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Applying Lot-Sizing Rules

For each Make and Buy planned-order group (including planned orders not grouped with any others), quantities are adjusted to conform to specified minimum/maximum/multiple lot size restrictions as per the Order Policy group box on the Planning subtask of the Manage Parts screen in Costpoint Product Definition.

Lot size restrictions never apply to transfer reservation planned orders, nor to scheduled receipts for which you override the lot-sizing rules.

For Make Planned Orders

Period Order Policy

If the Policy type is Period in the Planning subtask of the Manage Parts screen in Costpoint Product Definition, planned orders within the same work period will be grouped together, sorted in ascending order. (The work period will be defined in terms of calendar days or shop days, depending on the Lead Time Calculation group box in the Configure Production Control Settings screen.)

For example, five planned orders are grouped together with due dates of 1/1/03, 1/5/03, 1/18/03, 2/1/03, 3/4/03. Assuming that the shop calendar is not used and the part has a Policy Type of Period and a period-days number of 30, this group of planned orders will be broken into three manufacturing orders, with a due date of 1/1/03 (which will include the quantities from the second and third planned orders), 2/1/03, and 3/4/03.

Minimum/Multiple Lot Size Policy

For parts with a Policy Type of Min/Mult Lot Size in the Planning subtask of the Manage Parts screen, and if the extra quantities of Make parts are not to be ignored (Minimum Lot Size Allocation-Make field on the Configure Material Requirements Planning Settings screen), Costpoint adjusts the sum of the grouped planned orders to meet the minimum/multiple quantities specified for the part. If this quantity is less than the minimum quantity or is not evenly divisible by the multiple quantity (if not zero), the order quantity is increased to meet both requirements.

If the extra quantities of Make parts are to be allocated, the extra quantity is allocated proportionately to the other planned orders in the group. This is accomplished by dividing the order quantity by the total order quantity and the percentage applied to the extra quantity. If the quantity cannot be evenly divided by whole number, the remainder is allocated to the order with the earliest due date and the lowest project ID.

If the extra quantities of Make parts are to be allocated to common stock, the extra quantity is allocated to the common stock Inv Abbrev for the part (Planning subtask of the Manage Parts screen in Costpoint Product Definition). If that value is not available or the inventory abbreviation is inactive, the Default Common Stock Inv Abbrev from the Configure Production Control Settings screen in Costpoint Production Control will be used.

Max Lot Size

For parts with a Policy Type not that is not Min/Mult Lot Size in the Planning subtask of the Manage Parts screen, if the Max lot size specified is greater than zero and the sum of the order quantities is greater than the maximum quantity, the planned orders in the group are sorted by due dates and regrouped into two or more groups to prevent the maximum quantity from being exceeded. Planned orders are not split unless the quantity of an individual planned order is greater than the maximum quantity itself. If a given planned order takes the proposed manufacturing order quantity past the maximum, the entire planned order is split into the next group. If the order quantity itself is greater than the maximum, the order is split up into maximum size lots (with any remainder allocated to a separate planned order group).

For Buy Planned Orders

Period Order Policy

If the Policy Type is Period in the Planning subtask of the Manage Parts screen, planned orders for the same part within the same work period will be assigned the same due date. The work period will be defined in terms of calendar days or shop days, depending on the Lead Time Calculation group box in the Configure Production Control Settings screen.

For example, five planned orders are grouped together with the due dates of 1/1/03, 1/5/03, 1/18/03, 2/1/03, and 3/4/03. Assuming that the shop calendar is not used and the part has a Policy Type of Period and a period-days number of 30, the due dates for the orders will be modified. The due dates of this group, 1/5/03 and 1/18/03, will be changed to 1/1/03.

Minimum/Multiple Lot Size Policy

For each part in a planned order group with a Policy Type of Min/Mult Lot Size in the Planning subtask of the Manage Parts screen, if the extra quantities of Buy parts are not to be ignored (Minimum Lot Size Allocation-Buy field in the Configure Material Requirements Planning Settings screen), the sum of the grouped planned orders is adjusted to meet the minimum/multiple quantities specified for the part. If this quantity is less than the minimum quantity or is not evenly divisible by the multiple quantity (if not zero), the order quantity is increased to meet both requirements.

If the extra quantities of Buy parts are to be allocated, the extra quantity is allocated proportionately to the other planned orders in the group having the same part. The program does this by dividing the order quantity by the total order quantity and applying the percentage to the extra quantity. If the quantity cannot be evenly divided by a whole number, the remainder is allocated to the order with the earliest due date and the lowest project ID.

If the extra quantities of Buy parts are to be allocated to common stock, the extra quantity is allocated to the common stock Inv Abbrev for the part (from the Planning subtask of the Manage Parts screen). If that value is not available or the inventory abbreviation is inactive, the Default Common Stock Inv Abbrev from the Configure Production Control Settings screen will be used.

Max Lot Size

If the order quantity on an individual planned order is greater than the maximum quantity, the order is split up into maximum size lots (with any remainder allocated to a separate planned order within the same group).