Produce by aggregating the same material code in different plants with intermediate storage

[former_member795264]

chart-example.pngScenario:

Currently, P1 is the unique production plant in company.

The material M1 (HALB) is manufactured in production plant P1. Here the type procurement is "E" in plant P1.

The raw material M0 (ROH) is in M1's BOM in plant P1. Here the type procurement is "F" in plant P1, because there's a external supplier.

M1 is produced by 3 very different processes (Machining, Heat Treatment and Finishing) in plant P1.

There's one routing of material M1 in plant P1, countaining 3 operations O1, O2 and O3. These operations are in 3 different work centers.

So each planned order created by MRP, consider this 3 operations in 3 different work centers, inside of that same planned order.

Case:

Considering the differences of these 3 production processes...

Lot sizes, order scheduling and order confirmation, etc, are very different for each manufacturing process.

It would be necessary create 2 intermediate storages between these 3 processes. This would solve problems currently, due to the long lead time of the orders.

So I decided to use 2 additional plants (P2 and P3). So, it would be used one plant production, for each manufacturing process.

So far, I've read this would only be possible using different material codes in BOM. I mean 1 material code to process for each production plant.

That's correct? There's another way to make this using the same material code?

Trying make this, I've tried extend material M1 for 2 new plants production (P2 e P3) and link the BOM in same material M1, using recursive list but I didn't get sucess.

I used the sepecial procurement to directly in P2 and P3. But the planning doesn't extend to all production plants and not consider 3 productions to finish material M1.

Basicly... I need that each plant, can be produce the material M1 and transfer to next plant to produce too, the same material code, Aggregating value.

I need each plant to create planned orders to run its own process and then transfer to the next subsequent production plant.

The focus is to insert the intermediate deposits. I mean, using 3 production plants, 3 routings, with their different operations and work centers. But with the same material code.

Example:

- P1 receive M0 (Raw Part)

- After this...

- M1 is processed by P1 (Machining);

- M1 is transfered to P2 (Heat Treatment);

- M1 is processed by P2 (Heat Treatment);

- M1 is transfered to P3 (Finishing);

- M1 is processed to P3 (Finishing).

- Now M1 is finished.

Please, can anyone provide me with the necessary information? I made an example attached...

[Caetano · Accepted solution]

Hello Leandro

Ideally you should have one finished product and two semi-finished products, if you want to use different lot-sizing procedures and add an intermediate storage at semi-finished levels, as mentioned above by Mahesh Kumar.

If your company policy does not allow the creation of additional materials, then you need to work to change this policy 🙂

The creation of additional plants won't be the ideal representation of the manufacturing processes, as you won't be able to differentiate when a material is finished or when does it need additional processes.

Regards,
Caetano

[former_member795264 · Accepted solution]

caetano.almeida and maheshkumar.komatineni,

It really doesn't make sense to use only 1 material code for this management level for MRP. I will focus on this organizational policy and restructure it.

Thank you very much for your support!

[maheshkumar_komatineni]

Hi leandrocgl

Why dont you create 2 semi finished materials for the 2 processes and create a BOM then system can generate 3 different planned orders and do scheduling. Ex- M0 raw material is consumed and produced Semi finished M3 in first step this can inventoried M3 can be consumed and produce M2 in second process this can be stored as required M3 can be used and produce M1 .so create two SFG codes for two process mainatain master data as required and do the process.

[former_member795264]

Hi maheshkumar.komatineni,

I've tried to structure this at the beginning, but my company doesn't allow me to work with more than 1 material code for manufacturing at the moment (this is a internal policy). We are trying to reverse this. But in parallel, do you know if we can create this structure you mentioned, but using the same material code?

Ex:

Material A - Operation 10 - WC X - Plant 1

Material A - Operation 20 - WC Y - Plant 2

Material A - Operation 30 - WC Z - Plant 3