Auto-replenishment production

Order explosion and auto-replenishment

Auto-replenishment production

In auto-replenishment production, schedules are drawn up such that items created during a process are saved up as inventory, which are then gradually consumed by later processes in producing various kinds of finished products.

We will explain this feature using the example below.

There are two products, A and B.
A is made from material D through processes P1 (Process number 10) and P2 (Process number 20).
B is made from material D through processes P1 (Process number 10), P3 (Process number 30), and P4 (Process number 40).
We will bulk produce intermediate items B1 and C.
We will produce B1 in batches of 5 and at the maximum of 10, and C in batches of 10 and at the maximum of 50.

Item Table
Item CodeAuto-replenish flagProduction lot size MINProduction lot size MAXProduction lot size UNITSafety stock

Integrated Master Editor
ItemProcess numberProcess codeInstruction typeInstruction codeItem/resourceProduction
A1P2Input instructionInC
B11P3Input instructionInC
B2P4Input instructionInB1
C1P1Input instructionInD

Let the assignment start time be 2003/11/1 00:00, and the inventory level of the bulk production items at that time (i.e., the theoretical inventory) be 7 for B1 and 8 for C.
These inventory levels will be deducted from the amount to be actually produced.
Also, ProductA and ProductB have one manufacturing order each.

Order table
Order codeItem codeQuantityDue datePriorityOrder type
01A102003/11/0580Manufacturing order
02B102003/11/0780Manufacturing order
z01B172003/10/31 0:00:00 Inventory (absolute)
z02C82003/10/31 0:00:00 Inventory (absolute)

Low Level Code

This is the value of the item that represents the depth of the BOM seen from the final item. Let the low level code of the final item be zero and the level code be incremented by 1 for each process on the way back to the raw material in the Integrated Master and the Purchase Master.
Also, even if there are by-products in the same process, incrementing by 1 will be carried out (there is a detailed explanation toward the bottom of this page). Pegging and auto-replenishment of orders are done in ascending order of this low level code.
In the example above, the low level code for each item is as follows.

[Assigning low level code]
ItemLow Level Code

Calculation of low-level code

Low-level code is calculated automatically at the start of rescheduling or by the Explode orders command.
In Ver. 14.0 and later, the necessity of calculating the low level code is automatically judged, and if calculation is not necessary, [Skip low level code] becomes set to [Yes] in the project settings and calculation is not carried out, and the calculation speed increases to that extent.
If [Skip low level code] is set to [No], the low level code is forcibly recalculated at the next rescheduling.

Integrated Master loop

If the Integrated Master is looping, the low-level code cannot be specified as a unique value and the order for pegging and automatic replenishment of orders cannot be determined.
In the default setting, low-level code is not set for items where looping of the Integrated Master was detected, and no pegging of items or automatic replenishment of orders is done.

However, even if you create processes with different sequences or set an Integrated Master that cannot calculate low level code by using valid condition expressions, if during actual scheduling, the user him/her self performs control to prevent loops from occurring, pegging and automatic replenishment of orders will be carried out if you set the [Integrated master loop] property to either [Do pegging (No warnings)] or [Do pegging (Show warnings)].
However, in this case, the low-level code is forcibly calculated. All the "auto-replenish flags" in the item table can be set to "No". However, in that case, items with small low level codes are automatically refilled with items with large low level codes, which may result in quantity shortages.
If there is a danger of this occurring and you want to receive a warning in that case, make the setting [Do pegging (Show warnings)].
Note that the [Integrated master loop] property in the project settings is a Ver. 15 restricted feature. This property is not displayed when there is no license.

Low level code when by-products exist

When by-products exist for an item, low level codes of by-products will be larger than of the finished item and smaller than that of the raw material.

For example, for item A below, item AA is specified as by-product of process P20. With this setting, low level codes will be Item A 0 Item AA 1 Item X 2


Low level codes of by-products will be assigned according to the above rule because when replenishment orders have master data in which by-products are specified output instructions of the by-products will be generated only after the replenishment orders are exploded. Therefore, by-products need to be pegged after pegging the final item.

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