Sales Order Scheduling – BTO

In this sample, scheduling a BTO production will be explained. Using the same sample in the previous article Sales Order Scheduling – MTO, switch the Auto-replenish flag of item “A” to “Yes” and set its production lot size Min/Max to 1000. By doing this, the production of item “A” is changed to “Make to Stock” production and will produce based on the set production lot size.

Assu1

Run the Reschedule button and switch view to Order table. You will see that three production orders were created automatically. The order quantities 300 and 500 of item “AX” are replenished for each sales order of “AX”. You will also notice that the production order quantity of item “A” is 1000, this is because we have set the lot size as 1000.

Assu2

Looking at the result in the Resource Gantt chart. The sales order quantity is set to 300 and accordingly the manufacturing order quantity of item “AX” is 300 (see Assembly1 bar). The blue bar shows that item “A” is being produced in 1000s as specified in the lot size.

Assu3

In this chart, we can also input inventory of item “A” and see how it is scheduled based on sales orders.Input “Inventory “A”” as Order code and select Inventory (absolute) as Order type. Set the due date and order quantity accordingly. Run the reschedule button to see the result in the Resource Gantt chart.

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You will see that the manufacturing order of item “AX” is replenished from Inventory where 300 items from inventory “A” are supplied to the manufacturing order of “AX”. Looking at its inventory level, the beginning on-hand is 400, then drops to 100 after replenishment to order “AX”.

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To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 22. How to make a prototype).

 

Auto-replenishment

In this sample, auto-replenishment is explained in which insufficient items for production orders and purchase orders are automatically replenished. This way, there is no need to create additional production orders for an item.

To set up auto-replenishment, switch auto-replenish flag in the Item Table to “Yes” and set Production lot size MIN and Production lot size MAX to 1000 pcs. This will be the basis of the system how much to automatically order.

ass1

When the setup is complete, run the reschedule button to see the production order being replenished automatically. In the Resource Gantt chart, you will see that the production order of item A has been replenished automatically with a quantity of 1000 as specified in the lot size. Coming from the multi-process setup, item A can be produced with Cut, Press and Inspection processes and is supplied to order 2 and order 1. Note also that this feature will send notification as soon as materials are needed to be purchased.

ass2

Monitoring the quantity and availability of every material is only one of many ways Asprova can help you manage inventory and orders. To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 22. How to make a prototype).

 

Sales, Production and Purchase Scheduling

This article explains how a user can run scheduling from sales orders to purchase orders, using automated replenishment production.

In this sample, the factory produces bolts “AX”. The final product “AX” is made from items “A” and “X”. Product “A” can be produced by supplying the raw material “M1” to the “Cut” process, then passes through “Press” and “Inspection” operations. To finally make the product “AX”, product “A” has to go through “Assembly” and “Inspection” operations with product “X”. These processes can be viewed in the Graphical Master display.

On the other hand, confirming details can be done in the Spreadsheet display. This is where order, production, setup, time constraints (e.g. waiting time) and auto-replenishment details are registered. Auto-replenishment is a function that automatically registers replenishment orders to prevent shortage of a raw material. This is setup in the item table – set the auto-replenishment flag of the item to “Yes (one-to-one production)” for manufacturing orders to be set into a one-to-one scheme with the sales orders. This is also where the production lot size is set. Production lot size is the minimum or maximum amount of stocks that can be produced or ordered. Obtain method can be set as either “Prefer to produce” if items will be produced or “Prefer to purchase” if items will be purchased.

Example of “Prefer to produce”:

5000 items of “A” have to be made at once so its production lot size Min/Max should be set to 5000 and obtain method as “Prefer to produce”. The 5000-items manufacturing order will be automatically registered when “A” is about to run out.

Example of “Prefer to purchase”:

The raw material “M1” is a purchase item with a lot size from 1 to 100. Therefore Purchase lot size Min is set to 1 and the Purchase lot size Max is set to 100. A purchase order will be automatically registered when “M1” is about to run out.

As soon as all these setup are registered, you can now run the re-schedule button and see orders being replenished automatically. The result is displayed at the Resource Gantt chart.

10.1

To learn more about Asprova specific to this sample demonstration, you may visit Asprova’s e-Learning videos at http://lib.asprova.com/ (see 21. Try out sample data).