Manufacturing Integration - Re-use Planning Lines in Production
Design Detail: Re-using Planning Lines
Engineer-To-Order often involves complex products that require long running projects to complete. To control that process it is not only up to the engineering of the final product but also to the engineering of how to build it. Often standard components are involved that can be build as soon as the project starts to be used later in higher level assemblies which still have to be engineered.
IEM provides the basic structure for these types of projects. The project tasks can be sequenced by the setting the next task, or plan tasks in parallel, and with the estimated no. of workdays and non-working days calendar the critical path for the project can be calculated and maintained. With the Milestone type tasks you keep track of the originally agreed timeline.
The material planning facilities of Business Central calculates the material requirement either per item or per order. The reservation system that binds material to a specific project task creates, however, limitations. Material ordered for a planning line has a reservation type of order-to-order binding, a hard reservation, which assumes that the ordered material will be consumed, or delivered, for that planning line in that project task.
To address these limitations IEM is providing the re-use feature: A project planning line can be used as a production order component in one, or more, higher level assemblies. This also implies that the costs that were made for the planning line to be reused must be off-set. Otherwise the cost will be incurred twice: First to create the item for the planning line, secondly as component in a production order. That off-set is posted when the production order for the final assembly is posted as a project ledger entry with a negative cost.
Scenario
The company creates special wheels which are designed and built on customer specifications.
The hubs of those wheels are standard components.
When a customer order is received a project is created with several tasks:
- On one of the first tasks the standard components are planned and a production order is created from the project planning line to manufacture the standard components asap.
- On one of the next tasks the complete wheel is planned and a production order is created as soon as engineering completes the Production BOM and Routing. Note that the production BOM for the wheel includes the standard components.
In standard projects the hub is now reserved for the first task and cannot be used as a component in the production BOM on the second task.
Mark a planning line for re-use
When a, standard, item in a project planning line will be re-used in a future production order set the Application Type of the project planning line to Re-use. This line type will prohibit the project planning line from being posted once the production order is completed.
Process a production Order
From the project planning line where the complete item is planned use the Reuse Planning Line action to select the planning lines that will be re-used in the production order to be created. The selection page will show the project planning with application type of Re-use.
Once the production order for the complete item is created check the component lines and note the Re-use column. The lines marked as re-use will be excluded from the material planning since these are already in inventory or planned in a production order.
When the usage for the production order is posted (Production Journal or Consumption Journal) the reservation for the "re-use item(s)" will be changed from the project task to the production order component just before posting.
When the status of the production order is set to Finished the project tasks(s) for the "re-use item(s)" will be credited with the costs of the "re-use item(s)".
See Also
Return to Manufacturing and Service Integration