Sage 100

Have a client using WO and MRP and for some reason Planned WOs are not appearing as demand to subassys on the MRP report or Inquiry screens. Any ideas? The subassy items are Make.

Does the specific Warehouse Group appear to be working? Meaning you see Parent Demand in the specific warehouse group (Not ALL, but in specific warehouse group in MRP Inquiry)?

Have you run the Bill Validation Report?

It's been a bit since I've checked this, but I believe so. However, I will have them double check the inclusion tomorrow. This is very weird. While I was onsite a couple of weeks ago, we checked the ""logical"" elements - make vs buy, warehouse groupings, etc. For the life of me I couldn't figure out why the PWs were not passing demand to the subassys.

Not sure if I ran it there. Good call, will double check tomorrow.

I've also found cases where ""Alpha"" codes for MRP Warehouse Groups don't blow through. I always use Numerical Group Codes.

I've seen issues when the sub BOMs are kits, or when they are eng BOMs From my phone Clark Walliser Quantera Systems Clark@QuanteraSystems.com Office: 408-280-7587

I believe they are using numeric, if I remember correctly, but will affirm tomorrow. It's a definite problem.

Hi Clark, hadn't thought of kits - will check that out. Don't think they are using BOMs, but will confirm. Great ideas!

Actually reviewing my notes - kits are not allowed in BOM.

Well technically Sales Kits can be used in B/M if enabled.

That's what I meant Brett, the option for kits is disabled in BOM setup.

Here's some info regarding MRP and components of parent item on Firm Planned WO.-> The MRP Report lists concluding information from the last run MRP Generation process. The report includes current on-hand inventory information, and detail for all demand and supply information. You can see recommended actions, quantities, the action by date, and any new required dates. The report can be printed in detail or summary format for all items, a selected range of items, or for certain product or procurement types. The components of a work order are considered a demand. The purchase order is the supply of these components. These items appear on the MRP Report as PW (planned work order component) and PO (purchase order). The parent item of the work order appears as a supply (FP for firm planned).

thanks Joan, but this all I knew. What I don't understand is why the Planned WOs are not passing demand to the components and subassys.

Any more info from the client system?

Running through the typical checks,,,Make sure that the BM Option component level is defined at least 2 more levels than what a bill sub-assemblies might be. Example, if most in depth bill is 8 levels then the option setting would be 10. Again that is in BM Options This version contains embedded IOs so I would run the replacement script for all modules for this company code. Once the directional pointers are in, rename and manually reinitialize the 5 WO sorts file and then rebuild WO Sorts, yes to recalc prompt. Once that is done, doubt check the MP Option setting for the Fiscal period and Year to make sure it is not outside the parameters being set for planning. Validate the WO records by accessing the WO and clicking on each tab to view. If no errors, re-run the MRP Generation and then check the MRP Report. Are there any PW line items displayed on this report? If copied to a new company code do I get different results.

@MikeBrown , so far I've found 4 endless loop issues and six invalid bills (not bills, but asterisk appeared in Revision field). Have the invalid assemblies fixed and some of the endless loops. They still have to figure out the real structure for two of them. Until we get them resolved not trying to regen MRP...hoping these are the issues. Otherwise, back to the drawing board. Will let you know.

@JoanSerr - they have 10 in place and looks like deepest BOM is around 5 levels. As for the rest of what you said (besides rebuild sorts) - what? All I read is ""bark, bark"" :)

Fixing the loops and invalid components has cleared up the planned order problem. However, MRP appears to not be calculating the right qtys. Having them rebuild sorts and regen MRP. We'll see what that does. Otherwise, any other ideas?

Verify unit of measure. Often you'll find fractional BOM quantities with unitary UoM (like EACH).

I will. However, they know about the EACH issue. However, the item is on the BOM twice and it appears to only display the qty for one of the listings.