PIR Connsumption on Production not on Sales

Question

Dear PP Gurus,
I must work with the planning without final assembly strategy, and need my PIR to be consumed when my process orders are confirmed (or perhaps when they are created), not when the actual sale is made.  This is because I am working using reorder points from my finished goods storage location, which triggers material transfers to these slocs, which then trigger planned orders if the requirement is not available in the plant. Then when I produce the product, it can stay on the shelf for months.  In the mean time the PIR still reserves the component materials until the sale is finally made and the PIR is consumed.  This causes redundancy in demand for component materials in my material resource planning cycle.
I am considering resorting to an ABAP program that could do the job by deducting them forcefully from table PLAF, and doing a scheduled run for this program before my MRP runs, and stop consumption for all materials in the material master, but I thought I'd ask you for one last cry of help...
Thanx in advance for your help.

Answer 1

Dear Mario,
I understand that using an ABAP program is the worst option, and this is why I am glad that i can get some help from this forum and you.
Our industry is a B-to-B process industry that suffers from very low levels of accuracy in planning.  This forces us to use a planning strategy without final assembly in order not to waste RMs.  The Second problem is that we have very high lead times for procurement i.e. 90 - 120 days, and at the same time we are required to deliver after a Sales Order with maximum 5 days.
We have more than 1000 products and 2000 raw materials that go interchangeably in each BOM.  We produce fragrances and flavors, which are very much like blending colors.
An example of this dilema is:
Yellow and blue makes green, and yellow and red makes orange.  If you waste yellow on unneeded green then you can not create any orange if you are required to.
You can imagine the effect of this issue when you have more than 2000 raw materials that go interchangeable in your 1000 finished products, which also are offered in more than 5 different package variations.
We have three distribution channels that are all trying to produce their orders, some planned and some not, and thus if we produce any material out of plan it can affect the raw materials allocated for a few other finished materials that where planned by another distribution channel.
So...
In order to solve this issue we are working with a planning strategy that allows us to procure materials for the plan, however does not produce. This gives us the luxury to still use the raw materials for other materials, if a planned independent requirement is not actually sold.
Our planning now is done 3 months in advance, and we buy raw materials accordingly.  We also buy some safety stock in order to create a buffer for some change.
We then procure these materials all on time however wait for an order to start actual production.
Case 1: Large Factories
When an order comes we externally (on excel) verify that this order from the respective distribution channel is actually planned.  Then we create the process order.  If not then we make sure that if we produce this material no shortages will occur, then if this is the case we proceed, if not then we delay the order so that no shortages occur.
Case 2: Traders
There is a second case which causes us the major part of my current problem.  Because we have traders that consume smaller quantities however much more frequently, we created a finished goods SLOC and made a reorder point for all materials pertaining to the traders and a replenishment quantity.  When stock reaches this reorder point in the SLOC, a transfer order is created to replenish this WH. Then since there is no stock of this material in the plant, a planned order is created. Again we make sure that the distribution channel has not passed its planned requirements like above in an external excel sheet before we turn the planned order to a process order.
The PROBLEM:
After all this happens when we produce this material and send it to our finished goods SLOC, the planned independent requirement is not consumed until after the material is actually sold.  This could take months.  In the mean time you have the material in-stock and at the same time the PIR for this material is creating demand for its components.  This demand is fake demand because we have already produced the product.
This problem also exists in my previous case (CASE 1) when a large customer creates an order and leaves it in my stock for a few weeks, for any reason.  During these two weeks I have his materials in stock, however have to wait until the material is delivered to him before my PIRs are consumed.  During these two weeks, I could have started procurement of a large amount of raw materials with no need.
Sooooo...... Finally all i need is for my PIRs to be consumed when I do my process order or when I do my confirmation, not when I actually sell the material to the customer.
If you have read to this point then you are a hero, and I thank you even if you don't have an answer for me.
If I am not clear in any point please tell me and I will try to explain more.
You help is extremely appreciated
Thank you...