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Thank you for coming in.

I have a problem with replenishment mechanism (or scheduling) that i can't understand how to solve. I'm using Odoo 15.

We produce products that have multi-level BOMs, each BOM contains products with are purchased and/or manufactured. Each product has different VLT/MLT. Standard mess.

To automate orders and stuff we rely on Replenishment mechanism, which helps alot. Helps - but only when it works properly. And here is the problem. Replenishment in Odoo wants to do things on time - not too late, not too early, just spot on. That is propper only in a perfect world.

Due to all the scheduling stuff (delivery date on SO, delivery date on WH/Out, MO date, product MfgLT, VLT, etc) in case of dealing with multilevel BOMs we had to find some way to avoid delays and to create PO/MO "in real time", as soon as possible. When you have multilevel BOMs Odoo does not look deep into the path of each product, wanting to order stuff from bottom to top. Instead it works top to bottom, which causes parts from deeper BOMs to not be shown in Replenishment or beeing shown too late.
Thing that helped was setting Mfg Security LT to be longer, than longest operation (or sum of them) we can deal with (90 days in our case). Thanks to that Replenishment looks 90 days ahead to look for anything to be needed.
Result- replenishment shows all the stuff that is needed with right quantities. Everyting shown on time (ASAP in our case), nothing lost or forgotten. Great success, right? Not exactly.
That only worked when we had all the dates in Odoo set to past. Now we wanted to begin working with correct dates in every needed place (i.e MO planned for the future) and here things are getting harder to deal with.

When we have Mfg Sec. LT set to be 90 days all MO are seen by Odoo in Forecast with these 90 days added to the reciept date. That has negative affect on Replenishment, when i plan all the production in the future.
For example: Client ordered product X on monday (day 1, lets say 1 Jan), delivery is scheduled on friday (day 5, 5th Jan). Product X has MfgLT set to 0 days. When i go to Replenishment (with 90 day set Mfg Security LT), Odoo correctly shows product X to be replenished in qty=1. I click "replenish", MO is created and scheduled for today (1 Jan). Fine to that point. I go to client WH/Out or product X Forecast and here problems begin. Odoo says that reciept date of item X coming from production is on the 1 April (day 90), despite the fact that the production is already scheduled for today! With 0 day LT! That is causing mess in communication within our company and with clients in terms of dealing with delivery dates, delays etc. Reciept date should be based on real date on MO, not calculated with Mfg Security LT within.
The second problem that appears, that is even more frustratin than one above is when i schedule production in the future. In that case Replenishment shows item X to be replenished again! 
Following previous example: I schedule producion on tommorow, 2 Jan (day 2), Odoo shows reciept date in forecast on 2 April (day 91). When i go to Replenishment Odoo shows that product X needs to be replenished again!!!!! It needs to be replenished because within 90 days there is no product X to be reciept. You can see where this is going... Parts and products ordered twice or more... and on top of that production planning is not easier at all.

We deal with hundreds of components on daily basis and these 2 problems above are a real dealbreaker in terms of trusting Odoo and working efficiently. Do you have any ideas how to work that around? I'm already after couple of months working like that and i cant find words to describe how frustrating it is. Whats more funny - these were one of the most important factors that lead us to get into MRP program - be more specific with clients about delivery dates and to easily produce only what is needed, when its needed.

How to make Odoo show only correct things in replenishment as soon as possible, instead of as late as possible which is currently?
How to make reciept date beeing spot on, without added Mfg Sec. LT?

If you've made it to that point - thank you. Hope i didn't made you bored with that long description. Wanted to be specific. If you can help in any way - give it a shot. I'll be gratefull for whatever you could do to help me.





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Лучший ответ

We had a very similar issue and ended up creating a solution that takes away the consideration of Vendor Lead Time for Reordering Rules. Now, we have Auto Reorder Rules for our purchased products and as soon as they go below their min quantity, the rule is triggered and the products are added to an RFQ. 


The app is only for v15 but if you are using a different version we can update it for you. 

https://apps.odoo.com/apps/modules/15.0/replenish_ignore_vendor_lead_time/

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Лучший ответ

Sorry.

Since Odoo so far only work with fixed lead times and has no dynamic calculation, you will depend on a lot of manual planning to solve those more complex flows.  And when actual delivery times changes - like when your vendor reports he is late.

There are tools to show what is late, but that only helps only for you to manually change dates on whatever order.

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We have similar issues. If one MO shows it is past its start date or will be made too late to satisfy another MO's required date it will hit the replenishment screen. I wish there was a way to take dating our of the equation for replenishment. IE if you need 10 and you have 10 in que to be built no added items would be required. Instead it appears if you need 10 by a certain date and 2 will be late it tells you to make 2 more. Its nice to be told you have an issue but to simply make more is not a logical solution. If you running late making 1 of everything you need it would be logical to assume building more than you need would be detrimental.    Can we turn this portion of the logic off?


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Автор Лучший ответ

Hello Apiuser

Thank you very much for your answer.

I'm afraid that MTO is not an option. In theory that is somewhat of a solution, but not quite what i'm looking for. While product is made for sale order, whilst beeing MTO it checks each and every one needed component, looking in stock for required quantity. When even 1pc of only 1 component is missing in stock, then MTO rule orders all the components components in total required quantity (even these that are in sufficient quantity). That leads to total overstock and makes mostly unnecessary PO/MO. 
If i remember correctly one of the reasons why Odoo Developers developed Replenishment was strictly to solve issues related to MTO rule and to provide better way for controlling MO/POs. Thats why since it became part od Odoo, MTO rule became hidden in setting by default.

...or maybe i dont understand something? Please correct me if im wrong.

Greetings

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Hello @pari,
than maybe this OCA Modul can help you:
Stock MTS+MTO Rule
Please check if this will help you or not.
Thanks and greetings
Michael

Лучший ответ

... We kind off stumbled upon the same problem which is not fully solved but ...

Try enabling MTO routing. To do that enable debug mode and go to inventory->configuration->routes and here filter archived, and unarchive MTO replenishment.

Then you have to go to the top tree products and go down to each product that is an assembly manufactured for each sale order rather than made from stock.

So if bom is made for sale order enable MTO.

If bom is made to stock do not enable MTO.

Try this and tell me if that helped.

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