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MRP Detail Displaying Differently For Purchase Items With Yield Factors (Doc ID 2552754.1)

Last updated on NOVEMBER 29, 2019

Applies to:

PeopleSoft Enterprise SCM Supply Planning - Version 9.2 to 9.2 [Release 9]
Information in this document applies to any platform.

Symptoms

MRP detail displaying differently for purchase items with yield factors than it does for make items

Users started using yield factors on purchase items and have seen that after planning has run and they look at the MRP detail page for the purchase item, that it displays and nets using the entire quantity of the purchase order rather than what the purchase order is planning to yield. This behavior is different than a how a make item with yield works. A make item on MRP detail will show and net off what the pid is planning to yield. Why is this different? It seems Purchase orders should show and net off what it the po is planning to yield just like it does for a make item.


Steps to reproduce the issue:

1) Identify Test Items and Data Setup:

GR8014 (US008) – Purchase Item.  Define Purchase Yield of 80% in the Item Planning Attributes > Order Modifiers page.
Also create demand (I used Forecast) for this item.   Create an Actual PO to make sure Yield is considered.  I believe this can only be done by taking a Planned Purchase Order message, Posting it, Approving it, then going through the PO processes (Stage, Calc, Create) to generate the actual PO.

 
Notice the difference between the Quantity Base (inflated because of Purchase Yield) and Remaining Qty (expected number of good items).  In order to generate this PO you must create a Planned PO (Solver or manual), then Post and Approve the message, then turn into an actual PO.  It is not possible to create a Purchase Order within PO that automatically includes the Yield quantity.   The Quantities for Actual Purchase Orders (with Yield) are handled correctly by the Plan Detail, Planning Workbench, and Planning Report.   Problem only exists with Planned Purchase Orders.
 

GR8010 (US009 => US008) – Transfer Item source in US009 and destination BU of US008.  Define Transfer Yield of 80% in the Item Planning Attributes > Order Modifiers page.  Also create demand for this item in US008 – I used forecast.   Express Putaway inventory into Source BU so starting QOH is not 0.  Define Transfer Option.  Create an Actual Transfer.   I believe this can only be done by taking a Planned Transfer Order message, Posting it, Approving it, then going through the apply Inventory Messages (INPAPLNS) process.

2) Yield can be defined here or in the Planning Order Modifiers.
 
Notice the difference between the Requested Base (inflated because of Transfer Yield) and Remaining Supply (expected number of good items).  Also notice the Remaining Demand (includes the Yield Qty).  This is what should be showing in the Plan Detail, Workbench, and Planning Report for the Source BU.   It does show correctly for Actual Transfer Demand but not for Planned Transfer Demand.  In order to generate this Transfer you must create a Planned Transfer (Solver or manual), then Post and Approve the message, then turn into an actual Transfer.  It is not possible to create a Transfer Order within Inventory (Stock Requests) that automatically includes the Yield quantity.   
 

GR8500 (US008) -  Make Item with Operation Yield of 80% at last operation in Routing for GR8500.  Create forecast demand for this item.  Change the Bill of Material  for GR8500 to include component GR8009.  This item will be sourced via a Transfer from US009.  Also create an actual PID for GR8500.
 

Notice the difference between the Start Quantity (inflated because of Production Operation Yield) and End Quantity (expected number of good items).  Also notice the Scheduled and Remaining Quantities for the Components being for the Start Quantity of the PID.  In order to generate the Production Order you can either create a Planned Production Order (Solver or manual), then Post and Approve the message, then turn into an actual PID.  OR, you can create a Manual PID in Production Control but you have to assign the Start and Remaining Qty manually to reflect the Production Operation Yield.
 

GR8009 (US009 => US008) -- Transfer Item source in US009 and destination BU of US008.  Define Transfer Yield of 80% in the Item Planning Attributes > Order Modifiers page.  Demand for this item in US008 comes from Production Demand (planned and actual) for item GR8500.   Express Putaway inventory into Source BU so starting QOH is not 0.  Define Transfer Option.  Create an Actual Transfer.   I believe this can only be done by taking a Planned Transfer Order message, Posting it, Approving it, then going through the apply Inventory Messages (INPAPLNS) process.

Notice the difference between the Requested Base (inflated because of Transfer Yield) and Remaining Supply (expected number of good items).  Also notice the Remaining Demand (includes the Yield Qty).  This is what should be showing in the Plan Detail, Workbench, and Planning Report for the Source BU.  It does show correctly for Actual Transfer Demand but not for Planned Transfer Demand.  In order to generate this Transfer you must create a Planned Transfer (Solver or manual), then Post and Approve the message, then turn into an actual Transfer.  It is not possible to create a Transfer Order within Inventory (Stock Requests) that automatically includes the Yield quantity.   
 

GR8301 (US008) – Purchase item that is a component on BOM for GR8500.  Define Purchase Yield of 90% in the Item Planning Attributes > Order Modifiers page.  Demand for this item comes from Production Demand (planned and actual) for Item GR8500.   Create an Actual PO to make sure Yield is considered.  I believe this can only be done by taking a Planned Purchase Order message, Posting it, Approving it, then going through the PO processes (Stage, Calc, Create) to generate the actual PO.

 

Notice the difference between the Quantity Base (inflated because of Purchase Yield) and Remaining Qty (expected number of good items).  In order to generate this PO you must create a Planned PO (Solver or manual), then Post and Approve the message, then turn into an actual PO.  It is not possible to create a Purchase Order within PO that automatically includes the Yield quantity.   The Quantities for Actual Purchase Orders (with Yield) are handled correctly by the Plan Detail, Planning Workbench, and Planning Report.   Problem only exists with Planned Purchase Orders.
 

3) Setup BU Group and Planning Instance:

   1) Setup BU Group containing both US008 and US009 business units.  I used Bu Group CHRIS.
   2) Define Planned Instance.  I used “YIELD_PLAN”.
   3) Generate Sourcing Templates.  You can run the batch process (PL_GEN_TMPL) and or manually adjust to make sure the test items identified have the correct sourcing option.  You can also verify that the Yield was defined correctly for the following items:  GR8500, GR8010, GR8014, GR8009, GR8301.
 
4) Load Planning Instance and Run Solver

   After everything is setup and defined, run the Load Planning Instance process.  Be sure to include the Forecast and actual demand/supplies.
 
5) Start the Planning Engine.
6) Run the Material Solver.
7) Check Material Plan Detail, Material Plan Workbench, and Planning Report
(Items: GR8014, GR8010-US008/US009, GR8301, GR8009-US008/US009, GR8500-PLS2002 Yield)

8) Material Plan Detail Problems

  The Planned Purchase Supply should not include the Yield.  2500 should be 2000 and 375 should be 300.  Notice the Actual Purchase Order shows 3000.  This is correct.  The Quantity Base (with Yield) is 3750.   Behavior is the same for Item Purchase Item GR8301.
Planned Transfer Supply and Actual Transfer Supply is correct for GR8010 in Destination BU.   

Planned Transfer Demand is incorrect in the Source BU (US009) for Transfer Item GR8010. While Actual Transfer Demand is correct.  200 should be 250, 400 should be 500, and 500 should be 625.  Behavior is the same for Transfer Item GR8009.
 
9) Material Plan Workbench Problems
Planned Purchase and Actual Purchase Supplies are correct.  Items GR8014 and GR8301 behave the same.

10) Planned Transfer and Actual Transfer Supplies are correct in the Destination BU (US008) for items GR8010 and GR8009.
 
11) Planned Transfer Demand is INCORRECT in the Source BU (US009) while Actual Transfer Demand is CORRECT.  Behavior is the same for items GR8010 and GR8009.   200 should be 250, 400 should be 500, and 500 should be 625.
 
12) Planning Report Problems

    First problem is with Make Item GR8500.  The Yield (CUM_YIELD) in the report heading is being retrieved from table EN_RTG_HEADER when it should be coming from PL_PROD_OPT.
 

  Second problem is with Planned Purchase Supply.  Items GR8014 and GR8301 have the same problem.  We should be showing the “Remaining” Qty not the Requested Quantity.   Notice that the Actual Purchase Supply (Scheduled Purchases) is correct.
 
  Third problem is with Planned Transfer Demand in the Source Business Unit (US009).  Items GR8010 and GR8009 has the same problem.  We should be showing the Requested Base Quantity not the Remaining Quantity.  Notice that the Actual Transfer Demand (Scheduled Transfers) is correct.
 



Changes

 

Cause

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In this Document
Symptoms
Changes
Cause
Solution
References


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