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Hello...

We create MOs from a Sale Orders (SO).


We know that we have a defect rate of 10%. Meaning...we need to produce 10% more to have enough to deliver.


How do we build that defect rate into the manufacturing process? Is there a place in the BoM for that?

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Najlepsza odpowiedź

You increase the quantities of components on your BoM to account for the extra materials you normally need.

A 10% defect rate means a scaling factor of 100/90 or an increase of 11.11% for each component. 

Let's say you make 100 chairs at a time.

Without defects, if you need:

  • 400 chair legs
  • 100 chair seats
  • 100 chair backs

Then with defects you would need:

  • 445 chair legs (400 * 1.1111)
  • 112 chair seats (100 * 1.1111)
  • 112 chair backs (100 * 1.1111)


Create a BoM for 100 chairs using the increased quantity of components.

Be sure to configure your BoM to support flexible consumption so you can consume the quantity of components you actually use each time (could be less, could be more).

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Autor

@Ray. I'm hoping to get your attention on my clarification.

Thanks.
___
Thanks Ray.

One clarification: Odoo assumes we want to produce 100 chairs - not 110. However, we may consume more parts than in the perfect/ideal manufacturing process. This is what the scaling factor does. Correct?

What if I wanted to increase production of the final product? Would that be a manual intervention? Or can we do that programmatically?

Question about the workflow...

Let's say I produce 100 chairs.

At the leg work center, I scrap 10 legs.
At the seat work center, I scrap 10 seats.
At the back work center, I scrap 10 backs.
The BoM accounted for that, so I picked the right amount of parts.

Let's say the entire MO took 1-week to process. I have to remember (or check the scrap data) to tally the consumed parts and add that to the confirmation step.

Is that right? Or, can Odoo know, based on what I scraped and MO, what I consumed in the operation?

What have you tested yourself? (That's the best way to understand my reply). The quantity field on a Manufacturing Order is editable, meaning you can increase the amount you produce. You can try this and see that we scale up the quantities of each component accordingly. As long as you scrap within the MO (from the Action Menu, SCRAP PRODUCTS) Odoo will include the cost of both the consumed and scrapped components in the calculation of the cost of the finished product(s).

Autor

Thanks Ray. Yes, I did test your suggestions.

Grossing up the components assumes that the scrap happens during the MO or that the components themselves are defective.

Our workflow is about the end product... meaning we can't account for the defective project until production is done.

For us then...the answer is a manual intervention. Or, custom dev to gross up the number of end products that needs to be produced.

Thanks.

Autor Najlepsza odpowiedź

Thanks Ray.

One clarification: Odoo assumes we want to produce 100 chairs - not 110. However, we may consume more parts than in the perfect/ideal manufacturing process. This is what the scaling factor does. Correct?

What if I wanted to increase production of the final product? Would that be a manual intervention? Or can we do that programmatically?

Question about the workflow...

Let's say I produce 100 chairs.

  • At the leg work center, I scrap 10 legs.
  • At the seat work center, I scrap 10 seats.
  • At the back work center, I scrap 10 backs.

The BoM accounted for that, so I picked the right amount of parts. 

Let's say the entire MO took 1-week to process. I have to remember (or check the scrap data) to tally the consumed parts and add that to the confirmation step.

Is that right?  Or, can Odoo know, based on what I scraped and MO, what I consumed in the operation?



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