Plans are generated using "New" option located at the bottom of the Master Production Schedule window. The definition window accessed by clicking on "New" button is used to specify Code and Description of the schedule and Plant to be processed in production scheduling.
Material Requirement Planning (MRP) window is displayed by clicking on "Save" button.
Filter option located in the right mouse button menu is used to specify conditions for requirement planning.
The filter options and functions of the Material Requirement Planning window are:
Filter | Value |
|---|---|
Warehouses | Defined warehouses |
Schedule Start Date | Date entry |
Period to be Scheduled (Day-Week-Month) | Period To Be Scheduled Options (Day-Week-Month entry) |
Period to be Frozen (Day) | Number entry |
Frozen Periods | Will be Changed / Will Not be Changed |
Distribution Parameters | From Week To Days (To All Days/To First Day/To Last Day) / From Month To Days (To All Days/To First Day/To Last Day) |
Calculation Options Validity Date | Date entry |
Calculation Options | Add Consignments Received / Add Purchase Orders / Subtract Sales Orders / Subtract Demand Slips / Add Planned Inputs / Subtract Planned Inputs |
Sales Order Subtraction Options | All Sales Orders Will Be Deleted / Only Reserved Orders |
Schedule For Sales Orders | Yes / No |
Number Of Decimal Digits | Number entry |
Material (Class) Type | Commercial Good / Mixed Case / Deposit Item / Raw Material / Semi Finished Good / Finished Good / Consumer Good / Material Class (General) / Material Class (With Table) |
Material (Class) Code | Group / Range |
Material (Class) Description | Group / Range |
Material (Class) Aux. Code | Group / Range |
Material (Class) Authorization Code | Group / Range |
Material (Class) Group Code | Group / Range |
Material (Class) Vendor Code | Group / Range |
Parent Material Class Code | Group / Range |
Material (Class) Characteristics | Characteristic 1 – 10 (Value / Code) |
Warehouses: A selection is made from among the warehouses of the plant to be planned. The safety inventory level quantity to be transferred into the schedule window and information of other quantities are calculated for the selected warehouses.
Schedule Start Date: The scheduling start date. Date columns to be displayed on the schedule window are generated according to this date.
This date is also processed to determine Carrying Over Quantity and bill of material revisions of materials with procurement type "production" to be used in Production Orders. Approval status is not processed for the revision to be used.
Period to be Scheduled (Day-Week-Month): Columns to be displayed on the schedule window are transferred into the window by being filtered (Day / Month / Year) in accordance with the numbers entered into the related fields.
Period to be Frozen (Day): This filter is used if changes on the schedule are to be avoided. The freezing transaction is performed at the date calculated by adding the number of days entered on this field to the Schedule Start Date. When the freezing schedule is accessed by clicking on "Update" button, related days are displayed in red and any changes cannot be performed according to the Frozen Periods parameter. Frozen periods provide precision for sales orders and user demand entries.
Frozen Periods: The information that indicates whether or not changes will be allowed in frozen periods.
Distribution Parameters: This parameter contains the From Week to Days and From Month to Days options. There are three available values for both options:
- To all Days
- To First Day Only
- To Last Day Only
The Distribution Parameters filter allows weekly and monthly demand quantities to be automatically distributed to days.
Calculation Options: The filter used to specify parameters to be processed in calculation. This filter contains six options:
- Add Consignments Received: The calculation information of consignments received for transferred and daily totals.
- Subtract Sales Orders: The calculation information of sales orders for transferred totals only.
- Add Purchase Orders: The calculation information of purchase orders for transferred and daily totals.
- Add Planned Inputs:
- Calculation information of planned inputs for transferred and daily totals.
- Subtract Planned Outputs: The calculation information of consignments issued for transferred and daily totals.
- Subtract Planned Demand Slips: The calculation information of planned demands for transferred and daily totals.
Sales Order Subtraction Options: The functions of this option depend on the Subtract Sales Orders parameter of the Calculation Options filter. This option contains the following options:
- All Sales Orders Will Be deleted
- Only Reserved Orders
Once the condition is specified on filter lines, the Requirement Planning window is opened by clicking on "OK" button. Points to be considered in planning are:
- Planning is performed using the main unit of each material.
- The user specifies materials to be included in planning, Plant and MPS Date Range through related filters.
- Planning can be performed as daily – weekly or daily – weekly – monthly.
- The Transferred Quantity of the first day of planning is determined according to the inventory totals before that date.
- Total order quantities for given Plants and Date Ranges are specified in main units by scanning customer orders.
- Customer demand estimations and/or internal demands can be entered on a daily, weekly or monthly basis. The distribution method of weekly and monthly entries to daily records is specified using parameters selected during the filtering operation.
- Production dates of materials without bill of material cannot be specified.
- All or a part of planned days can be frozen by the user. In this way, when MPS is run for the same period, any changes on order quantities and demand entries of frozen days are prevented.
Materials complying with conditions specified on filter lines are displayed on the schedule window. Details of each line can be displayed by clicking on "Display Details" button or double clicking the related line. Information and functions included within details are:
Unadjusted Procurement Quantity: The difference between the net requirement quantity and Previous Procurement Quantity.
Previous Procurement Quantity: Displays Production Orders with "Work in Process" status and orders with "Deliverable" status.
Transferred Total = Actual Inventory + (-Consignment issued + Consignment Return) + (Consignment Received – Consignment Return + Purchase Orders – Planned Outputs + Planned Inputs – Sales Orders)
Warehouse Totals = Actual Inventory + (-Consignment issued + Consignment Return) + (Consignment Received – Consignment Return + Purchase Orders – Planned Outputs + Planned Inputs)
Planned Inventory Change: The quantity of planned inventory change.
Inventory Target Quantity: Indicates the inventory target quantity.
Available Quantity= Transferred Total + Warehouse Totals + Planned Inventory Change + Inventory Target Quantity
Sales Orders: Indicates the order quantity of sales orders for the day selected on the schedule.
Demand Slips Total: Indicates the demand slips total.
Demand Quantity: Displays the quantity entered by the user.
Independent Requirement Quantity = Sales Orders (MIP) + Demand Slips Total + Demand Quantity
Dependent Requirement Quantity: Displays the input requirement resulting from BOM explosion.
MPS Requirement Quantity: Displays the MPS requirement quantity.
Requirement Quantity = Gross Requirement Quantity – Available Quantity
Gross Requirement Quantity = Independent Requirement Quantity + Dependent Requirement Quantity + MPS Requirement Quantity
Net Requirement Quantity = Displays the net requirement quantity.
The calculate transaction is used to specify days on which backward requirements on the schedule will be delivered and total delivery quantities. The requirement delivery method is specified using Plant Parameters of the material. Bill of material relation definitions applied for plant and planning periods of materials for which Planning option is selected, quantity dependent/independent durations, information regarding product lines with assigned shifts, and the Lot Sizing Method defined on Plant Parameters of the material are processed in calculation.
The Delivery Time on the Material record is processed if the Procurement Type is Purchase. The production start day is specified using this information and by going backwards from days required. Daily production quantities are displayed on the line of the Planning window containing the material code. Production dates of materials without valid bill of material relations cannot be specified. Lead Time is considered as zero if not specified.
In case that a material included to MRP calculation is configurable, the variants of semi finished goods and raw materials to be used for this material's production are also generated automatically during MRP calculation transaction. In order to do so, click on "OK" option when "Do you want to generate material variants that do not exist?" message appears. In order to include generated variants to calculation, planning transaction should be performed again. When calculation is completed, the variants generated for semi finished goods and/or raw materials can be displayed by using "Automatically Generated Variants" option with date and hour info which is located at the bottom of the MRP window.
Schedule results are recorded by clicking on "Save" button. Production Planning Proposals can be generated after the related record transaction is completed.