We have subassembly item A which can be configured into finished good item 1,2 or 3. Items 1,2 and 3 are made up of subassembly A, plus unique labels and packaging per each configuration.

Consider the following example:

We build items 1,2 and 3 to a forecast.
Item 1 has a forecast = 100
Item 2 has a forecast = 100
Item 3 has a forecast = 100

Baan creates 3 finished good MRP orders, each for 100. This creates one subbassembly MRP order for the subassembly A for 300. Item A is converted into 100 of item 1, 100 of item 2, and 100 of item 3.

During that period, the customer who orders items 1,2 and 3 decides that they would rather buy 300 peices of item 1, rather than 100 of each finished good. We enter a sales order for item 1 for 300 peices, and then MRP tells us to build 200 more peices of item A and convert that into 200 peices of item 1.

What I would rather do is simply re-work item 2 and 3 into item 1. This means I would only have to re-label and re-package these items, rather than rebuilding 200 new subassemblies.

The problem is that MRP does not see any relationship (the subassembly) between item 1,2 and 3, so it does not know that we would rather re-work the existing inventory than build new subassemblies and finished goods.

Is there any way in Baan for us to tell MRP not to plan new subassemblies when this happens. We have a huge product mix and over 2,000 finished good SKUs so this we cannot manage this manually.

We also cannot store inventory at the subassembly level.

thanks!
:eek:

You might try the following: (not sure if this works....)

try to make items 1,2 and 3 also distribution items (sourcing rules:Item 1 is 50% made from item A and 50% supplied from item 2)
and make supplying rules so they are a supply-source to each other.

You still have to enter the 'rework' orders yourself when Baan plans the distribution orders......