One-to-one production

Auto-replenishment Production


The one-to-one production is basically a feature to replenish orders for the quantity required by orders to be pegged and peg the orders one-to-one.There are three types of one-to-one production as below.

One-to-one production

Regardless of the production lot size of the item and inventory, orders will be replenished for the quantity required by orders to be pegged and pegged one-to-one.

Inventory + one-to-one production

Orders will be pegged to the inventory first and then replenishment orders for the insufficient quantity will be pegged one-to-one. If no insufficiency exists, manufacturing orders will not be generated.

Supply-demand adjustment one-to-one production

Orders will be pegged to the inventory and surplus orders first and then necessary replenishment orders will be generated one-to-one. Not only that, but orders to replenish the insufficient quantity due to changes in reported quantities and order quantities will be generated and pegged.

How orders are pegged and quantities are adjusted differ depending on the above three type of one-to-one production.


One-to-one pegging and inventory

Master data is set as in the following diagram. In the item table, the auto-replenish flag for item C is set to "Yes (one-to-one production)". (The data used here is created by adding a few changes to Sample J.)


In the order table, manufacturing orders for item A and B and an inventory (absolute) order for item C are specified.


If you reschedule, the following schedule will be created. Since the auto-replenish flag is set to "Yes (one-to-one production)" for item C, manufacturing orders are pegged one-to-one ignoring the inventory order.


Set the auto-replenish flag of item C to "Yes (inventory + one-to-one production)".(In the following description, if you set the auto-replenish flag to "Yes (supply-demand adjustment one-to-one production)" instead of "Yes (inventory + one-to-one production)", you will get the same scheduling results.)


If you reschedule, the scheduling result will be as below. This time, one of the manufacturing orders is pegged to the inventory. The quantity of the inventory order for item C is 8 and it is pegged to order 1. For an insufficient quantity of 12, replenishment orders are generated and pegged one-to-one.


Here, add an inventory order for item C for the quantity of 5.


If you reschedule, the scheduling result will be as below. The manufacturing order is pegged also to the additional inventory and the quantity of the replenishment order is changed from 12 to 7 because of the reduced insufficiency.


Change the quantity of the added inventory order for item C to 100.


If you reschedule, the scheduling result will be as below. Since the quantity of the additional inventory is sufficient, order 1 is pegged only to inventory orders and the replenishment order is deleted.



One-to-one pegging and results

Here, we will explain behaviors of one-to-one production, inventory + one-to-one production, and supply-demand adjustment one-to-one production concerning reported quantities.

One-to-one production

In the case of one-to-one production, the quantity changes as if operations pegged one-to-one according to "One-to-one production" are one order.

For example, assume that results is input for an operation of order 1-C from the following scheduling status.


If the reported quantity of 2, which is smaller than the scheduled quantity of 20, is specified for order 1-C and rescheduled, the quantity of order 1 will reduce to 1. Also, the order is not pegged to inventory.


If the reported quantity of 22, which is larger than the scheduled quantity of 20, is specified for order 1-C and rescheduled, the quantity of order 1 will increase to 11.



Inventory + one-to-one production

In the case of inventory + one-to-one production, the production quantity changes according to the results of pegged orders while using inventory.

For example, assume that results is input for an operation of order 1-C from the following scheduling status.


If the reported quantity of 2, which is smaller than the scheduled quantity of 12, is specified for order 1-C and rescheduled, an operation of order 1 will use the inventory as much as possible.However, since the reported quantity of order 1-C is 2, the production quantity of order 1 will reduce to 5.


If the reported quantity of 22, which is larger than the scheduled quantity of 12, is specified for order 1-C and rescheduled, the quantity of order 1 will increase to 15. The pegging with inventory will be maintained.



Supply-demand adjustment one-to-one production

In the case of supply-demand adjustment one-to-one production, while using inventory, replenishment orders will be generated to compensate for an insufficient quantity.If a surplus occurs, the surplus quantity will be pegged to other orders. Unlike one-to-one production and inventory + one-to-one production, pegged orders will not behave as if they were one order.
Therefore, strictly speaking, supply-demand adjustment one-to-one production is not exactly one-to-one production. In that context, the naming rule of replenishment orders will not follow "Auto-generated one-to-one order code expression" but follow "Replenishment manufacturing order code expression" or "Replenishment purchase order code expression".

For example, assume that results is input for an operation of order 1-C from the following scheduling status.


If the reported quantity of 2, which is smaller than the scheduled quantity of 12, is specified for order 1-C and rescheduled, replenishment order M0008 will be generated to compensate for the insufficient production quantity (10) for the operation of order 1, which cannot be covered by the inventory order and reported quantity.


If the reported quantity of 22, which is larger than the scheduled quantity of 12, is specified for order 1-C and rescheduled, a surplus quantity of 10 from the quantity of order 1 will be pegged to order M0003. Therefore, the production quantity of order M0003-C will reduce by 10.


In the above spec, if you replace manufacturing orders with purchase orders, the behaviors will be the same.



Supply-demand adjustment one-to-one production and pegging condition

By combining supply-demand adjustment one-to-one production and pegging condition, you can specify to generate a replenishment order for each order to compensate for an insufficient quantity.

For example, there are two sales orders for item C and the quantity of each order is 20 as in the following diagram. Since the inventory quantity is 10, a replenishment order with the quantity of 10 and another with the quantity 20 are generated.


In this scheduling status, suppose that operations of replenishment orders "M0000" and "M0001" are frozen.


Then, suppose that the quantity of each sales order is increased to 30.
If you reschedule without making any other settings, a replenishment order will be generated but insufficiency of both orders will be collectively compensated by one replenishment order. This is because the quantity of sales order 1 is allocated from orders of which the quantity is fixed (10 from Stock-taking C, 10 from M0000, and 10 from M0001) and then the insufficient quantity of 20 is replenished by replenishment order M0002.


To generate a replenishment order for sales order 1 instead of allocating the quantity from a frozen future order (M0001) as in the above schedule, you can use a pegging condition to prevent sales order 1 from being pegged to a frozen future order.
Specifically, enter the following expression in the property "Pegging condition" of item C.

ME.Order.LET<=OTHER.Order.LET

Also, to make the above condition work, the following expression needs to be specified in the property "One to one pegged order property assign expressions" (in the Code generation tab of the properties window) of the project settings.

ME.LET=OTHER.LET

(The expression is set by default.)

If you make the above settings, replenishment orders will be generated for each sales order to compensate for each insufficiency as in the diagram below.



Supply-demand adjustment one-to-one production and Inventory MIN/Target inventory MIN

For supply-demand adjustment one-to-one production, you can use inventory MIN and target inventory MIN.

When inventory MIN is specified

Assume that orders are assigned as in the diagram below while the inventory MIN is 0.


When the inventory MIN is set to 10, the quantity of the replenishment order will increase by the amount of the inventory MIN. Sales order 1 will not be pegged to inventory.


Similarly, when the inventory MIN is set to 20, the quantity of the replenishment order will increase by the amount of the inventory MIN. Sales order 1 will not be pegged to inventory.


If the replenishment order is frozen, the replenishment order will be actively pegged to inventory and other orders of which the operations are frozen.



When target inventory MIN is specified

Assume that orders are assigned as in the diagram below while the target inventory MIN is 0.


When the target inventory MIN is set to 10, the quantity of the replenishment order will increase by the amount of the target inventory MIN.


Similarly, when the target inventory MIN is set to 20, the quantity of the replenishment order will increase by the amount of the target inventory MIN.


If the replenishment order is frozen, the replenishment order will be actively pegged to inventory and other orders of which the operations are frozen.


Note that the only thing you can control when using inventory MIN and target inventory MIN is the sequence of pegging. To assign replenishment orders for inventory MIN first and those for target inventory MIN the last as in the above example, you need to make settings in the scheduling parameter.

Specifically, using the property "Replenishment order for inventory MIN" of the order class, specify to prioritize replenishment orders for inventory MIN and not prioritize replenishment orders for target inventory MIN in the dispatching rule of the scheduling parameter settings.



Items to peg one-to-one

Even when "one-to-one production" is not selected for the "Auto-replenish flag" of an item, by specifying the property "Items to peg one-to-one" of an order, Asprova will auto-generate an order of that item for the quantity required by each base order and peg the auto-generated order one-to-one to the base order regardless of the production lot size and inventory level of that item.


Integrated Master Editor
ItemProcess numberProcess codeInstruction typeInstruction codeResource/ItemProduction
B11P3Input instructionInC1
B2P4Input instructionInB11
C1P1Input instructionInD1

If "Items to peg one-to-one" is specified as below while the Integrated Master is set as above, manufacturing orders will be auto-generated and pegged for all items tracking from item B because "*" (meaning all items) is specified for "Items to peg one-to-one".

Order Table
Order codeItemQuantityOrder typeItems to peg one-to-one
01B30Manufacturing order*

Also, if you specify only B1 for "Items to peg one-to-one" as below, manufacturing orders will be auto-generated and pegged only for orders of the specified item.

Order Table
Order codeItemQuantityOrder typeItems to peg one-to-one
01B30Manufacturing orderB1

For items to peg one-to-one, orders will always be generated to peg one-to-one.


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