Running latest version of NAV
MRP is making unrealistic suggestions
It seems it is treating all purchase orders as un-released when in reality that are released
examples, Assume MRP Run OCT 1 for ease of conversation
Assume reorder cycle is 7 days- (The term period refers to one reorder cycle)
Example 1,
A PO was placed for 200 parts 60 days ago due Oct 15
Sales order demand was moved from OCT 15 to Oct 14 (period 3 to period 2)
MRP suggest “cancel” Current PO and Suggest a NEW PO for period 2. MRP “should’ Reschedule the current PO
Example 2,
A PO Was placed for 100 parts 30 days ago and is due in period 1 let’s say tomorrow
Demand has increased from 100 to 115 in period 1
MRP suggest increase QTY on current PO due tomorrow , MRP should suggest placing a NEW PO for the increased QTY.
Example 3
PO Placed for a long leadtime item, The planning Flexibility for that order is set to “NONE”
The reorder cycle is 30 days
The PO is due Oct 21
When MRP runs it sees the Flexibility = None and suggest a NEW PO Like it should if it finds demand prior to this PO’s schedules date. BUT, the system sees demand prior to the scheduled date and it then looks at ALL demand for the reorder cycle of 30 days and suggest a NEW PO for the whole demand. In this example there is a demand of 200 prior to OCT 21 and a demand for 500 after Oct 21. MRP suggest a NEW PO for 700 in error. The NEW Sugg PO Should be for 200. Using the current suggested PO will result in 500 excess parts as the current PO covers demand after the OCT 21 date.
Summary
MRP is assuming it can make any change needed to any PO regardless of leadtime or when it was ordered
“MAIN ISSUE” MRP is planning within each “reorder cycle” and if there is a demand in a different “period” it suggest cancel the current order and placing a new PO for the other period. What the system should do is reschedule the current PO. It “seems like” it only reschedules “IF” the supply is within the “same” period.
The site went live within the last 90 days, I do operational consulting and assist businesses in improving MRP performance and was just recently engaged. I am assuming that there is something the dealer did not setup correctly or that there is a bug that needs to be addressed as the suggestions are unrealistic and do not reflect normal MRP suggestions.
Appreciate any suggestions
Feel free to call if you know what it is or what needs done (I am in EST)
Dave Mowrey
Cell- 603-867-1523