FINI

Sch. Aggr.-100-FINI

SPRIN
G

MRP Run

10 Planned OrderFINI

MI

BLAN
K
MB

LOT SIZE-1-10

BLANK-Planned
Order-1

Partial Conversion40kg Each

40kg1Batch
Number

Consumption of Rubber from Store

1. Suppose I have 50kg of rubber blank required for one Production Order. In
Rubber mixing they are producing 1batch quantity is 40kg Approx (see
BOM file). So how to issue the remaining 10kg quantity from store? They
are not agree to divide the batch quantity.
SuggestionIssue one Full Batch quantity of Rubber against several Route card. In
advance take print out of Route card and issue the Rubber against the
Route Card. After Production through RFKANBAN02 do the IM Staging
process.
I dont understand the problem ? They are not agree to divide the batch
quantity ??Partial issue we can do.
If we produce 2 x 40kg on the IM 202, we have 2 batches with each 40kg.
SEMI Production order 1 40 kg Batch 1
SEMI Production order 2 - 40kg Batch 2
If the FINI Production order needs 50kg, they can take 40 kg of Batch 1
RFKANBAN02 on order and then they take 10kg of Batch 2
RFKANBAN02.
Why it is not possible to take out 10 KG from Batch 2 ????Because the
remaining 30kg balance in cool room will get expired and
scrapped if not consumed in a week span. And this is due to the
fact as Every compound batch weight is fixed which need to be
accelerated to produce (blank/rope/chapatti).

ACC

2. Applies for both Rubber and Master Batch:

Suppose I am making one scheduling agreement of 100FINI part for one
week. After MRP run I shall see the system generated planned order
according to MRP1-LOT Size. In lower BOM level system will generate the
dependant requirement and to fulfil the requirement Planned Order will be
proposed. But that Planned order will be of Total requirement quantity to
fulfil the dependant requirement. If we will put MIN & MAX LOT size in
MRP1 for BOM level material then system will be able to generate multiple
Planned Orders. Rubber mixing department need the whole month
requirement from the starting of the month for the better production line
plan and smooth operation.
CASE1
Put Min and Max Lot size and get several Planned Order-But You cannot
see the whole requirement proposed by Sales department. For each 40kg
we will get one Planned Order and subsequently Batch number.
CASE2
Do not put MRP Lot size data. System will show you the whole requirement
quantity as a single Planned Order. User can see the whole requirement
quantity for one week. Partially convert the Planned Order to Production
Order and for each Production Order one batch no will be generated. One
batch quantity should be 40kg.
As explained the MRP views 1-4 are in the responsibility of Team SCM =
Kadir Avci/Manuel Ebner. They decide the lotsizes and have template rules.
Case 2 I dont agree to make Partial conversion of planned orders. Is
there a problem with Case 1? No we dont have any problem , if there
is no linkage of producing master batches with the moulding fini.
System should only generate complete 4 weeks requirement and
we should be free to plan our mixing lines independent from day
to day fini requirements. The linkage with the Molding fini should
start only from the off line weighing station as per our routing
where we actually weigh the master batch and its accelerators to
produce the accelerated compound exactly before the blanks
cutting of same what we weighed at off line weigh station against
moulding FINI requirements .Planned orders on our master batch
lines should be confirmed at Offline weighing station exactly
before the blank fini operation. This will generate full traceability
and linkage finally.
I see a problem with the requirement of Rubber Mixing department to see
the MONTH Requirements. This would mean they need the depended
requirements from the FINI plannend orders, but they could change after
every MRP run. We really should discuss this with Kadir Avci and Ashwin.
FINI
04.05.2015
15.05.2015
20.05.2015
25.05.2015

100pcs
100pcs
200pcs
100pcs

Production order
Planned order
Planned order
Planned order

SEMI Level Rubber blanks

02.05.2015
02.05.2015
02.05.2015
02.05.2015
13.05.2015
13.05.2015
18.05.2015
18.05.2015
18.05.2015
18.05.2015
23.05.2015

40
40
40
40
40
40
40
40
40
40
40

KG Planned
KG Planned
KG Planned
KG Planned
KG Planned
KG Planned
KG Planned
KG Planned
KG Planned
KG Planned
KG Planned

order
order
order
order
order
order
order
order
order
order
order

So if the FINI planned order for the date 25.05.2015 is deleted by the MRP,
it will be deleted automatically on SEMI Level too. But when they make the
planning on MONTH level it is in my opinion only a rough forecast.