How to create a single production order for a part having multilevel BOM

[former_member143179]

Dear Sir,

We need to create a single production order for manufacturing a part and this part has multilevel BOM . The case scenario is as per below example .

As per the above scenario , Part-1 need sub-assemblies S-Assy-1 and S-Assy-2 and to manufacture S-Assy-1 it need different raw materials and 3 operations .

Our requirement is that , for Part-1 , we need to create a single production order which include manufacturing of S-Assy-1 & S-Assy-2 . In brief , under normal scenario there shall be 3 production orders , but in this case we need to create only a single production order .

The purpose of this simplification is to have lesser numbers of production orders , as we are making big size custom heavy equipment and there are several small component which need to manufacture in-house and their cycle time is very small comparing to the total cycle time of complete equipment manufacturing . So with this approach there will lesser nos of production order .

I request experts to kindly guide on this requirement please .

With Regards

B Mittal

[kiran_kumar179]

Mittals,

What about your S Assy 1 and S Assy 2 stock valuation do they maintain stocks for these Sub Assemblies?

If your answer is yes then making Sub Assemblies as Phantom does not suit your requirement in that case you should consider Collective order scenario Please refer below link which would explain the functionality and process steps

Its based on your business scenario and requirement you can map either as Phantom assemblies or Collective order.

BR
KK

[Former Member]

You need to setup the 2 subassemblies as phantom materials.

You can achieve this either by setting the special procurement = 50 in the material master of the subassemblies, or setting up the special procurement indicator in the ITEM detail of the BOM of superior assembly.

The choice depends on your business requirements: do you want the subassemblies to be ALWAYS considered phantoms, or only when used in the superior assembly?

In the first case you need to setup the spec proc = 50 in material master of the subassemblies, in the second you need to setup the same value in the bom item detail of the superior assembly (trx CS02, basic data screen), per each of the subassembly you want to consider and manage as phantoms.

regards

Mauro

[former_member184574]

Hi,

Define S-Assy-1 & S-Assy-2 as phantom item in their material masters. In Material master MRP2 view in the field Special procurement maintain as 50 (Phantom assembly) for these two sub-assembly materials. If you maintain this during MRP system will not create any planned orders or PR' s for these items but their BOM's will get exploded and their components (in your case RM-1, RM-2 & RM-3) are planned. In this way you can avoid the production orders for these S-Assy-1 & S-Assy-2

Hope this helps.

Thanks

Kumar

[former_member143179]

Dear Mr Kumar

Thanks for your reply .

The problem is that in this approach , production order of Part-1  shall not be having any operations related to S-Assy-1 & S-Assy-2 .  We need that it should have all 5 operations to be included .

Regards

B Mittal

[former_member184574]

Hi Mittal,

include all the 5 operations of S-Assy-1 & S-Assy-2 in to the Routing of Part-1. Once you define S-Assy-1 & S-Assy-2 as phantom items no need to maintain routing for these two assembly. Once you do this Production order of Part-1 will have all the operations of S-Assy-1 & S-Assy-2

Thanks

Kumar