How to setup overlapping between production orders?

thjens45

Hi. We have a customer with basicly four production cells (Cellular Manufacturing). They are in line after one another. The output of the first cell is producing a semi-finished product (Liner), this item will continue to the next cell, after aobut 100 items is finished. Cell 2 has its own production order. The point is that the send-ahed field on the routing lines can't be used. It is not the operations in the routing that needs overlapping, but production orders. To further explain the scenario:
(The policy is make-to-stock)

Item A
-CmpX
-CmpY
-Liner (this is a BOM with two components)

Item B
- CmpX
- CompZ
- Liner

Sales Orders:
Cust A: Want 1000 Item A (del date 20.december)
Cust B: Want 2000 Item B (del date 30.december)

By setting Lot accumulation period to 1 month, NAV will suggest to manufacture 3000 Liners in cell 1(work center).
The Item A will be planned after all 3000 Liners is finished. And this is not want we want. When Cell 1 is finished with lets say 100 items, the production order with Item A should get a starting date at that point, not after all 3000 is finished.
So, basicly, some type of solution that uses send-ahead qty, but "between" prod. orders is want I want.
Either some clever setup of work centers or resources, or a suggestion on how to program NAV for this purpose.
Or, mabye I have to think about this a completly different way?

Please, if you need more information of any kind, I will be happ to provide it.
We are upgradring the customer to NAV 2013 R2.

Br
Thomas Jensen.

Reinhard

hi Thomas,
sounds interesting!

I wanted to throw one idea out there.
If you change the "Order Qty" of item A to 1,000 then you will get three orders. Each of those would have a different completion date. So item B can be started once the first order finishes.

I'm sure there are better solutions out there on Mibuso
Good luck!

- Reinhard

thjens45

Hi Reinhard. Thanks for your replay. However I am unsure what you mean? Item A has qty 1000? Could you specify your idea a little more?
Bear in mind that one of the reasons for this appraoch is that, on the routing line, I want to have setup time for the BOM "Liner". This reflects what they need to do with their equipment in order to produce this particular Liner (the Liner differs in size). So, when the 2 next sales order is to be produced with items like these:

Cust 1
Item C (qty 2000)
CompXX
CompYY
LinerSizeY

Cust 2
Item D (qty 3000)
CompXX
CompZZ
LinerSizeY

I want the planning to suggest 5000 of LinerSizeY in one batch. This Liner has a different setup time than the LinerSizeX, and therefore must be calculated correctly.
If the planning suggest smaller batches (e.g. by using phantoms for Liners), the setup time would be impossible to calculate correctly. And this setup time is ciritical, as the customer uses between 4 and 16 hours do do this depening on the size of the Liner, and the batch size does not matter.

br
Thomas.