Re: BPCS-L Digest, Vol 3, Issue 173 -- BPCS-L

  Hi Frederick,

When I am running MRP500, it is exactly happening as you have mentioned i.e. 
upto creation of KMR for 1st level child.

However, when I run MRP600 in Regenerative mode, all the KMR (Master scheduled 
as well as non-MPS item) record disappears. I checked low level code both in 
IIM & CIC & they are correctly populated. Still this happens.

What could be the reason ?

Thanks & Regards,
Prashanth


On Sat, 13 Aug 2005 bpcs-l-request@xxxxxxxxxxxx wrote :
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>Today's Topics:
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>    1. Re: Re: [BPCS-L] MRP-MPS query (Frederick C Davy)
>    2. Re: RE: [BPCS-L] MRP-MPS query (p d)
>    3. RE: MRP-MPS query (Al Mac)
>
>
>----------------------------------------------------------------------
>
>message: 1
>date: Fri, 12 Aug 2005 16:41:41 -0400
> from: Frederick C Davy <fcdavy@xxxxxxxxxxxx>
>subject: Re: Re: [BPCS-L] MRP-MPS query
>
>MRP500 (MPS Generation) uses the Requirements represented by Forecast
>and/or Customer Orders that reside in the KMR file and creates planned
>Supply Orders in the KFP file. The KMR Requirements file used by MRP500 is
>specifically for Items that are flagged as Master Scheduled items
>(CIC/ICMRP field equal "M"). MRP500 creates the KFP Supply planned orders
>for the Master Scheduled items, and also generates the KMR Requirements
>for the Level 1 child in the Bill-of-Material for the Master Scheduled
>item.
>
>MRP600 (MRP Generation) uses the Requirements  created for the Child Item
>in the KMR file, and generates Resupply planned orders (KFP file) that
>satisfy unsatisfied requirements (netted requirements) for the Child, AND
>passes demand for these unsatisfied requirements to its Childern (B/M
>level 2). This process is repeated by MRP600 untill the program reaches
>the end of the bill-of-material, or untill a child requirement has
>sufficient stock on hand to cover the requirement (so no additional supply
>order would be needed).
>
>I hope this helps you.
>
>
>
>
>"p d" <prd2005@xxxxxxxxxxxxxx>
>Sent by: bpcs-l-bounces+amkavoulakis=sealinfo.com@xxxxxxxxxxxx
>08/11/2005 06:21 AM
>Please respond to
>"SSA's BPCS ERP System" <bpcs-l@xxxxxxxxxxxx>
>
>
>To
>"SSA's BPCS ERP System" <bpcs-l@xxxxxxxxxxxx>
>cc
>
>Subject
>Re: Re: [BPCS-L] MRP-MPS query
>
>
>
>
>
>
>Thanks Dave.
>
>So I think my understanding that, MPS run (MRP500) creates KFP as well as
>KMR for all level MPS items & MRP run (MRP600) creates KFP as well as KMR
>for all level non-MPS items, is incorrect.
>
> >From your explanation, I think, MPS run (MRP500) creates only KFP records
>for MPS, whereas MRP run (MRP600) creates only KMR for MPS & KFP as well
>as KMR for non-MPS items.
>
>Am I right in this understanding ?
>
>I am sorry, but I did not mean any child for non-MPS item. What I meant
>was the process continues till all level non-MPS items are taken care.
>
>
>Regards,
>Prashanth
>
>
>On Thu, 11 Aug 2005 Dave Murvin wrote :
> >Sounds pretty good to me, except I would change the last sentence (which
>may have been a typo) to "This continues till end of explosion of all
>non-MPS items.".
> >
> >For this to work correctly, you need to be sure that your non-MPS items
>do not have any children that are MPS items.  If a non-MPS item has a
>child that is an MPS item, MRP600 will generate requirements for the MPS
>Item, but since MRP500 (that plans the MPS items) has already been run,
>there will not be any planned orders generated for that MPS item.  I have
>seen this happen occasionally.  The Item low level codes (which should be
>maintained automatically during BOM maintenance) must also be correct.  If
>not, you could generate requirements for items that have already been
>planned.
> >
> >At 09:37 PM 8/9/2005, you wrote:
> >>        Hi, Would like to have your feedback on following (my
>understanding of MPS-MRP processes in BPCS): Forecast (in case of
>make-to-stock) or Customer Order (in case of make-to-order or
>assemble-to-order scenario) creates Demand or Requirement for FG (Finished
>Goods) MPS item i.e. KMR record for FG MPS item. Upon running MPS
>(MRP500-Master Schedule), this Demand or Requirement (KMR) drives &
>creates Planned Order (KFP record) for this FG MPS item which further
>drive & creates Demand or Requirement (KMR) for next (Child) MPS item
>which in-turn creates Planned Order (KFP) for that MPS item. This
>continues till the end of BOM structure. Upon running MRP (MRP600-Explode
>Requirements) which takes MPS item Planned Order (KFP) as Input &
>generates Demand or Requirement for next (Child) non-MPS item which
>in-turn creates Planned Order (KFP) for the same non-MPS item. This
>continues till end of explosion of all MPS items. Pl. correct me wherever
>I am wrong. Regards, Prashanth
> >
> >Dave Murvin
> >DRM Enterprises, Inc.
> >
> >
> >-- This is the SSA's BPCS ERP System (BPCS-L) mailing list
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> >Delivered-To: prd2005@xxxxxxxxxxxxxx
>
>--
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>
>
>------------------------------
>
>message: 2
>date: 12 Aug 2005 05:24:15 -0000
> from: "p d" <prd2005@xxxxxxxxxxxxxx>
>subject: Re: RE: [BPCS-L] MRP-MPS query
>
>      Hi,
>
>
>
>
>    Sorry to bother
>
>
>
>    Finally, is the following correc
>
>
>
>    MPS / MRP Logic<
>    1)     Forecast or Customer Ord   ?0? level MPS item i.e. KMR for Fi
>
>
>
>    2)     M
>
>
>
>            a)        CIC
>
>
>
>         &n   requirements,
>
>
>
>
>        &nb   (for e.g. if scrap is 90%, then takes requirement as 110%),
>
>
>
>               ILI files), reduce this available inventory from above 
> requirements, <   /FONT>
>
>
>
>
>            e   shop order) (FSO File ???), reduces this & works out Net 
> Requiremen
>
>
>
>             Net Requirement for this Finished Product.
>
>
><   Min.Balance) * scrap factor ? Inventory Available ? Schedule   Receipts 
>from Shop Order;
>
>
>    Planned Order = Net Requirement
>
>
>
>
>    3)&   levels of child MPS items, if exist, considering net requirem   as 
> explained above (only the difference is it takes requirement o   demand from 
> Planned order of Parent (KFP)).
>
>
>
>
>    4)     MRP run (MRP600), takes parent MPS item?s KF
>
>
>
>
>
>
>
>         &   child MPS as well as non-MPS items &
>
>
>
>
>    <FONT    down level child non-MPS items only.<
>
>
>
>    Net Requirements =    using BOM + Min.Balance)    from Purchase Order;<
>    Planned Order = Net Requir
>
>
>
>    regards,
>
>
>
>
>    Prashanth
>
>
>------------------------------
>
>message: 3
>date: Fri, 12 Aug 2005 19:40:16 -0500
> from: Al Mac <macwheel99@xxxxxxxxxxx>
>subject: RE: [BPCS-L] MRP-MPS query
>
>MRP500 600 work a little different if you are running individually by
>facility or for the whole company irrespective of facility.  In general you
>run your company a certain way, and setup codes in various files consistent
>with that way.
>
>On the basis of all the info available, MRP creates "planned orders" which
>you can firm up several ways, such as by releasing shop order, purchase
>order. resupply order, etc. using the due date of the MRP planned due
>date.  Then the customer order gets changed so now we really need the parts
>on a sooner date, or in a larger quantity.  MRP will put a reccommended
>reschedule date into those shop orders, purchase orders, resupply orders,
>etc. but if you do not change the date in those orders, MRP assumes the
>humans know what they are doing, like not paying attention to MRP advice,
>on purpose.
>
>For example, you have subcomponents that really need to get in house
>sooner, because the customer order got pulled up, but MRP drives due date
>of components based on due date of firmed up shop order, not on reschedule
>date suggested because customer order got changed.  Then if you update
>parent shop order to agree with MRP expedite date, and rerun MRP regen, it
>goes down another level (or more?) to provide reschedule dates for the
>child items.
>
>There are multiple opportunities to not setup your items correctly, leading
>to MRP ignoring items because of your collective errors of
>omission.  Depending on your version of BPCS, there are other things that
>can go wrong.
>
>Suppose you have negative inventory ... will MRP seek to replenish it?  In
>our case, the negatives are probably because of float in reporting and
>processing transactions, and we would prefer that BPCS compute as if the on
>hand was zero.
>Suppose you have negative allocations ... will MRP fail to plan those
>items?  In our case, we need to run an allocations reorg to fix this.
>Suppose you enter a customer order that is past due when you key it in, and
>also dated prior to your MRP planning date.  Will MRP ignore it?
>
>Suppose you have a brand new item, and when you key in the BOM, you use an
>effectivity date of the day you key it in, and you get a customer order
>right away, and there are lead times that go back a few days, to a date
>before the date you keyed in the parts, with a current effectivity date,
>which means you need the components before the date you entered the
>engineering for the parts.  Will MRP ignore the requirements because they
>are past due relative to the effectivity date?
>
>These questions, and more, are why we need to study the documentation, and
>TEST TEST TEST, to make sure it is working the way we think.
>
>Oh and one more thing ... before you came to work at your company, is there
>a possibility that prior employees modified stuff so that MPS MRP does not
>work at your company the standard BPCS way?  Do you know how to figure out
>if that is the situation?
>
> >      Hi,
> >
> >
> >
> >    Sorry to botherou, but..
> >
> >
> >
> >    Finally, is the following correc ?
> >
> >
> >
> >    MPS / MRP Logic<P>
> >
> >    1)     Forecast or Customer Ordr creates Demand or Requirement for
> >    ?0? level MPS item i.e. KMR for Fiished Product.
> >
> >
> >
> >    2)     MS run (MRP500) then takes this KMR as input,
> >
> >
> >
> >            a)     hecks minimum balance for Finished Product in IIM or
> >    CIC   depending upon how you have set up in MRP system paameters),
> >
> >
> >
> >         &nsp;  b)     adds this minimum balance to the abov
> >    requirements,
> >
> >
> >
> >        &nbp;   c)     checks scrap factor from MBM, ads that much %
> >    (for e.g. if scrap is 90%, then takes requirement as 110%),
> >
> >
> >            )     checks the available inventory balance (in IIM, WI,
> >    ILI files), reduce this available inventory from above requirements,
> > <   /FONT>
> >
> >
> >
> >            e     checks any Scheduled Receipts from shop orders (oen
> >    shop order) (FSO File ???), reduces this & works out Net Requiremen &
> >
> >
> >
> >            f)       then create Planned Order (KP) equal to this
> >    Net Requirement for this Finished Product.
> >
> >    < Indent>Net Requirements = (Requirements rom KMR +
> >    Min.Balance) * scrap factor  Inventory Available  Schedule
> >    Receipts from Shop Order;
> >
> >    Planned Order = Net Requirement
> >
> >
> >
> >    3)&bsp;     MPS run will also create Planned Orders (KFP)or all down
> >    levels of child MPS items, if exist, considering net requiremnt logic
> >    as explained above (only the difference is it takes requirement o
> >    demand from Planned order of Parent (KFP)).
> >
> >
> >
> >    4)     MRP run (MRP600), takes parent MPS item?s KF as it?s input,
> >
> >
> >
> >           a)     works out net requiremen as above,
> >
> >
> >
> >         &bsp;  b)     creates requirements (KMR) for all dwn levels
> >    child MPS as well as non-MPS items &
> >
> >
> >
> >    <FONT ize=2>        c)   &nbp; Only Planned Orders (KFP) for all
> >    down level child non-MPS items only.<FONT>
> >
> >
> >
> >    Net Requirements = Requirements from Parent Planned Orders i.e. KFP
> >    using BOM + Min.Balance) 96 Inventory Available  Scheduled Receipts
> >    from Purchase Order;<P>
> >
> >    Planned Order = Net Requirment
> >
> >
> >
> >    regards,
> >
> >
> >
> >    Prashanth
> >--
> >This is the SSA's BPCS ERP System (BPCS-L) mailing list
> >To post a message email: BPCS-L@xxxxxxxxxxxx
> >To subscribe, unsubscribe, or change list options,
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> >or email: BPCS-L-request@xxxxxxxxxxxx
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> >at http://archive.midrange.com/bpcs-l.
> >
> >Delivered-To: macwheel99@xxxxxxxxxxx
>
>-
>Al Macintyre  http://www.ryze.com/go/Al9Mac
>Find BPCS Documentation Suppliers
>http://radio.weblogs.com/0107846/stories/2002/11/08/bpcsDocSources.html
>BPCS/400 Computer Janitor at http://www.globalwiretechnologies.com/
>Replacement company web site (same company, new
>domain)  http://www.globalwti.com/
>
>
>------------------------------
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>End of BPCS-L Digest, Vol 3, Issue 173
>**************************************