material requirements planning overview - sapman v12€¦ · module(s) mrp datasheet name mrp...

Datasheet Number & Version MRP100 Ver1

Based on Software Build No. 12.6.1.11011

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Module(s) MRP

Datasheet Name MRP Overview

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All new procedures and processes should be checked in a ‘Test’ environment before being applied to the ‘Live’ business system .

Note that fields marked are mandatory and must have data entered. When commissioning a new module please note that the parameters will need to be set, and reference should be made to datasheet SYS101, System Manager – Module Parameter Settings

Material Requirements Planning Overview

Contents 1. Parameter Settings .............................................................................................................................................. 2

2. Setting up Product for MRP ................................................................................................................................ 8

2.1. Example of Suggested Order Quantity based on MRP Type/MPS ...............................................................11

3. MRP Calculate Requirements ............................................................................................................................11

4. Production Schedule ..........................................................................................................................................14

5. Purchase Schedule .............................................................................................................................................19

6. Full Supply & Demand ......................................................................................................................................23

7. Oversupply Report .............................................................................................................................................26

8. Projected Order Report ......................................................................................................................................27

9. Planning Board ..................................................................................................................................................28

10. Run Next Phase .............................................................................................................................................28

11. Reviewing MRP Run .....................................................................................................................................30

12. Running the Pull Forward/Push Back Report ..................................................................................................32



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1. Parameter Settings a.) To navigate to the parameter settings for the MRP, select ‘System Manager’ from the tool menu, then

select ‘Sapman System Manager’, then ‘Open System Manager’ from the drop-down menu.

b.) This will open the Sapman System Manager screen, select ‘Settings’ tab then ‘MRP’ sub-tab.



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c.) The MRP parameter settings will be shown on the screen: The following parameter settings will set the default filter options filter when running the MRP Calculation Requirements:

• Include Reorder Level

• Include Free Stock

• Include Works Order Demand

• Include Transfer Request Demand

• Detailed Supply Breakdown

• Live Designs only for Shortages

• Default PO Batching Horizon

• Default WO Batching Horizon

d.) To set the working days that is used for the MRP Calculation Requirements, select the Yes/No drop-down list for the day to change.



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e.) Holidays can be entered by selecting the Holidays button.

f.) This will open the MRP Holiday Edit form.

g.) Enter the holiday date, description and whether Manufacturing, Purchasing or both will be closed on this day.



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h.) To remove a single Holiday from the grid, select the Holiday on the grid and press the ‘Delete‘ key.

i.) To remove all the holiday displayed on the grid before the current date, select ‘Cleanup’.

A confirmation form will appear, select ‘Yes’ to delete all the holidays before the current date.



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j.) To import holidays from a CSV file, select ‘Import CSV’.

Example: Import Template for MRP Holidays:

k.) This will open the windows explorer, find and select the CSV file to be imported with the holidays and select ‘Open’.



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l.) This will add the holidays from the CSV file onto the grid.

m.) Once complete, select ‘Save’.



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2. Setting up Product for MRP a.) To set up a Product to be used for MRP, select Product Module > Product Manager Task option.

b.) This will open the Product Manager screen, select and right-click the Product and select ‘Edit Product’

from the drop-down menu.



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c.) This will open the Edit Product form, select ‘Stock Details’ tab then ‘Item Master’ sub tab.

d.) To include this product in MRP Calculations, enable ‘Include In MRP’ and this will also allow amending the MRP Details on the Product:

MRP Details:

• MPS Item – Enable the checkbox to set this as a Master Product Schedule Item. MPS provides an alternative demand for the MRP module, and is used to effectively de-link the Sales Orders from the optimised quantities that Production intends to manufacture. Leaving this unchecked will use the standard demand (MRP) which plans items that have dependant demand. This is demand that is passed down because of the need to produce an item.

• MRP Type – Select from LFL or ELS:

❖ LFL– Lot For Lot – This type of product ignores ROL (re-order levels) and generates suggested Works Orders and Purchase Orders to meet demand. Minimum Order Quantity and Increments will be used in the calculation of suggested PO/WO’s if included in Item Master.



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❖ ELS – Economic Lot Sizing. This type of product uses the ROL and if the Stock level is at or below the ROL (or will be based on supply and demand) Minimum Order Quantity and Increment values will be used to calculate the Economic lot size of suggested PO/WO if these are included in Item Master.

• Buffer – Enter the Buffer quantity to be applied to the suggested order quantity. The buffer is the

amount that will be added onto the suggested order quantity. (Note: Leave at Buffer quantity to ‘0’ for no Buffer.) (Note: Only available for MRP Type LFL)

• Reorder Quantity – Enter the Reorder Quantity. If a Product has a Re-order Quantity greater than 0 this will be used in the MRP calculation for suggested order quantity and the Increment value instead of the Minimum Order Quantity. (Note: Only available for MRP Type ELS)

• Campaign Figure – Enter the Campaign Figure to set the demand amount for the Product. (Note: The campaign figure will only be used if it is higher than the demand for the Product.) (Note: Only available for MPS Item)

• Schedule – Add a quantity demand for a specific date. Right click in the box and select ‘Add’. Add the quantity needed and the date required from the drop-down box.

e.) Once complete, select ‘Save’.



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2.1. Example of Suggested Order Quantity based on MRP Type/MPS

PROD

A PROD

B PROD

C PROD

D PROD

E PROD

F PROD

G PROD

H

MRP Y Y Y Y Y Y

Y

Y

MPS N Y N Y N Y

N

Y

LFL Y Y

Y

ELS Y Y Y Y

Y

STOCK QTY 100 100 100 100 100 100

100

100

ROL 120 120 120 120

120

MINOQ 100 100 100 100

100

INCREMENT 50 50 50 50

50

ROQ 300 300

300

BUFFER 50

50

CAMPAIGN 500 500 500

500

DEMAND 200 200 200 200 200 200

0

700

SUGGESTED ORDER

QTY 150 450 250 550 300 550

300

600

3. MRP Calculate Requirements a.) To use the MRP Calculate Requirements, select ‘MRP’ Module > ‘Calculate Requirements’ option.



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b.) This will open MRP Calculate Requirements Form, select the MRP filter settings:

MRP Settings:

• Demand From – Select an Object from the drop-down menu. (Note: Currently only ‘Sales Orders’ and ‘MPS’ available.)

• Include Reorder Levels – This will include Reorder Levels in the MRP calculations. (Note: This setting over-rules the settings set at Product Level for LFL and ELS regarding the use of ROL.)

• Include Free Stock – This will include Free Stock in the MRP calculations.

• Include Works Order Demand – This will include Works Order on Demand in the MRP calculations.

• Include Transfer Request Demand – This will include Transfer Request on Demand in the MRP calculations.

• Demand Manufacturing Department – This will only calculate for Products from the selected manufacturing department

• Use Detailed Supply Breakdown –This controls the level of detail on all supply events. To enable the display of due dates for individual supply events (e.g. purchase / works orders) check this box.

• Demand Product Group – This will only calculate for Products from the selected product group.

• Include Demand up to: Choose a date from the drop-down calendar

• Include Supply up to: Choose a date from the drop-down calendar

• Live Designs Only for Works Order Shortages – This will set the MRP calculations to only use Live Designs when calculating the works order shortages and projected shortages.

• PO Batching Horizon – Enter the number of days over which the MRP calculation will batch supply orders for Purchase Orders.



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(Note: The PO batching occurs after Purchase Orders projection has been made, this is phase 3 when using interactive mode.)

• WO Batching Horizon – Enter the number of days over which the MRP calculation will batch supply orders for Works Orders. (Note: The WO batching occurs after Works Orders projection has been made, this is phase 2 when using interactive mode.)

• Use Detailed Supply Breakdown – Enabling this will consider each supply order from outstanding Works Orders, Purchase Orders and Transfer Request for the products. This will also include the Works Order, Purchase Order and Transfer Request delivery dates into the MRP calculations. Leaving this unchecked will consider the products stock total ‘On Order Quantity’ as the supply for each product which is still built up from the Works Orders, Purchase Orders and Transfer Requests assuming that the items have already arrived. (Note: To use this setting, this requires ‘Include Free Stock’ to be enabled.)

• Interactive Mode – This will make the MRP calculation to run the order projection through the phases separately allowing the user to interact with the MRP calculation between the phases to change the suggested orders:

➢ Phase 1: Extracting the Supply and Demand details. ➢ Phase 2: Projecting the Works Orders and Shortages ➢ Phase 3: Projecting the Purchase Orders.

• Orders To Project – Select the type of Order to be projected from the drop-down menu. c.) Once complete, select ‘OK’.



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d.) This will then display the details after completing the phase(s).

• Production Schedule – See notes section (4).

• Purchase Schedule – See notes section (5).

• Full Supply & Demand – See notes section (6).

• Oversupply Report – See notes section (7).

• Projected Order Report – See notes section (8).

• Planning Board – See notes section (9).

• Run Next Phase – See notes section (10).

• Close – This will close the window form.

4. Production Schedule a.) On the MRP Calculate Requirements Form, select ‘Production Schedule’.



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b.) This will open the Production Schedule form, the ‘Date Required’ and ‘Start Dates’ can be amended as

required. When the user creates Works Orders on the Production Schedule these dates will be used as the Works Order ‘Date Required’ and ‘Start Date’.

c.) The Quantity shown in the "In" column (highlighted green) is the suggested order quantity calculated by MRP. To confirm that quantity select the option buttons below (highlighted in red) or to over-ride the suggested quantity enter the quantity manually into the confirm Quantity field:



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• Confirm All – This will confirm all stock for all the Products displayed on the on the grid as per the ‘In’ column quantity.

• Confirm Selected – This confirm all stock for the Products that are selected on the grid as per the ‘In’ column quantity.



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• Invert Selection – This will confirm all suggested products and cancel all confirmed products.

• Create Works Orders – When there are confirmed quantities made this will create a Works Order for the confirmed amounts. (Note: Works Orders can only be created when the Production Schedule is frozen. The MRP production schedule is automatically frozen unless when using interactive mode, where the user will be asked if they wish to freeze the production schedule after all works order projection has been completed on the MRP calculation.) (Note: When the Production Schedule is frozen it means that MRP calculation will no longer allow the user to make changes to projected orders on the production schedule.)



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d.) Selecting and right-clicking on a Product will have the available drop-down options:

• Stock Profile – This will display the Supply & Demand form for the selected Product.

• View Created Order – This will view the created Works Order made by MRP for the Product. (Note: This requires a Works Order to be created for the selected Product on the Production Schedule)

• Stock Card – This will print the Stock Card to the Print Spooler. i.) Select Stock Card from the drop-down menu.

ii.) This will open Stock Card form, select/enter the required filters.



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iii.) This will open a preview form of the report with the selected filters. Close the preview

window when you are finished viewing.

5. Purchase Schedule a.) On the MRP Calculate Requirements Form, select ‘Purchase Schedule’.



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b.) This will open the Purchase Schedule form, the ‘Date Required’ and ‘Start Dates’ can be amended as required. When the user creates Purchase Orders on the Purchase Schedule the ‘Date Required’ will be used as the Purchase Order Due Dates and ‘Start Date’ as the Purchase Order ‘Order Date’.

c.) This will open Purchase Schedule Form. The Quantity shown in the "In" column (highlighted green) is the suggested order quantity calculated by MRP. To confirm that quantity select the option buttons below (highlighted in red) or to over-ride the suggested quantity enter the quantity manually into the confirm Quantity field:

• Confirm All – This will confirm all the stock for all the Products displayed on the on the grid as per the ‘In’ column quantity.

• Confirm Selected – This confirm all stock for the selected Products as per the ‘In’ column quantity.

• Invert Selection – This will confirm all suggested products and cancel all confirmed products.

• Create Purchase Orders – This will create a Purchase Order for the selected Product using the selected Supplier and Authorisation Group:

(Note: Purchase Orders can only be created when the Purchase Schedule is frozen. The MRP purchase schedule is automatically frozen unless when using interactive mode, where the user will be asked if they wish to freeze the purchase schedule after all purchase order projection has been completed on the MRP calculation.)



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(Note: When the Purchase Schedule is frozen it means that MRP calculation will no longer allow the user to make changes to projected orders on the purchase schedule.)

❖ Supplier – Select the Preferred Supplier from the drop-down list to be used for creating the new

Purchase Orders. If there is only one preferred supplier for the product this will be automatically selected and cannot be changed. (Note: This will display all supplier accounts if no preferred supplier is set for the product and the user will be able to select the supplier from the drop-down list.)

❖ Authorisation Group – Select an Authorisation Group to be used for creating the new Purchase Orders.

e.) Selecting and right-clicking on a Product will have the available drop-down options:

• Stock Profile – This will display the Supply & Demand form for the selected Product.

• View Created Order – This will view the created Purchase Order made by MRP for the Product. (Note: This requires a Purchase Order to be created for the selected Product on the Purchase Schedule.)

• Stock Card – This will print the Stock Card to the Print Spooler. i.) Select Stock Card from the drop-down menu.

ii.) This will open Stock Card form, enter the required filters.



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iii.) This will open a preview form of the report with the selected filters. Close the preview

window when you are finished viewing.

d.) Once finished using the Purchase Schedule form, close the window.



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6. Full Supply & Demand a.) On the MRP Calculate Requirements Form, select Full Supply & Demand.

b.) This will open the Supply & Demand Form, select from the available options:

• Print – This will open a preview of the Supply and demand report and also add the report onto the Print Spooler.

• Show Full Process S&D – This will filter the grid to include projected supply and demand orders.

• Product Group – This will filter the Products displayed on the grid by the selected Product Group.

• Use Reorder Level – Enabling this will set the balance to be compared against the Reorder Level.



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c.) Right-clicking a Product will display the available drop-down menu options:

• Stock Profile – This will display the Supply & Demand form for the selected Product on a new window.

• View Projected Shortages – This will display the Projected Shortages for the selected Product on a new window.

• Drill Up to Projected Works Order – This will display the list of Projected Works Orders that have shortages from the selected Projected Works Order Shortage. (Note: This is only available for Projected Works Order Shortages)

• View Order – This will display the selected Order on a new window.

• View Line – This will display the selected Order Line on a new window.

• View Stock Card – This will print the Stock Card to the Print Spooler.

i.) Select ‘View Stock Card’ from the drop-down menu.



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ii.) This will open Stock Card form, select/enter the required filters.

iii.) Once complete, select ‘OK’.

iv.) This will open a preview form of the report with the selected filters. Close the preview window when you are finished viewing.



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7. Oversupply Report a.) On the MRP Calculate Requirements Form, select ‘Oversupply Report’.

b.) This will open a preview of the MRP Oversupply Report and add it to the Print Spooler.



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8. Projected Order Report a.) On the MRP Calculate Requirements Form, select ‘Projected Order Report’.

b.) This will open a preview of the MRP Projected Orders Report and add it to the Print Spooler.



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9. Planning Board On the MRP Calculate Requirements form you can select Planning Board. This feature is under development, please contact SMS consultant for more details.

10. Run Next Phase (Note: This is only available when on Interactive Mode is selected on the MRP settings.) a.) On The MRP Calculate Requirement Form, select ‘Run Next Phase’.

b.) This will open a confirmation form, select ‘Yes’ to continue the next phase of the Works Order Projection.



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c.) Once the MRP calculation has completed the next phase, the user will be able change any projected orders before continuing onto the next.

d.) There are also three pop-ups that will appear when projected orders are completed:

• Projected Works Orders are completed – A pop-up to freeze the production schedule will appear after selecting ‘Run Next Phase’. Select ‘Yes’ to freeze the production schedule or ‘No’ to continue. (Note: Once the production schedule is frozen, works order can be created by the MRP.)

• Projected Purchase Orders are completed – A pop-up to freeze the purchase schedule will appear after selecting ‘Run Next Phase’. Select ‘Yes’ to freeze the production schedule or ‘No’ to continue. (Note: Once the purchase schedule is frozen, purchase orders can be created by the MRP.)



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• Both Works Orders and Purchase Projections are completed – A pop-up confirming that both Production and Purchase Projections are completed and frozen will appear after selecting ‘Run Next Phase’. Select ‘OK’

11. Reviewing MRP Run (Note: No works orders or Purchase Orders can be created by reviewing a MRP Run.) a.) To review any MRP ran previously, select MRP Module > MRP Utilities > Review MRP Run option.



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b.) This will open the MRP Run Summary, select an MRP run that was run previously from the drop-down list.

• (Optional) To delete an MRP run from the list select the MRP run from the drop-down list

and select the cross icon .

c.) Once an MRP run is selected, select ‘OK’.

d.) This will open the MRP Calculate Requirements that was run previously. Once finished reviewing, select ‘Close’.



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12. Running the Pull Forward/Push Back Report a.) To run the Pull Forward/Push Back Report, select MRP Module > MRP Reports > Pull Forward/Push

Back option.

b.) This will open the Pull Forward/Push Back Report form. Select the filter options then select ‘OK’.



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c.) This will open the preview of the report, this report displays details for manufactured products orders and suggests what orders could be moved to an earlier (Pull Forward)/ later (Push Back) date to suit demand needed for the product. Close the preview window when you are finished viewing.

material requirements planning overview - sapman v12€¦ · module(s) mrp datasheet name mrp...

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