Print Shortages by Production Order (tisfc0418m000)

Use this session to check if the material that is required for a production order is available in time. Knowing sufficient material is available when work starts on the production order is essential. An availability check is especially useful in production environments where a bottleneck may occur in the material supply.

An availability check helps:

  • To decide not to release a production order.
  • To take corrective actions towards logistic personnel and suppliers before production starts.
  • To prioritize orders in work centers.

The planned inventory transactions and the inventory data are the basis for the shortage report. For a production order that you want to start on a specific date, the inventory receipts and issues of the required material are taken into account. On the other hand, planned production orders that consume the same material are considered. To choose you can select the Include Projected Inventory check box, whether you only want to take the actual inventory into account or also the planned inventory receipts/issues.

If multiple production orders require the same material, the orders will use up the available material in the order of the allocation dates. Only planned inventory transactions that are very likely to occur are taken into account. The following planned inventory transactions are ignored:

  • Forecasts
  • Rough material requirements
  • Requests for quotations

The following warehouses are taken into account:

  • Normal warehouses
  • Shop floor warehouses
  • Consignment (not owned warehouses)
Note: The requirements of various effectivity units are not taken into account in this session.

Ideally you do not have material shortages. However, shortages occur if the material supply does not go according to plan. Material shortages can be caused by the following reasons:

  • Unreliable suppliers: The delivered material quantities are incorrect, the delivery dates are not right, or the material quality is insufficient.
  • Production material consumption is higher than expected because of unplanned rejects.
  • Unreliable material requirements planning (MRP).

  • Pessimistic analysis of material supply

    If you expect your suppliers and/or MRP to be unreliable you can best make a pessimistic analysis of the material supply. To make a pessimistic analysis, select the following check boxes:

    • Ignore Scheduled Receipts

      The expected and planned material receipts and issues are not taken into account when analyzing the production orders' material supply. Select this check box if you expect materials to be late, or the quantities to be insufficient. Note that you must select the Include Projected Inventory check box before you can select the Ignore Scheduled Receipts check box.

      • Ignore Blocked Inventory: The inventory that is blocked for inspection is not taken into account for analyzing the production orders' material supply. Select this check box if you expect the material quality to be poor.

  • Optimistic analysis of material supply

    For a more optimistic analysis of the production orders' material supply, select the following check box:

    • Print Total Warehouses in Planning Cluster: All warehouses (normal and WIP) in a cluster are checked for inventory when analyzing the material supply of the production orders.

  • Lots

    If you are using lot control, and you want to check if inventory is available for the same lot as your item you must:

    • Select the Sort by Warehouse check box.
    • Clear the Print Planned Receipts check box.
    • Clear the Print Total Warehouses in Planning Cluster check box.

If you use these settings and insufficient inventory of the lot item is available, the report shows the details of the inventory shortage. If you are not using lots, these settings generate a report with details for all inventory shortages.

Note: 
  • If you use this session to see whether planned inventory is free, this does not guarantee that you can use the inventory. The inventory might be claimed by another work center. To check this, look at the planned inventory requirements by selecting the Print Planned Receipts check box.
  • If you want to print inventory shortages for all the production orders in an JSC order group, select the Production Order Group check box and enter the order group.

Field Information

Selection

Select how the production orders are chosen.

Allowed values

  • By Order
  • By Group
Site

site

Production Order Group

Enter the range of JSC order groups that contain the production orders whose inventory shortages you want to print.

You must first select the Production Order Group check box.

JSC Order Group

Enter the range of JSC order groups that contain the production orders whose inventory shortages you want to print.

You must first select the Production Order Group check box.

Date of Production

Production orders with a production start date that falls within this range are checked for material shortages.

Date of Production

Production orders with a production start date that falls within this range are checked for material shortages.

If this check box is selected, LN prints a list of planned purchase receipts, planned production receipts, and transfers with corresponding delivery dates, along with the shortage list. These lists help you to assess how serious the shortages are, and to set your priorities for material requisition.

Note: Although the calculation of the total shortage takes all firm-planned inventory transactions into account, this list only shows the planned transactions for production and purchase.

If this check box is selected, all warehouses (normal and WIP) in a cluster are checked for inventory when analyzing material shortages. If a shortage occurs in a specific warehouse, the shortage can be solved by warehouse transfers.

If this check box is selected, the actual inventory that is physically present in the warehouse(s) as well as the inventory that will be consumed by planned production orders is taken into account when analyzing material shortages for the selected production orders.

Ignore Scheduled Receipts

If you expect your suppliers and/or forecasts to be unreliable you can best make a pessimistical analysis of the material supply. You can do this by selecting this check box.

If this check box is selected, the expected and planned material receipts and issues are not taken into account when analyzing material shortages. Select this check box if you expect materials to be late, or the quantities to be insufficient.

You can also use the Ignore Blocked Inventory check box to make a pessimistical analysis of the material supply. The inventory that is blocked for inspection is not taken into account for analyzing the production orders' material supply. Select the Ignore Blocked Inventory check box if you expect the material quality to be poor.

Note: You must select the Include Projected Inventory check box before you can select the Ignore Scheduled Receipts check box.

Ignore Blocked Inventory

If this check box is selected, the inventory that is blocked for inspection is not taken into account for analyzing the production orders' material supply. Select this check box if you expect the material quality to be poor.

If you expect your suppliers and/or forecasts to be unreliable you can best make a pessimistical analysis of the material supply. To make a pessimistic analysis select this check box.

You can also use the Ignore Scheduled Receipts check box to do a pessimistical analysis of the material supply. In that case, the expected and planned material receipts and issues are not taken into account when analyzing material shortages. Select this check box if you expect materials to be late or the quantities to be insufficient.

Simulate Upto Date

If this check box is selected, you can enter a date in the date field. This date determines up to which date the planned inventory is taken into account when analyzing material shortages.

Simulate Upto Date

The date up to which the planned inventory is taken into account when analyzing material shortages.

Note: You can only enter a date if you selected the Simulate Upto Date check box.
Min. Inventory

Usually, a material is in short supply if the material's inventory is less than 0 (zero).

Example

If you require four pieces of material for a production order, and you have four on hand, you have a sufficient amount of materials. If your requirements are five pieces of material, then you have a shortage of one, because 4 - 5 < 0.

However, if the inventory is inaccurate, the quantity of materials in inventory can be more or less than you expected.

Example

You require four pieces of material for a production order. You expect, after you run the Print Shortages by Production Order (tisfc0418m000) session, to have four pieces in inventory. However, because of inaccuracy only two pieces of material are available in inventory. You now have an unexpected shortage of two. This type of unexpected shortage can be very disruptive during production.

You can use the Min. Inventory field to enter a value that accounts for any inaccuracy in inventory. You can also enter a value in this field if you need a margin because you are not sure about the required quantity of materials.

Example

If you enter 2 in the Min. Inventory field, a shortage is already determined if the following is valid: Note Be cautious in entering a value in the Min. Inventory field because of the following:

  • The value in the Min. Inventory field applies to all materials of a specific production order. Therefore, the assumed inventory unit must be in line with the inventory units that are used for the materials in the production order.
  • The value in the Min. Inventory field must not be too big or too small. For example, you need 0.03 kg of material A, and 20 kg of material B for a specific production order. A value of 5 in the Min. Inventory field is useless if, for example, the maximum inventory of material A is 1 kg.
Upto Date

The date up to which the planned purchase and production receipts are printed.

If this check box is selected, only the inventory that is physically present in the warehouse(s) is taken into account when analyzing material shortages for the selected production orders. The material in inventory that will be consumed by planned production orders is not taken into account.

Sort by

The order in which production orders are printed on the report.

Sort by Warehouse

If this check box is selected, LN only checks the inventory in the warehouse that you specified for a material in the Warehouse field in the Estimated Materials (ticst0101m000) session.

If a production order has multiple material lines for the same material in various warehouses, the total demand is calculated by warehouse, and subsequently compared to the inventory for each warehouse.

If this check box is cleared, LN checks the total inventory in all warehouses. If a production order has multiple material lines for the same material in various warehouses, the total demand is calculated and subsequently compared to the total inventory.

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