,00 10,00- 0,00 31,00

W 51/2012 0,00 8,00- 12,00 35,00

W 52/2012 0,00 8,00- 12,00 39,00

W 01/2013 0,00 2,00- 0,00 37,00

W 02/2013 0,00 11,00- 12,00 38,00

W 03/2013 0,00 11,00- 12,00 39,00

W 04/2013 0,00 11,00- 0,00 28,00

W 05/2013 0,00 11,00- 24,00 41,00

W 06/2013 0,00 12,00- 0,00 29,00

W 07/2013 0,00 12,00- 12,00 29,00

W 08/2013 0,00 12,00- 12,00 29,00

W 09/2013 0,00 11,00- 12,00 30,00

W 10/2013 0,00 12,00- 12,00 30,00

W 11/2013 0,00 11,00- 12,00 31,00

W 12/2013 0,00 14,00- 12,00 29,00

W 13/2013 0,00 2,00- 0,00 27,00

W 14/2013 0,00 12,00- 24,00 39,00

W 15/2013 0,00 10,00- 0,00 29,00

W 16/2013 0,00 9,00- 12,00 32,00

W 17/2013 0,00 14,00- 12,00 30,00

W 18/2013 0,00 9,00- 12,00 33,00

W 19/2013 0,00 4,00- 0,00 29,00

W 20/2013 0,00 13,00- 12,00 28,00

W 21/2013 0,00 7,00- 12,00 33,00

W 22/2013 0,00 14,00- 12,00 31,00

W 23/2013 0,00 9,00- 12,00 34,00

W 24/2013 0,00 13,00- 12,00 33,00

BR,

Ioannis

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1 Answer

  • Best Answer
    Posted on Apr 17, 2012 at 02:58 PM

    Hi,

    Lot sizing procedure FS generates fixed quantity lot sizes each put forward in time by the takt time. In order to put lots at earlier dates in time by takt time, create a new procedure by copying FS, and change the overlapping indicator to '-'. Then use this new lot sizing procedure with fixed lot size and rounding value of 12, and maintain takt time as you wish. Takt time may be 7 if you want requirements of additional 12 pieces to be one week before real requirement date.

    Regards.

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