Rolled up Lead Time

As a Production Planner or Planning Administrator
I want to calculate how long it would take — from scratch — to procure all components and produce each finished item, considering the full multi-level BOM
So that I can set realistic planning horizons and know how far in advance we need to start planning for each item

Setup:

1. Open Calculate Rolled up Lead Time from the Simple MRP journal, Direct Replenishment journal, or by searching for the report directly.
2. Set item filters to limit the calculation to specific items or leave blank to calculate for all items with a production BOM or routing.
3. Run the report. The system traverses the BOM tree for each item:
   • For purchase components: uses the lead time from the item or SKU card.
   • For produced sub-components: recursively calculates their own rolled-up lead time.
   • Takes the longest path (critical path) through the BOM as the result.
4. Results are stored per item/location/variant and are immediately available in the Rolled Up Lead Times page.

Note: The calculation supports up to 50 BOM levels. Items with circular BOM references or structures exceeding 50 levels will raise an error.

As a Production Planner
I want to see the rolled-up lead time for each item alongside the individual lead time and replenishment system
So that I can identify which items have the longest cumulative lead times and which components are the bottleneck driving those times

Setup:

1. Open Reverse Planning – Rolled up Lead Time (search or navigate from the Simple MRP or Direct Replenishment journal).
2. The list shows one row per item/location/variant with:
   • Lead Time: the item's own lead time (purchase or production).
   • Rolled Up Lead Time: the cumulative date formula from the critical path through the BOM.
   • Rolled Up Lead Time Integer: the number of calendar days in the rolled-up lead time.
   • Failed to Roll up Lead Time: flagged if the calculation could not complete for this item (e.g. missing BOM data).
   • Failed to Calculate Lead Time: flagged if the item's own lead time could not be read.
   • Lot Size: the lot size from the item or SKU.
   • Replenishment System: Purchase or Prod. Order.

As a Planning Administrator
I want to configure a Planning Template so that the planning horizon for each item is automatically set to that item's rolled-up lead time — rather than using a fixed end date for all items
So that items with long procurement chains are planned far enough in advance, while simple purchased items use a shorter, appropriate horizon

Setup:

1. On the Planning Template (Simple MRP or Direct Replenishment), set Calculation Period to Rolled Up Lead Time.
2. Run the Calculate Rolled up Lead Time report first to ensure the stored values are current.
3. When the planning calculation runs, each item's planning horizon is automatically set to its rolled-up lead time from the stored table — no manual date setting is needed.
4. Items without a stored rolled-up lead time fall back to their individual lead time.

As a Production Planner
I want to update the individual lead times for each item — based on a simulated production order — without recalculating the rolled-up BOM values
So that I can quickly refresh lead times after changing routings or lot sizes without waiting for the full multi-level rollup calculation to complete

Setup:

1. Open Calculate Rolled up Lead Time.
2. On the request page, uncheck Calculate Rolled up Lead Time. By default this is enabled; unchecking it runs only the first phase.
3. Run the report. The system calculates each item's individual lead time by simulating a production order (creating and immediately deleting a simulated order with status Simulated to read back the calculated routing time), then stores the result in the Rolled Up Lead Times table.
4. The Rolled Up Lead Time and Rolled Up Lead Time Integer columns are not updated — only the Lead Time column is refreshed.

Note: The individual lead time calculation creates a temporary production order with No. = SCBTEMP and status Simulated for each item. This order is deleted automatically after the calculation. If a previous run was interrupted and a SCBTEMP order still exists, it is deleted at the start of the next run.

As a Logistics Planner or Planning Administrator
I want to understand how the rolled-up lead time is determined for items replenished by transfer order — and ensure the calculation runs in the correct order so transfer items pick up the rolled-up lead time already calculated for their transfer-from location
So that the planning horizon for transfer items correctly reflects the full procurement time at the source, not just the shipping time

Setup:

1. For items replenished by transfer (Replenishment System = Transfer on the SKU card), the individual lead time is derived from the Transfer Route for the relevant transfer-from/to location pair: specifically the Shipping Time on the Shipping Agent Service linked to the route.
2. The rolled-up lead time for a transfer item is calculated as: the rolled-up lead time already stored for the same item at the transfer-from location plus the transfer shipping time. This means the transfer-from location's items must be calculated first.
3. To ensure correct sequencing: run Calculate Rolled up Lead Time for all items at the source (transfer-from) location before running it for items at the destination (transfer-to) location. Use the Location Filter on the report request page to control which locations are included in each run.
4. After both runs, the Rolled Up Lead Times list for the transfer-to location items will show the full cumulative lead time including the procurement time at the source.

Note: If the transfer-from location's rolled-up lead time has not yet been calculated when the transfer-to location is processed, the Failed to Roll up Lead Time flag is set on the affected rows. Re-run the calculation for the transfer-to location after the source location's values are available.