Re: BPCS-L Digest, Vol 3, Issue 178

Hi,

Would like to fine-tune the following :

MPS Run (MRP500) Logic :

1) Customer Order (in make-to-order or assemble-to-order scenario) or 
Forecast (make-to-stock scenario) creates DEMAND or Requirement record
(KMR file) for Finished Product (Level 0 MPS item in BOM structure).

2) When MPS is run (MRP500), this KMR for Level 0 MPS item acts as an
Input & creates SUPPLY Planned Order record (KFP file) for the same 
Level 0 MPS item. While creating Planned Orders (KFP), system takes 
into consideration Minimum Balance, On-Hand Stock, Scheduled Receipts
& then arrive at a Net Requirement which is converted into Planned Order.

The Logic is :

For Manufactured Item

Net Requirement = Demand from Customer Order or Forecast or Parent or sum of all
                + Minimum Balance
                - On-Hand
                - Scheduled Receipts (Open Shop Orders)

Planned Order = Net Requirement

For Purchased Item

Net Requirement = Demand from Parent
                + Minimum Balance
                - On-Hand
                - Scheduled Receipts (Open Purchase Orders)

Planned Order = Net Requirement

While putting Planned Order Due Date, system takes into consideration
'Horizon Days' for that item & even if the DEMAND is within horizon
date (which is calculated by adding Horizon Days to Planning Start Date)
of that item, it creates Planned Order 1 day after the Horizon
Date for that item.

3) This KFP record for Level 0 MPS item creates DEMAND or Requirement
record (KMR) for it's children i.e. Level 1 items.

4) At this stage, if the child is non-MPS, the MPS run leaves it as
it is with the KMR record only.
However, if child is MPS item, taking this KMR Demand as an input, 
it creates Supply Planned Orders for this child using Net Requirement 
Logic & Horizon Days concept as explained in step 2 above.

5) If at least 1 item is found to be MPS at any Level, MPS proceeds 
further & creates DEMAND (KMR record) for its child i.e. Next Level,
in the above case Level 2.

6) Again it loops as per step 4 above. So while going down the Levels, 
if at a particular BOM Level, if no MPS item is found or if DEMANDS are 
satisfied with the available stock for all items at that Level, 
MPS stops there. 
From that Level onwards (downside),the generation of Planned Order(KFP) 
& next Level child Demand (KMR) is taken care by MRP run (MRP600).


MRP Run (MRP600) :

1) MRP takes over from a point where MPS run left. i.e. Last BOM Level
at which only DEMAND (KMR) is created & no Planned Order (KFP) is 
created for any of the items at that Level.
for e.g. if MPS run has left at Level 2, creating KMR for all items 
at Level 2 & no KFP for any of the item at that Level, MRP will take 
over from Level 2 downwards & works out KMR & KFP as mentioned in
steps of MPS run.

2) So, last level KMR becomes Input for MRP run which will work out
Net Requirements as per the Logic explained in Step 2 of MPS run,
convert these Net Requirements into Planned Orders (KFP) for that
Level children taking into consideration 'Horizon Days' for that 
Level items & pass this as a DEMAND to the next Level creating KMR
record for next Level & so on.

Would appreciate if anybody would like to share the thoughts on above.

Regards,
Dnyanesh



On Thu, 18 Aug 2005 bpcs-l-request@xxxxxxxxxxxx wrote :
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>Today's Topics:
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>    1. Re: Re: [BPCS-L] Re: BPCS-L Digest, Vol 3, Issue 173 (p d)
>    2. Negative Invoice Number on RAR (Kylea White)
>    3. Re: Re: [BPCS-L] Re: BPCS-L Digest, Vol 3, Issue 173
>       (Frederick C Davy)
>
>
>----------------------------------------------------------------------
>
>message: 1
>date: 17 Aug 2005 12:08:21 -0000
> from: "p d" <prd2005@xxxxxxxxxxxxxx>
>subject: Re: Re: [BPCS-L] Re: BPCS-L Digest, Vol 3, Issue 173
>
>
>Hi Frederick,
>
>I will check the possibilities mentioned by you.
>
>However, Sorry to miss out some points as follows :
>
>When I run MRP500, Planned Orders (KFP) as well as Requirements (KMR) is 
>getting populated for ALL LEVEL MPS items (CIC/ICMRP field equal "M"), say if 
>there are MPS items at 0,1,2,3 levels, then for all these level MPS items, KFP 
>as well as KMR is getting populated.
>
>Whereas as explained by you, it should generate KFP for Level 0 MPS (i.e. 
>Finished Product) & KMR for Level 1 items - MPS as well as non-MPS items (if 
>any at level 1), am i right ?
>
>And further MRP600 run, from this KMR for 1st level child, should generate the 
>KFP for the same 1st level child/s to satisfy unsatisfied (Net) requirement of 
>this 1st level child/s.
>This KFP should generate demand for Level 2 child (MPS as well as non-MPS 
>child item) (if Level 1 child is MPS) & so on till All levels down. Am I right 
>?
>
>Regards,
>Prashanth
>
>
>On Tue, 16 Aug 2005 Frederick C Davy wrote :
> >Prashanth,
> >
> >I do not loose the KMR records when I do a generation run. A few questions
> >I would have for you would be: 1. Do you have the BPCS Forecasting module
> >setup and interfacing? If so, there is a routine that clears the KMR when
> >FOR540 is run just before it downloads the new Forecast into MRP100. 2. If
> >you have the Forecasting module setup, do you have the Item Master record
> >marked that it is a Forecasted item (IIM/IFRFG = Y), and the planning
> >warehouse flagged as a Forecasted warehouse (IWM/LFRFG = Y)? If so, your
> >last place to check would be the MRP820 System Parameters to see if your
> >default settings for demand code, horizons, and prorate forecasts are set
> >properly. If your KMR records are cleared when you do a generation run
> >that would mean that all your planned orders for Forecasted items would
> >not have a pegged-to association in MRP300 (open MRP300 for a forecasted
> >item, observe a planned order, and then press F13 to see the forecast or
> >customer order requirement that represents the demand), and if that
> >happens, the next time you do a generation run all the planned orders
> >would be removed by BPCS MRP since there is no longer any demand. If this
> >is what is happening, I would suggest that you call (312) 474-7400
> >(Helpline) because you have a program problem.
> >
> >
> >
> >
> >
>