We have some materials that we can make 30 pieces out of it. but if we make 31 then we would need a 2nd qty of that material.
It isn’t really a fixed quantity. but I don’t want to say it is 1/30th per parent. because if we make 29 it is 1/29th per parent.
How have others handled it?
I would specify the lowest quantity per piece as the BOM quantity. For example, if you get 30 pieces per blank, but occasionally (due to whatever reason) you only get 29, the material callout would be .0345.
At least that way, you’ll never run short, but might have the occasional extra piece if you yield 30.
The alternative is to call out your raw material dimensionally. If you have a bar that is 12 feet long, and each piece is .0345 of that, the BOM would be .414 feet of material per piece. Your unit of measure of the raw material should correspond to the same unit of measure you specify in your BOM callouts.
This gets to be “fun” in the sheet metal world.
Is the unused portion of the material (the component) unusable and therefore always scrapped?
Like if a job was to make 25, would the leftover portion (the qty that could have made 5 more) scrapped?
You could make the Qty per to be “fixed” (independent of the Job Qty), adjusting it to be a the ceiling (a function that “rounds up”) of the real qty Per * Job Qty.
Thanks guys for the additional questions.
The business case is specifically Master cartons and skids.
When we make a part we can get 30 in a master carton.
And we stack 300 (10 master cartons) on a skid.
Our mfg multiple is 30. Our min is 30. We can’t consume .0345 of a master carton. And we can’t consume .1 of a skid.
So when we get an order for 600 pieces we need to know that we need 20 master cartons and 2 skids.
Anyone solve that type of material requirement?
And what if you get an order for 500 pc’s? Not take it? Force the customer to buy 600?
We would build 500. That would use 2 skids (more than 300) and 17 master packs.
Would you sell 500?
Or sell 1 Skid + 6 Master Cartons, + 20 Individual pieces?
(1x300 + 6x30 + 20 = 500)
So… there is a trick that I always like to show…
BRILLIANT! Worst case, make a new UOM of PC (for piece), with no decimals.
BTW - if one ever plans to use serial numbers, you need a UOM with zero decimals.
Ok so we were doing this already. It just seems so strange.
Thanks everyone for talking through this.
Hi @timshuwy,
Sorry to bring this old thread back to life, but we’re facing a similar situation during our implementation. I tried this method, and it works more or less as expected.
However, when batching jobs, we might end up over-issuing material since this method doesn’t account for the possibility of using the remaining length to cut another part in the batch. I realize that automating this would be quite complex, so I understand if that’s beyond the scope.
My question is: why adjust the quantity per each instead of accounting for this difference as scrap?
For example:
Part usage = 0.442957746 (EA) per parent
Wouldn’t this achieve the same result while keeping the original quantity values intact?
The attached image represents a job for 100 of this component.
Again, sorry to revisit this old thread—I just want to make sure we get this right! 
Yes, that would acheive the same results… Just remember that you cannot (or should not) be able to return partial eaches back to stock.
Hi @timshuwy,
Thanks for the quick response! We’re hoping the ‘Salvage Material’ functionality might help us with returning items to stock. Our idea is to set up a generic part number for each material specification, which would be included in the method—specifically in the salvage section. Once the part is produced and we determine the actual offcut (salvage) length, the shop floor team would then assign a more specific part number for the salvage.
We’ve also considered setting up salvage part numbers for different material specifications based on length categories—e.g., salvage over 1m, over 2m, etc. This way, when consuming salvage, we can allocate parts under 1m to the 1m+ salvage category while anything smaller becomes true scrap.
The real challenge is in consumption, as we don’t typically include salvage parts in methods as consumed material by default, since their availability depends on prior job processing. While we could assign a standard cost to these lengths, figuring out how to efficiently consume them remains a hurdle. Ideally, they would be consumed by POTF or one-off items, but there are some complexities in aligning this with our business needs.
Has anyone successfully set up a system to manage salvage material consumption in a similar way? Any insights would be greatly appreciated!
one “trick” i used for one customer who processed “Sheets of glass mirror” to make smaller mirrors… they PURCHASED them in large sheets (4x10 feet or something like that)… but their habit was to issue the sheet to the floor, cut it up into smaller pieces, and when done, anything that was too small, simply was thrown away, but things that were bigger were held for possible use in the next job (salvage)…
BUT they didnt do the typical “salvage” type transaction. In fact, we chose to design their BOM complely different.
On a daily basis, when they wanted more “floor stock” they would do a Kanban completion of 40 sq feet of Y. This would automatically convert part X into a part Y.
Then when the completed a 2x3 foot mirror, it consumed 6 sq feet of Y.
At the end of each day, they did a “true up” of what was left in the floor stock, and adjusted part Y.
What this accomplished was:
