Dynamic creation of part list

[rupitale]

I am implementing PeopleSoft 8.10 for an Al alloy casting company which is using different varieties of Al Scrap which has different % composition of 8 different elements.

The client uses Linear Programming [Excel Based] to calculate the optimum mix of these varieties for a heat [batch] of 5 metric tons.
There are around 50 such varieties out of which they can use 5-10 varieties in particular quantities based on availability, cost, melting & process loss.

How to address such a dynamic creation of part list as there is no fixed BoM.

I would be grateful if the list can come out with some suggestions.

 

[Bill Meyer]

Maybe create say 10 template items and describe them in a meaningful way which means something to the folks puting together the parts lists. So you have say ten Items varieties templates, with a bill. At time of parts lists creation, attach the "closest" parts lists from the template bill, and make minor changes to the parts lists as required. The template should work, since the batch size is constant at 5 metric tons.
What do you use for standard costing, an average mix of most probable elements?

 

[rekblad]

Take the results from the Excel spreadsheet and upload it to the WO parts list.

 

[rupitale]

Thanks Bill... for a very logical answer. But out here the scenario is a bit different - Here they have a Linear Programming Software which optimizes all of the about 50 RMs based on parameters like %Composition of 8 elements, cost, process loss, melting loss and availability.
Hence client is not ready accept template solution as he can use any of the 50 RMs in different qtys every time.

We are thinking on lines of taking up the optimized data from the software and importing or creating a UBE to upload the optimized receipe [part list].

Another issue we are facing is that -

The client is into Al Alloy manufacturing. They import Al scrap then do segregation of the scrap into different types based on its Al content & % composition of 8 elements in each.
We have mapped this segregation as a 'Process WO' as we have multiple outputs which are the different types of Al Scrap.
The next process is Alloying, this can be easily mapped as 'Discrete WO' as we have a single output coming out in the form of Al Ingot after melting in the furnace.

As you can see this is Multi-mode Mfg ... But the client is insisting on Actual Costing ! As the first WO is Process WO how to get him actual costing?

 

[Nova614]

Develop customised report for this.

 

[yogigjoshi]

In such cases client always want to use scrap and/or returns to max possible extent instead of virgin metal to reduce cost. Hence, after using template minor corrections need to be done. Also excel sheet can be used for deciding optimum mix only and its uploading may not be advisable everytime. This is because actual consumption may differ from that suggested from optimum mix. Hence, only solution is to create a standalone application. Store raw matl. consumed for every charge or heat alongwith WO nos. in a table. Then using a form exit in WO parts list, copy data from that table to WO parts list. This calculation will be based on individual charge wt. (5T) and WO charge wt. You can also use this customization for making dynamic parts list for various items that use same charge.