I have an inventory part that is not used in Production. We have a min and max set on the part. We allow consumption of minimum and we reorder to max (to minimize how often we reorder this part). My buyer generates weekly POs to replenish our spare parts inventory and would not add a part to these orders without a PO Suggestion. For this case, we kept getting PO suggestions for this part, even though we were projected to have stock levels above maximum. I am not sure why the suggestions kept coming through in a quantity of 6 also. Here is our Time Phase:
Mark,
Thank you. Yes these are POs, but they came in as New PO Suggestions and my buyer just kept ordering them (with a hundred other parts) every week. Once the Max on hand was projected to be satisfied, why did we continue to get New PO Suggestion?
Matt,
I agree that Time Phase is calculating that the open POs will put us over Max.
My buyer would not issue a new purchase order without a Suggestion. So why would Epicor have made the suggestions (that my buyer has already turned into POs) that show due dates of 11-8-2022, 11-15-2022, 11-29-2022, and 12-13-2022? That is 4 more POs (that were suggestions at one point in time) that will not be needed as we will already be over max. I am also trying to understand why the quantity is 6.
locking has caused me to over-order in the past but not the case here.
I know from testing on a previous issue that the re-order to max does not prevent you from going over your max. The only use I see for the exception column stating Above Maximum is that you can use that as a criteria in this report:
That QTY of 6 is odd. We don’t currently use re-order to max so not sure what is going on.
After reading this thread - you may want to look into using Kanban PO’s
You can set the trigger level at the warehouse or bin location to create a new release on an existing PO.
When your inventory drops below the minimum, a new release is created (even if the PO is closed)
The buyer prints a weekly open PO report filtered for that supplier to request the replishment.
So I have it figured out. Our vendor will sometimes change the part number on us. In this case, we had 2 on hand for the old part and the min was set at 3 and max set at 8. We are set to reorder to max so to get to 8 from 2 on hand, we need 6 (so that is why the suggestions/POs have been for 6). When we get the confirmation back from our vendor, showing a new part number, the Buyer is supposed to contact the people in charge of adjusting the inventory levels to have them change the min/max between the two parts, set the old one to run-out, set up an alternate part number.
I notice your Days of Supply is set to 0. I’m not sure what that does to looking forward at PO’s but it is something I would experiment with. We tend to let it look a month ahead.