This article considers that after managing your risk you performed some manual allocations of lots to manufacturing lots, packaging lots, or demands. That being done, you ended up with warning messages that you struggle to solve. The objective of this page is to help you resolve those warnings in order to reach a feasible and risk free production plan.
Allocation warning #1: An allocation is defined but only x were allocated.
Cause: the manually performed allocation doesn’t respect the bill of materials ratio while no exception has been defined for the output lot.
Solutions:
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Respect the defined bill of materials.
Update the allocated quantity in order to define the exact quantity. -
Overwrite the defined bill of materials.
Go to Manufacturing Lots or Packaging Lots and select Ignore recipe (last column of the table) for the output lot. Note that ignoring the recipe means that the system assumes the allocation created is sufficient to cover the complete demand. The extreme situation where Ignore recipe is checked without an allocation being created will have the same effect as the Fed option.
Allocation warning #2: The sum of allocations from LotX are greater than its available size.
Cause: more quantity of LotX has been allocated to lots or demands than what is available.
Solutions:
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Update the corresponding lot size on the input lot (available size, or release size if empty).
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Edit allocations thanks to the Lot to manufacturing or Lot to packaging button that appears in the warning. It lists all the performed allocations from this input lot. You can either decrease allocated quantities, or delete some allocations.
Allocation warning #3: An allocation is defined but only 0 were allocated.
Cause: the input lot doesn’t respect all the necessary constraints to be used for the output lot.
More common solutions:
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Ensure the input lot is usable from the manufacturing/packaging start date of the output lot:
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In case you don’t work at risk: the release date and the arrival date of the input lot need to be before the manufacturing start date of the output lot.
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In case you work at risk: the manufacturing end date and the arrival date of the input lot need to be before the manufacturing start date of the output lot.
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Reduce the expected expiry date from the study.
Go to Packaging Lots and ensure the expiry of the missed lot is defined as Exp. min from usage, or reduce the Exp. min from input entered manually if this isn’t the case.
Additional solutions in case the first ones didn't solve the issue:
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Ensure the input lot Use until date is after the output lot Manufacturing start date.
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Ensure the input lot can be allocated to all studies to which the output lot is allocated (directly or indirectly).
Go to the Manufacturing Lots table, look at the input lot and see if there are any study restriction applied in the Studies field. -
Ensure the input lot can be mixed with another lot to supply the need of a single demand or a single subsequent lot.
Go to the Manufacturing Lots table, look at the input lot and see if the Mix field is well on Always. -
Ensure the lot can be used at any site, at any date, for any demand.
Go to the Manufacturing Lots table, look at the input lot and see if the Usage field is well on Unrestricted.