I think that the goal should be to 1) minimize the vulnerability for your purchasing team to make buying decisions on bad data, 2) Find the root cause of the method inaccuracies.
To minimize the potential of inaccurate purchasing decisions I would suggest keeping a controlled stocking location with manual/discrete purchase receipts going in and manual/discrete bulk material issues to a shop floor location as needed. It is not difficult to maintain a high degree of accuracy in your controlled stocking location with this method. Be sure to backflush from the shop floor location. Your buyers can then manage the known (accurate) inventory in the controlled stock location. All of your BOM inaccuracies, usage variances, etc. will show up in the shop floor backflush location. If the variances are large you can slice and dice and make multiple floor stocking/backflush locations. Assign some jobs to backflush from location A, other jobs from location B, etc. That way you might be able to identify which jobs are causing the largest variances and begin to investigate root cause and maintain those BOMs.
These are just a couple of ideas.
Good luck!
Dale
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Dale Walker
Director, Continuous Improvement and Information Technology
Le Sueur Incorporated
ph.507.665.6204 x277
fx .507.665.8466
www.lesueurinc.com<http://www.lesueurinc.com>
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