Sell Sales Kit, Ship Units on consignment to 3rd party, Manage components' inventory

Kinetic ERP
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We need to hold inventory at a component level and sell sales kits of multi-level modular parts.

We sell add-on vehicle assemblies to major OEMs as Sales Kits (sort of like a backrack / trailer hitch / light bar combo). We manage transactions with Epicor’s 1EDI/MX product.

  1. We have a virtual 3RD site for installers

  2. We use a TO to stock them up on consignment of components, modularly shared across many sellable units and sales kits. Currently, this is shipped as sellable units.

  3. Installer gets OEM EDI trigger for a finished installation of sales kits into vehicles and uses our parts, sending an EDI ASN to OEM when done

  4. OEM generates EDI 850 PO for sales kits, which we consume using MX and Demand Management

  5. We ship the resulting SO in our system, which generates our own ASN sent to OEM which they pay us against.

The problem arises when anything goes wrong. Installer manages their inventory by smallest component; if they lose or damage parts we send them new inventory. Sometimes this is OEM-responsible (lost by OEM’s carrier from us to Installer), sometimes it’s Installer-responsible (they broke something) rarely it’s us but sometimes we eat it for simplicity. Either way, we need to reconcile, manage and adjust inventory by component, although we transfer it as finished units and sell it as sales kits.

We need to improve our process to allow them to receive as components even though OEM orders from us as Sales Kit, and then figure out how to manage warehouse activities by component.

Anyone have any ideas for this use case ?

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update We’ve discovered that a combo of Planning BOM and Phantom BOM together creates sales-kit-like behaviour, allowing a plan bom / phantom bom part to be inside a sales kit and then act as if it is itself a sales kit. Its components generate separate SO detail lines and releases, and upon shipping, those components go into the sales kit section of Customer Shipment entry.

Any known pitfalls?

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Sorry not helpful, but my head did just explode!