2012-11-29 - 5452 - Research - DR - Investigate single order option #ProductionBreakFix #ProductionOrders
5452.100 - Research - DR - Investigate single order option
Description
DR - Investigate single order option.
Investigate single order option for DR production. Create a document on single order option to have one order with blanks as the component. The document should list all the Pros and Cons.
Admin Info
Purpose
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Investigate single order option
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Requested by
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Rahul Attarde
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Issue Date
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11-29-2012
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Resolved by
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Adithya
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Resolved Date
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12-10-2012
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Document Status
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Complete
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Purpose
Easy traceability of requirement to proposal. In the current scenario particularly for blanks in make to stock it is difficult to trace the proposals specific to requirement.
Advantages and Difficulties
Advantages:
- Clear planning.
- Reduced Effort in processing the orders.
- Individual Order to the Requirement.
- Data can be reduced.
- Not many changes required to the current Configuration.
- Complexity of Production Order forms can be reduced.
Difficulties:
- The Process will be changed.
- Handling the current inventory on Blanks and Orders in WIP for Blank.
- Handling the current Demand.
- Existing BOM and Routings cannot be used.
- Required to change/create the Master Data.
- Need to Modify FGEN as per the requirement.
- On time delivery to customer in a short period is difficult.
“If stock maintained for blank based on anticipating demand for FG, deliveries can be done short period compared to single order scenario”
- Single order Option works when manufacturing is specific to DR.
Major Problems:
- Auto MIGO not possible in External Operation.
- Blank Stock transfer to MIAMI. No Manufacturing facility for Blanks in MIAMI needs to procure from DR.
- Sale of Blanks is not possible. If required, we need to maintain separate master data.
Current scenario and single order scenario
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Current Scenario
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Single Order Option
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Master Data
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Update production scheduling profile to exclude excess production from MRP consideration
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No need for production scheduling profile.
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BOM Maintenance
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Multilevel BOM: The FG BOM components include Blank and Text items.
The Blank has the BOM with raw materials as components
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The FG BOM components include the raw materials as components
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Routing
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FG and Blank both has different routing
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Only FG has the Routing
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Operation
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FG Routing Include 5 operations: COMPONENTS FOR BLANKS, OVERHEAD LOW, SCREEN PRINT, HEAT TRANSFER, and PACKING
Blank Routing include 3 Operations: OVERHEAD, CUTTING, and SEWING.
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There will be one Routing for FG Material combining the Blank and FG operations from current scenario. OVERHEAD, CUTTING, SEWING, SCREEN PRINTING, HEAT TRANSFER and PACKING.
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Planning
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The Planning is done for FG, Blanks and Raw materials, generating Proposals for FG, Blanks and Raw materials.
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Planning is done for FG and Raw materials
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External Sewing
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External Operation is last operation in Blank Routing, with Alternative Sequence.
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External Operation is included in FG Routing with the Alternative sequence.
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External Operation
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Auto MIGO is Possible
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Auto MIGO is not possible
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Development changes
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Changes need to be done for Production Order form.
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Blank Inventory
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Blanks inventory exists
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No Inventory for Blanks
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Blank Stock Transfer
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Stock transfer is possible to other plants from DR
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No Stock transfer, as Blank material does not exist.
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Pre Packs
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Orders are generated for Pre-Pack material, FG material and Blank
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Order is generated for FG material and Pre-Pack
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Production Orders
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Two
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One
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Process Strategy
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Materials are shared between plants
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Need to have two different strategies in 7410 and 1410.
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Points to be discussed
- Demand on current materials.
- Existing production orders.
- Existing Blank Stock.
- How we manufacture FG materials in MIAMI
- Do we need to discard the Blank materials and corresponding BOM, Routings and Blank Label
- Sale of Blanks.
Release Information
Provide link here to Release Notes