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Duplicated Production Orders

  • 1.  Duplicated Production Orders

    SILVER CONTRIBUTOR
    Posted 22 days ago
    Hello everyone,

    I wanted to check in and see if anyone else has run into this issue.  We typically create a new production order by releasing a corresponding sales order with a production line item.  The line on the sales order then becomes reserved to the new released production order.  We recently noticed an issue with this process though.  If a change needs to be made to the sales order at any point after the production order has been created we can reopen the sales order but we cannot release it again without cancelling the reservation.  We receive the following message "Reserved quantity cannot be greater than zero". When we cancel the reservation to release the order, a new production order gets created.  It looks like when this happens the sales line gets reserved to the new production order.  We check released production orders just in case every day for this reason.  Having a duplicated production order causes new demand to hit the planning worksheet, which would cause us to purchase components we already have fulfilled or on order.  I attached an example of this situation we encounter.

    We also use an assembly order process that functions similarly.  However, when we need open and make changes to the attached sales order no new assembly orders are created upon releasing.

    Does anyone know if we are using an incorrect process perhaps?  Or would this need to be something we need to get fixed?

    Thanks!

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    Joe Novak
    Purchasing
    Lesman Instrument Company
    BENSENVILLE
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    Conference-BCNAVUG_200x200


  • 2.  RE: Duplicated Production Orders

    GOLD CONTRIBUTOR
    Posted 20 days ago
    Edited by Alex A 20 days ago

    ​Hello Joe,

    I think you'll need to test for a work-around for this, or put in a user procedure change. From a configuration stand-point, you could try adjusting the Rescheduling Period for this Item and see if that helps (though I suppose it won't) or alter your Item card planning/replenishment parameters to try a more flexible method if you need to make changes to Sales Orders after they have been released. Sales Orders tend to become rigid once there are reservation links tied to supply orders.

    Try testing a couple of the following:

    *After you cancel the reservation, does NAV remove the values in the Supply Order Type and Supply Order No fields on the Sales Order line? If so, will it let you manually add the same former values into those fields before re-releasing (although this depends on what kinds of changes you were making to the Sales Order - does it really need a different/changed Production Order)?

    **Are you able to alter the status of the corresponding Production Order prior to attempting to re-open/re-release the Sales Order? Were any materials already consumed at the release of the Production Order, such as in forward consumption reporting?

    ***If you can't find a work-around and you must alter the Sales Order, then perhaps the best thing to do is to cancel the Production Order prior-to, or along with, re-opening the Sales Order and cancelling the reservations. Perhaps test and find out which order is best to do this in, and then follow the same procedure each time.

    Please let us know what you discover.



    ------------------------------
    If my response has helped you please mark the answer.


    Best Regards,

    Alex A
    Sr. NAV Consultant
    Los Angeles, CA, United States
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    Conference-BCNAVUG_200x200


  • 3.  RE: Duplicated Production Orders

    SILVER CONTRIBUTOR
    Posted 15 days ago
    Hello Alex,

    I listed answers to your inquires below.

    1. After you cancel the reservation, does NAV remove the values in the Supply Order Type and Supply Order No fields on the Sales Order line?.  It does not remove the values or let us enter the former supply order number manually.  We need to open the order after releasing to make changes to the shipping address, pricing, ship via, etc.

    2. Are you able to alter the status of the corresponding Production Order prior to attempting to re-open/re-release the Sales Order? Were any materials already consumed at the release of the Production Order, such as in forward consumption reporting?  Yes, the recent issues we have had have been with production orders that had their components posted out of stock.  I noticed last Friday that we had a production order that had been updated to "finished" status.  However, I noticed the following Monday that a new released production order had been created for the same item.  By that time the finished production item had been posted out on the corresponding sales order to a posted sales invoice.  

    3. If you can't find a work-around and you must alter the Sales Order, then perhaps the best thing to do is to cancel the Production Order prior-to, or along with, re-opening the Sales Order and cancelling the reservations. Perhaps test and find out which order is best to do this in, and then follow the same procedure each time.  I may have to look into the reservations a little deeper.  Currently, it looks like even if we cancel the reservation on the sales order first then try and reserve from the related production order we are still not able to release the sales order.  We receive the error message, "Reserved quantity cannot be greater than 0".  I am not sure if there is a setting that needs to be changed on the item card perhaps.


    Thanks for your help, this has given me a little more to think about.


    ------------------------------
    Joe Novak
    Purchasing
    Lesman Instrument Company
    BENSENVILLE
    ------------------------------

    Conference-BCNAVUG_200x200


  • 4.  RE: Duplicated Production Orders

    TOP CONTRIBUTOR
    Posted 19 days ago
    Joe,

    Your issue is related to the Reservation being cancelled.  You need to build in to your process to re-Reserve the Production Order output for the Sales Order after the changes are made.  If the Quantity or Date has changed on the Sales Order, you'll need to update and refresh your Production Order with the new information.  By setting the Reservation against the updated Production Order the net Demand for the Item will be zero.  At that time you should not see a suggestion from the Planning Worksheet.

    Since you are not setting the reservation, the system (w/ Order policy) does not look for available supply for the order and therefor creates another Production Order.  At the same time, you should be seeing a Cancel suggestion in the Planning Worksheet to delete the previously abandoned Production Order.  Are your planners currently ignoring the Cancel suggestion?  If so, this would create the duplicate component demand.

    Reservations can be tricky, and if your demand is constantly changing you may want to consider moving to a Lot-for-Lot policy, which is a bit more flexible.

    Do some testing with establishing the Reservation after the Orders are updated to see if it resolves your issue.

    ------------------------------
    Ben Baxter
    Consultant
    Accent Software, Inc.
    carmel IN
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    Conference-BCNAVUG_200x200


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