Example: Adjusting the Production BOM for Phantom Inventory Usage

Consider this current routing/BOM:

  • There is a customer order for Item-1 for a quantity of 8.
  • You have 4 of Item-2 on hand.
  • Item-2, Item-2a, and Item-2b are all defined with Qty/Per values of 1 per unit.

To adjust the production BOM for this example, follow these steps:

  1. Run APS Planning. The system creates a planned order for Item-1 for a quantity of 8. Because it uses the 4 on-hand of the phantom, the system creates planned orders for Item-2a and Item-2b for a quantity of 4.
  2. Open the Planning Detail form and firm the planned order for Item-1. When prompted, choose to copy the current BOM.
    Note:  If you do not plan to adjust the BOM for phantom usage after firming the planned order, you should not firm the planned orders for the phantom's component materials (Item-2a and Item-2b). Otherwise, it would be OK to do so.
  3. The Planned Phantom Usage form opens and displays this message:

    The Planner has suggested adding phantom item [Item: Item-2] for [Quantity: 4.00000000] to Job that has [Job: 163] and [Suffix: 0] and [Operation: 10].

  4. Open the Job Materials form and filter to the BOM record for Item-1.
  5. Add Item-2 as a material of Item-1 and change Item-2's Qty/Per value to 0.5. This value reduces the demand quantity of the phantom from 8 to 4.
  6. Filter to the BOM record for Item-2. For each of this phantom's materials (Item-2a and Item-2b), change the Qty/Per field to 0.5. This value reduces the demand quantity of the phantom's materials from 8 to 4.
Related topics
About Phantom Items in MRP and APS