Production Order Phantom Component Being Assigned To Wrong Routing Operation

[Former Member]

I’m wondering if anyone has seen an issue that we are encountering on a semi-regular basis and might know the cause/resolution. 

A phantom component of a production order is being assigned to the wrong ops step.  However, if I look at the BOM and Master routing, everything looks ok as far as that phantom component being called out and assigned.  What follows is approximately the situation:

Production Order for material:  111

Within the BOM for material 111 is a phantom 222 which is made up of  1 each:  333, 444

If I look at the Master Routing for 111 I see that  222, 333, and 444 have all been assigned to Ops Step 0115

When the production order is created for 111, however, 222 is in the first operation 0010 and 333/444 are are in operation 0115

This is not a consistent problem for all production orders for 111.  Some are fine (222,333,444 are all in Ops Step 0115) and some are not (222 is in Ops Step 0010 and 333/444 are in Ops Step 0010).

I have read that if a phantom material (i.e. 222) and all of it's components (i.e. 333, 444) are not assigned in the Master Routing for a material (i.e. 111) then the unassigned components and the phantom will be moved to the first ops step, in our case 0010. However, all components of my phantom appear to be accounted for.

One Production Order that I looked at did specify a qty of 2 each for 333 and 444, the components of the phantom 222, even though the BOM for 111 specifies a qty of 1 each for 333 and 444 so I thought that "maybe* the extra 333 and 444 were being considered "unassigned components in the Master Routing", however that theory was blown when I found another production order that was still wrong, even though the qtys were 1 as expected.

Any ideas?  I'm stumped.  Google has been no help.

Thanks!

[krscheffler]

Hi Gail,

Moving this to the SCM space for assistance.

Thanks,

Kristen