RE: Planned vs. Allocated Inventory & Scheduling Customer Orders

Jenny,
What are the BPCS planning products that you are running (MPS/MRP/CAP)?
If you follow the "date management" system you should be able manage the
exceptions. I know this may sound like a fairy tale, but if you follow
the rules, it will work. I do not care if it is BPCS or any other
software package; it is how you manage the data that will make or break
you. When I first put in BPCS v3.6 (sys38) at Signal Stat (now Federal
Mogul Signal & Lighting Systems) we had all kind of problems trying to
meet the automotive OEM demands. When we committed do the planning and
execution the correct way and use BPCS as a software tool, it became
very manageable.

I do not know what kind of business you are in, but you must set-up the
data correctly.  Why 8 levels in the bills?

Do you use MRP250? If so, what % is releasable?
Do you have any CPIM on your site?

If you would like to get more into the discussing the process vs. the
tool, please feel free to contact me 908-789-3237 or
ashaffer@BPCSpros.com

Arthur B. Shaffer, CPIM
Principal Consultant/Business Development Manager
ASAP - Advanced Systems and Products, Inc.
AShaffer@AS400Pros.com
Phone - 908-789-3237   Fax - 208-978-7735

-----Original Message-----
From: bpcs-l-admin@midrange.com [mailto:bpcs-l-admin@midrange.com] On
Behalf Of Jenny Carr
Sent: Friday, March 01, 2002 4:32 PM
To: bpcs-l@midrange.com
Subject: Planned vs. Allocated Inventory & Scheduling Customer Orders

This is a multi-part message in MIME format.
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[ Picked text/plain from multipart/alternative ]
We repeatedly have problems with the scheduling of customer orders (i.e.
don't have purchase parts when we need them).  Unfortunately, you have
to schedule items and wait for MRP to run (in our case, nightly) before
you know whether you can meet the scheduled date.  Although we use
reports that notify our buyers that they need to expedite purchase
parts, we have not found an effective way to easily identify those
customer orders.  I "think" this is because of the volume of orders,
common purchase parts, and the difficulty associated with pegging
through 4-8 levels of the bill.  I got excited when I saw the SFC350
program; until I recently discovered that it only includes allocations
of orders already released (not the ones that are still planned).  For
us, that is where most of our inventory is.  Does anybody have any good
ideas?

I saw on a flowchart that SFC350 is typically used before releasing
orders.  Now I know why.  Assuming that there isn't an easy way to pull
in the planned quantities into SFC350, what is a good procedure for to
reschedule the orders at that point without affecting capacity issues,
etc.?

Even if we solve this problem, the other problem still exists.  We still
need to figure a way out to figure out a realistic schedule date based
on 1) allocations (released to shop), 2) planned, 3) on order and what
is required on the customer's order request.  We at one time looked at
some APS systems to accomplish this, but it doesn't seem like it should
be that difficult.  I've considered building a database that pulls the
necessary data from BPCS.

I'm open for suggestions, but please remember, we are only on 3.7 with
Nexgen Y2K mods.

TIA,

Jenny Carr

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