Re: MRP200

A new question from me to someone familiar with what MRP200 is supposed to be doing.
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If we have a requirement that falls outside or beyond the buckets selected by the user to print on the report, is that supposed to be on the report?
I am thinking perhaps our users are not accustomed to requirements that are 12 months out, and what their impact might be on a report that is only looking 4 months out.

Thanks for the tips. You gave me ideas to help me in some more digging.
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These items are on a facility which we recently added with a conversion, and there are some doubts about the veracity of some of the input in the conversion.

The samples given me by the user are dated before my weekly reorgs.
We are drowning in negative inventory and negative allocations (not on these items right now) which is another problem that can contaminate MRP.

Item 913311 (Purchased Blocks) Order Policy Discrete
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Quantity 106 on hand with zero requirements ON THE MRP200 report in which 13 buckets plus past due column is printed.
The on-hand is in warehouse 32 location AA01 which is netable and allocatable
It only has one parent where-used 423898-1 with an order for 100 due 12/31/03

(I have previously suggested, on more than one occasion, that our customer service validate 100% of those orders where we have stuff due JAN FEB MAR APR DEC of 2003 with nothing needed between APR and DEC ... I suspect a transcription problem where perhaps that stuff REALLY due DEC 2002 and got mis-entered. Another idea I can check is WHEN those Dec 2003 customer orders got into our system, using Crowe's Customer Order Change History Tracking system. Those entered in late 2002 probably more suspect than those entered early 2003.)

This 423898-1 (a customer part #) uses 2 each of the 913311 item, so we have 200 requirements with 94 really due, but that is outside of our MRP radar screen window (I not remember right terminology). No safety stock requirement is involved in the parent.

913311 is obviously one of the items contaminated by flawed data into conversion (with subsequent fixes) because it has an Opening Balance of zero and an O transaction (physical inventory tag) of negative with a fraction.

Item 914517 (Terminals) Order Policy Discrete is the other sample from my user.
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73,000 on hand with 7,600 required and 4,174 past due, when all the way across the
report our on-hand is 10 times our gross requirements.

This also is in location 32 AA01 (WIP warehouse ... the new facility does not have a stock room yet) which is netable and allocatable. It also has a negative O starting off its life, so it too has been touched by conversion challenges. BOM where-used identifies about 700 items whose requirements might impact this guy, but MRP300 explains that 100% of the requirements not on the MRP200 report are due December 2003, which gets me to the question up top.

Is MRP200 supposed to show all items with exception problems in which the end user selection of radar screen (not enough buckets) means that if something shows up that does not seem to need any action, then user needs to look at this again with a larger radar screen (more buckets)?

Al Macintyre
BPCS/400 Computer Janitor at http://www.globalwiretechnologies.com/
See Al at http://www.ryze.com/go/Al9Mac
Find BPCS Documentation Suppliers http://radio.weblogs.com/0107846/stories/2002/11/08/bpcsDocSources.html

Al,
A. Presume most of the 73,000 are nettable? B. The sequence of execution for
MPS/DRP/MRP allows demand to be pushed all the way thru the BOM and across
facilities in one iteration? C. MRP200 is generated in more or less the same
timeframe as the MRP process?
Larry


macwheel99@sigecom.net writes:
> Date:1/22/2003 11:37:08 AM Central Standard Time
>
>
> We do have minimum balances on some items. I had thought it was primarily
> raw materials like these. I will have to check the BOM where used on these
> items to see if any of their parents have minimums. We do have
> inter-facility DRP and I had assumed that figure should show up in the
> total manufacturing allocations. I suspect that there is something
> generating a need, that is not showing up on MRP200, that should be on the
> report, to avoid this user confusion.
>
> This is a report I rarely look at, so I have to rely on what is stated by
> the person who uses it all the time.
>
> My user claims this extra stuff is happening with one particular facility,
> not the others, and wondered what we are doing differently with it to cause
> this, or if there is a bug ... my suspect list is humongous in terms of
> things apparently being done differently, at that facility, such as another
> report showing 12 pages of items there that have negative on-hand
> quantities with no transactions in 2 weeks & I wondering how often this
> stuff is checked, and what affect THAT has on MRP. I have to do a reorg at
> least weekly because of high volume of negative allocations. I sure hope
> that any figure that really is negative, is properly identified on vanilla
> BPCS reports.
>
> Anyhow my user gave me a couple of examples. In both cases the minimum
> balance is zero. I checked our CIC a few days ago ... we not using any
> dynamic safety stock yet, but I see it looks like MRP200 would not print
> that info, if we had any just added.
>
> One item printed has quantity 106 on hand with zero requirements.
> (item 913311 Purchased Blocks) Order Policy Discrete
>
> The other sample from my user has 73,000 on hand with 7,600 required.
> (Item 914517 Terminals) Order Policy Discrete
> I don't understand why we have 4,174 past due, when all the way across the
> report our on-hand is 10 times our gross requirements.
>
> In both cases the lead time is 20 days.
>
> Al Macintyre
> BPCS/400 Computer Janitor at http://www.globalwiretechnologies.com/

>
> >Hi Al,
> >
> >Quick question; does these items (or parent items) have minimum balances?
> I know mins will sometimes create those undesired requirements...
> >
> >DeeDee Virgei
>
>
>
> >-----Original Message-----
> >From: Al Mac
> >
> >
> >One of my BPCS users asked me how come,
> >when we run MRP200 we sometimes get items that do not need human
> attention.
> >Some pages have no requirements to make anything, and / or the on-hand
> >exceeds the requirements.
> >We are 405 CD Rel-2 & multitude of Y2K BMRs.
> >We have not modified MRP200.
> >We typically run it for planner 7 (raw materials that are REALLY raw
> >materials from outside vendors) in a certain range of item #s
> >BPCS documentation claims that it only lists those items which require
> >planning action.
> >We interpret doing something about excess inventory as something other
> than
> >planning action.
> >I spent a while looking at the documentation, and I do not have an answer
> >for my co-worker as yet.
> >
> >
> >Al Macintyre
> >BPCS/400 Computer Janitor at http://www.globalwiretechnologies.com/