[Unsolved] Production BOM Lead Time

Forza
Forza Member Posts: 64
edited 2007-03-14 in NAV/Navision Classic Client
Dear All Navision Expert,


My company is in the process of implementing Navision 4.0 for our company. We have not entered the manufacturing part of the implementation yet but I decided to test out some of the feature of the production BOM. What I found out is rather disappointing and might point to the fact that Navision might not work for our situation. Here is what I'm trying to do.

- Our company run a production line that assembly a product over a period of about 7 days. The raw materials are required at different stages of the production. Some are needed on the first day and some are needed on the 5th day, lets assume.

- I've tried out different options and found that i need to set the lead time in the item card for the product so that when a production order is created for the product, it take 7 days to produce.

- But when I set up the production lead time for the components of the product in the production BOM, the result is not what i expected. It turned out that the production lead time is used to pushed back the start date of the production order. Hence, the start date of the production order equals to the purchase lead time (in the component's item card) + production lead time (in the product's production BOM). THIS IS NOT WHAT WE WANTED TO ACHIEVE :|

- What we wanted to achieve is to set up a certain "time" in the production BOM that tells the system when is the component needed during the production process, not before, not after. And we are trying not to use routing for the component as the same component might be used at different time for another product.

Please provide some guidance on this issue. I have not brought up this issue to the NSC as I felt I need to know all the possible solutions before throwing the issue at them.


Thanks a million.


From a NAV Newbie

Comments

  • lubost
    lubost Member Posts: 633
    I forgot exact names of fields, but there exist field to "connect" the operation in TNG to BOM line. The same values means - connection.
  • Forza
    Forza Member Posts: 64
    lubost:

    I forgot exact names of fields, but there exist field to "connect" the operation in TNG to BOM line. The same values means - connection.

    What is TNG?
  • lubost
    lubost Member Posts: 633
    Routing line table.
  • muksha
    muksha Member Posts: 274
    You must use RLC in your routings and BOM to achieve this functionality.
    Mukesh Sharma
  • Forza
    Forza Member Posts: 64
    muksha:
    You must use RLC in your routings and BOM to achieve this functionality.
    I'm tried setting up the routing. It seemed like I need to perform a lot of settings like shop calendar and work shift etc. I've done all that and create a RLC, added it to the routing and Prod. BOM.

    I then created an SO with the item and run "Calculate Plan" in Order Planning. An Error occured with the following description:

    There is no Planning Routing Line within the filter.
    Filters: Worksheet Template Name: ", Worksheet Batch Name: ",
    Worksheet Line No.: 20000, Routing Link Code

    Anyone knows what contribute to this error?
  • muksha
    muksha Member Posts: 274
    This is the general error when Routing is not linking properly or setup of linking is not as per the system requirement. Please have a look on your flushing method also.
    Mukesh Sharma
  • fl
    fl Member Posts: 184
    Yes you need routing Link Code (RLC). You first have to define the different routing link codes. Then you add the routing link codes to the routing, and at last you add the routing link code to the bom. You must follow this steps, otherwhise you get errors.
    Francois
    Consultant-Developper

    http://www.CreaChain.com
  • Forza
    Forza Member Posts: 64
    Must I also add the Routing to the Item? If yes, does that means that all the RLC must be tied to one particular Routing record and one particular Prod. BOM? Let me illustrate:

    Routings: RouteA
    ____ Operation1: RLC1
    ____ Operation2: RLC2
    ____ Operation3: RLC3


    ProdBOM: ProdBOMA
    ____ Item1: RLC1
    ____ Item2: RLC2
    ____ Item3: RLC3


    Item: ItemA
    ____ Routing: RouteA
    ____ ProdBOM: ProdBOMA


    Is it true that it has to strictly set up as such in order for it to work? Can I omit setting up routing for the item? Or can the RLC be from different Routing entry?

    Probably I need to explain why we wanted to omit setting up routing for the item (at least for the time being). It's because we have a rather complex assembly system and we wanted to start off without using routing and capacity planning. We want to use Prod BOM to produce the item and timed the purchase of the raw material. (By the way, when I say we, I actually mean the m*n*g3m3nt)

    Any help will be appreciated. Thanks a million.
  • muksha
    muksha Member Posts: 274
    Please let us know at which operation your Item 1,2 & 3 are consumed.
    Mukesh Sharma
  • Forza
    Forza Member Posts: 64
    First of all, as I stated before, we want to do without capacity planning for the time being, the reason being our manufacturing line is rather complex. The assembly line is not a straight line from start to finish. There are 4 separate departments that handle different assembly stages. Inside each department, the item goes through various processes and is different from item to item. To further complication, there are sub-assembly process within each department. The illustration below exhibits a sample of the assembly structure:

    Sub1A (Dept 1)
    ___ Raw01
    ___ Raw02
    ___ Raw03


    Sub1B (Dept 1)
    ___ Raw04
    ___ Raw05


    Sub1C (Dept 1)
    ___ Raw06
    ___ Raw07


    Sub1D (Dept 1)
    ___ Raw08
    ___ Raw09


    Sub2A (Dept 2)
    ___ Sub1A
    ___ Raw10
    ___ Raw11


    Sub2B (Dept 2)
    ___ Sub1B
    ___ Sub1C
    ___ Raw12
    ___ Raw13


    Sub2C (Dept 2)
    ___ Sub1C (1 pcs is for Sub2B, 1 pcs is for Sub2C, total 2 pcs required)
    ___ Raw14


    Sub2D (Dept 2)
    ___ Raw15
    ___ Raw16
    ___ Raw17


    Sub3A (Dept 3)
    ___ Sub1D
    ___ Sub2A
    ___ Sub2B
    ___ Sub2C
    ___ Raw18
    ___ Raw19


    Sub3B (Dept 3)
    ___ Sub1D
    ___ Raw20
    ___ Raw21


    Sub3C (Dept 3)
    ___ Raw22
    ___ Raw23
    ___ Raw24


    Sub4A (Dept 4) - Finished Good
    ___ Sub3A
    ___ Sub3B
    ___ Sub3C
    ___ Raw25
    ___ Raw26


    This is just a simplified version of the Prod. BOM, the working one has more levels and more parts involved. Moreover, there are close to 500 items in active production. Currently, we have an experienced planner that can schedule the production well without using the system.

    We want each raw material to arrive (Expected Receipt Date) when they are needed by each department. Assume that the production run time for the item is 10 days. Dept 1 starts on Day 1, Dept 2 starts on Day 4, Dept 3 starts on Day 7, Dept 4 starts on Day 9.

    Looking at this, is it possible that we construct the Prod BOM in such a way that it won't touch on the capacity planning while being able to time the arrival of the raw material more closely to the production schedule?

    Our company needs to know if this could be achieved in Navision before entrusting the NSC to carry it out for us.

    Any help will be appreciated. Thanks a million.
  • muksha
    muksha Member Posts: 274
    We want each raw material to arrive (Expected Receipt Date) when they are needed by each department. Assume that the production run time for the item is 10 days. Dept 1 starts on Day 1, Dept 2 starts on Day 4, Dept 3 starts on Day 7, Dept 4 starts on Day 9.

    How the system will come to know that when you require the material for a particular department. To calculate it auomatically, we must tell the system production lead time for raising the requirement of a particular item to reach that dept. in time.
    Mukesh Sharma
  • Forza
    Forza Member Posts: 64
    To my understanding, without configuring routing, Navision will use the lead time in the item card to calculate the start date and end date for the production order.

    The start date of the production order will then depend on the availability of the components in the Prod BOM. Without routing information, the system will use the lead time for all the purchased item(component) in the Prod BOM to find the first available date for all the components to be replenished into inventory. This date will be the start date for the production order.

    The end date for the production order will be the start date plus the lead time in the item card of the Prod. Order item.

    Let me use another simple example to exhibit:

    ProductA
    ___ Replenishment: Prod. Order
    ___ Lead Time Calculation: 10D
    ___ Prod BOM: RawMat1, RawMat2

    RawMat1
    ___ Replenishment: Purchase
    ___ Lead Time Calculation: 5D

    RawMat2
    ___ Replenishment: Purchase
    ___ Lead Time Calculation: 8D


    Scenario:
    Created a production order for ProductA with a start date on 15 March.

    Result:
    After Calculate Plan on Order Planning, the system will prompt to purchase RawMat1 with Order Date on 10 March and Due Date on 15 March. For RawMat2, the Order Date will be 7 March and Due Date 15 March.

    Request:
    Assume that we know that RawMat2 will not be consumed in the production floor until the 5th day after the production order started. So the Due Date for RawMat2 should be 20 March instead. Consequently, the Order Date for RawMat2 should be 12 March instead.

    Can this request be achieved in Navision without resorting to capacity planning? Because we won't have enough resource at the time of go-live to setup all the capacity in the system.

    Any help will be appreciated. Thank you.
  • fl
    fl Member Posts: 184
    Can this request be achieved in Navision without resorting to capacity planning? Because we won't have enough resource at the time of go-live to setup all the capacity in the system.

    No, without routing or customised software is that impossible
    Francois
    Consultant-Developper

    http://www.CreaChain.com
  • muksha
    muksha Member Posts: 274
    System says if your replenishment system is production order on the Item Card then you must define the routing and will not read the item card lead time.
    Mukesh Sharma

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