Yeild

[stanlem]

Has anybody come across this problem before - particularly in the Pharmaceutical Industry? If we raise a WO for say 100,000 Tables we know that the actual yield will be around 95% - (950,000). This should not be a problem since it is possible to inflate the WO component requirements (and also MRP messages) by entering a Shrink Factor in the Parent item Manufacturing Data.

However since BOM's and hence Parts List are Validated in our industry, those "helpfully" QA guys will not allow component quantities to be more than the "Formulation" amounts! This means that we will always produce less than the actual planned requirement.

In our old system it was possible to entered WO shrink figure that would be interpreted as an expected shortfall in the actual output for MRP. i.e. Demand of 100,000 was inflated to 105,000 because of the expected yield loss. In this way the BOM component requirements did not need to be tampered with.

Any bright solutions would be appreciated.

 

[peterban]

Hi Mark!
There are three types of flexing that can happen in MFG and they are Shrink,
Scrap and Yield.
Unfortunately all three affect the way that the BOM is generated and the
subsequent product requirements.

In an ideal world how would you like this to work? Maybe from this we can
see a way forward.

Best regards

Peter

Peter Bannister : [email protected]
1st Consulting Ltd : www.1stconsulting.biz
Mobile : +(44)-7711-649358
Fax : +(44)-7739-256227
E-mail on the move : [email protected]



Product Specialist

 

[peterban]

Hi Mark!
There are three types of flexing that can happen in MFG and they are Shrink,
Scrap and Yield.
Unfortunately all three affect the way that the BOM is generated and the
subsequent product requirements.

In an ideal world how would you like this to work? Maybe from this we can
see a way forward.

Best regards

Peter

Peter Bannister : [email protected]
1st Consulting Ltd : www.1stconsulting.biz
Mobile : +(44)-7711-649358
Fax : +(44)-7739-256227
E-mail on the move : [email protected]



Product Specialist

 

[Kamal Ghosh]

Dear Stanlem
If you create a work order for say 1 ea for a parent item.
And it requires three items in the first operation in the routing of the parent item.
And say one of the child item needed to complete the wo is 10 in nos.
And in your routing you have cumilative yield for that operation seq. is 96.04
Hence your operation percent scrap calculated is 4.12
System will calculate in the following way the commitment of that particular child item from the inventory:-
=(96.04*(100-4.12)/10000)*10
=10.86 which is rounded of to 11

 

[peterban]

Thought it was you Mark!
Take a look at the additional details tab (b/pl mfg data) and there is a field called SRNK and SRKF (see attached) and the text associated with this is ...
A fixed quantity or percentage that the system uses to determine inventory shrinkage for an item. The system increases the planned order quantity by this amount in MPS/MRP/DRP generation
This sounds like its exactly what you are after......

Only note is that this is from an ERP8 Demo....

Best regards and talk to you soon.

Peter

 

[peterban]

Mark,
just remembered that your client is on U6 and I dont think that its feasable to retro fit the change from ERP8...so...

1) Add field to item/bpl screen (one/two of the U fields)
either
2) Change R3283/4 to create this uplift
OR
3) Add a row exit from P3411 to execute the uplift
OR
4) Change the batch message answer to perform the same (based on a PO)

Hope that helps a liitle more.

Cheers

Peter

 

[stanlem]

Re: RE: Yeild

Hi Peter,

Just thought that I would let you know I found out how to do this. This is the solution:

Let say the Std validated Batch size is 100,000 and there is a expected 5% yeild loss - 950,000 actual production.

Remember that the WO Qty and Components have to be for 100,000 since this is validated. However we want MRP to expect receipt of 950,000.

We entered 950,000 in the Order Policy Value (OPV) and used Order Poicy = 2 - Fixed Order Qty. But then we also added a Fixed (F) Shrink Factor against the parent.

When MRP is run it generates order suggestiond for 950,000 since this is the OPV and this is displayed in the S&D enquiries. However when a WO is generated from a MRP message an order is created for 950,000 but 100,000 with Shrink as displayed on the WO header and documenation. After processing the Parts list is attached and, provided the Processing Option are set correctly, the Component Qty's are for a parent requirement of 100,000 !!!

Also when MRP is run against Planned or Firm WOs the suggested PO requirements are for the full component demand - i.e. including the Parent Shrink.

Thanks for your input.

Regards
Nark