Hello I have some issues with assembly builds. I have no idea how this is happening or what is leading to it as I'm the netsuite admin and this is all being done by our supply chain manager. We have times where the assembly builds show a quantity of 0 for the components. I don't know how this is possible because when I try to make the quantity 0 on an assembly build netsuite gives me an error of "must be positive value". I'm assuming this has something to do either with a revision update or item update but I can't seem to find anything on it

@Jackie Yang Check back to the work orders. You can zero out the quantity of a line on the work order and it will carry over into the assembly build and allow the build to be completed.

@Matt Carter This is the work order lines

@Jackie Yang We don't use commitments, so I'm assuming here, but it's probably coming over as 0 since the committed amount is 0. Are your people supposed to go through a picking process to get components for a build?

@Matt Carter no we don't use picks

@Jackie Yang By chance do they make any adjustments when creating the work orders? We have some builds where the guys switch out components on certain occasions?

I think it is a possibility that the team is updating the revision

@Jackie Yang The work order changes are independent of the revision, the revision just gives the work order a starting point. I have two thoughts for you that was an issue for us a couple of times • One person who was making changes kept accidentally zeroing a line here and there • Another issue we had was the selection order of fields on the work order. If the assembly was selected first or pre-filled in from another process, then setting the sub and location can cause the form to reset and values at the line level can change. I had to train the guys to select sub, location, and then assembly to avoid quantities changing

@Matt Carter This is very helpful thank you so much. Yeah I have an issue where our supply chain manager just tries to save orders to get through his process if something pops up. He cuts corners and usually I can look at system notes and say "this is what you did that caused this" but in this case it's hard to find some hard evidence

You’re welcome. Sounds very familiar, lol.

@Matt Carter glad someone else can relate lol

@Jackie Yang I was looking at the docs earlier, it says that commitment occurs only when the full quantity is available. Looks like commit will be 0 even if there is a partial quantity of the component available. Here's a likely scenario PO comes in -> WO is generated, but one or more lines may show committed as 0 since the component inventory maybe low -> supply chain manager clicks to build without checking the lines of the WO -> NetSuite builds the assembly anyways as that is an allowed action with zeroed qty lines. You may need to implement some kind of stop gap on WO's being built if any lines are 0 committed.

@Matt Carter But i'm okay with him building it even though there is 0 committed. Committed doesn't mean we don't have the inventory it just means the available inventory is committed on different orders. My issue is that the actually build qty of components used is 0

I think that is going to be the root of your issue though. If WO-B is showing 0 committed, then the assembly build is going to show 0 consumed. As far as NetSuite is concerned, those components were not available for use since they were committed to WO-A and can't currently be consumed on WO-B. That's part of the reason we opted to not use commitments. The difference between qty on hand and qty avail caused a host of issues if we had to make an adjustment to when something was going to be built or shipped. Inventory had to be uncommitted from orders so it was available for other orders if a change was needed.

@Matt Carter I've been messing with some work orders in sandbox and so far this is the only way I can get this component qty issue to happen • The components are backordered because we are either out of inventory or it's committed to other orders already. In this example, to build 20,000 units we need 20,202 of component A but only 7,200 is committed. • You make the assembly build for 20,000 units using the correct component qty of 20,202 • You try to save the item receipt but get an error saying "total inventory detail quantity must be 7200". This is the amount that was committed to the order • When you click go back and try to make the assembly build again two things are probably happening a. User is entering the 7200 qty amount which is not correct because they are still trying to build for the full 20,000 and 7200 is only the amount committed so far to the WO, not the amount actually needed to be consumed for that large of a build b. User is entering 0 qty. When the component qty is 0, NetSuite lets you save the assembly build without needing to put inventory detail for that component line

That makes sense to me. Sounds like you may have more of a user issue than system issue unfortunately.