We have an interesting situation, that I’m curious if we can convince Epicor to navigate intelligently.
We recently changed the way we manufacture a few parts in our plant. In order to prevent buildup of stock in certain sizes, we chose a bunch of the more commonly used sizes that are larger, and have them set up to run with safety stocks and lot sizes. The smaller sizes that happen less frequently, and typically in less volume then are cut down from these. This has helped us hold less stock of many of these panels, cut down the number of part numbers stocked, and enabled us to cut down on damages from handling and rust because of more inventory rotation.
That side of it has worked out quite well.
This has developed and unfortunate side effect though, that I hope there may be a way to automate.
Let’s use 1005* for an example.
This panel gets sheared down from a 1010*. (slightly larger version of the same thing).
I’m not sure if we can get Epicor to consider if/then statements as part of MRP, but this would be a scenario where it would be beneficial.
The current issue occurs when we don’t have enough 1010* on hand to cover the 1005* that are required. In those instances, the jobs will be generated for a lot size order of 1010*, and then the made to order quantity of 1005* that will consume a portion of those 1010*. We also have the option to make the 1005* from scratch instead of making the 1010* first. When we have orders with larger volume, this is beneficial, as it allows us to save the material that we would waste from the shearing portion of the operation, and use it for other parts (as it is still in one piece in the sheet, before the 1005*/1010* panel is cut).
Is it possible, for some of these parts to have Epicor consider an if/then statement to generate jobs?
For example…
Demand for 55 pcs of 1005* is generated by some sales order or kit.
At that moment, there are 12 1010* available, with no demand.
In that situation, the preferred process should be to manufacture 55 pcs of 1005* directly, rather than prompt work orders for 1010*. Or some combination of using the 1010* that are available, and then manufacturing the remaining parts as 1005* directly.
Essentially…. If 1010* is available to cover 1005*, then use BOM and routings A.
If 1010* is not available to cover 1005*, then use BOM and routings B.
That if/then statement would need to be subject to date requirements by other orders as well, in order to function correctly long term.
We’ve considered a placeholder material then use material issue to consume the correct amounts of the correct part numbers but are wondering if there an easier and better way that doesn’t involve people remembering to do the right thing.
Hopefully that didn’t scramble your brain.