In Enterprise planning workbench, MRP will keep suggesting a new purchase order (PO) and cancel the existing PO. It fails to give an 'advance' suggestion, or suggestion to increase the quantity on the existing PO, which is expected behavior based upon experience with other MRP systems. For companies with simple products MRP can be managed by working through the details manually, but in a complex environment with large multi-level BOMs and many components, the requirements are going in every direction and it's almost impossible to get to the bottom of the suggestions.
Let's take a look at one scenario and how to fix it.
- GESITF: Manufactured item’s production LT = 30 days
- Reorder policy setup
- ADPVAL: General parameter LATSUGDAT in STO/REA is set to “First possible date + Lead time”.
- GESPCB: Requirements parameters setup with 30 days backward and forward LT for WOF.
- GESSOH: Generate a SO for QTY of 5 and the requirement date “04/18/19”.
- FUNMRP: Run MRP
- FUNDBENCH: Convert the WOS into a WOF.
- FUNMRP: Run MRP
- FUNDBENCH: MRP suggests to cancel the WOF and delay the WOS instead of suggesting to advance
Solution:
- To avoid suggestions while resources cover the requirement, increase the replanning horizon in order to include the production lead time of the products.
- This setup permits to have a good MRP message and to not have a new suggestion (WOS).