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Hi Frederick, I think I am nearing to the concept. Is the following observation correct ? MPS MRP Observations When MPS (MRP500) is run, it takes Demand or Requirement (KMR) of Finished Product (Level 0 item) & creates Supply Planned Order (KFP) for the same item. This KFP of Level 0 item creates Demand (KMR) for Level 1 items. If level 1 items are MPS items, it will create KFP for the same or else will leave it as it is with only KMR. The Level 1 MPS item KFP will create Demand (KMR) for Level 2 items. If Level 2 items are MPS items, it will create KFP for them or else will leave them as they are with only KMR. This will continue till the Level where there is continuity of MPS child items. The point where there is discontinuity of MPS child chain, that point onwards, it will not create any record (KMR or KFP) for further down MPS children at MPS run stage. for e.g., in BOM structure, there are continuous MPS child from Level 0 to Level 3 whereas next MPS child is at say Level 6. In this case, MPS run will create KMR as well as KFP upto Level 3 MPS items, & create only KMR for Level 4 but will not create any of the records (KMR or KFP) for Level 6 MPS item (in fact from Level 5 onwards) because there is discontinuity of MPS item. is this correct ? However, when MRP600 is run, for non-MPS items, it will create KMR (if not already created through MPS run, in the above case Level 5 onwards) as well as KFP (Level 1 onwards) and for MPS items, it will check whether they are already having KMR & KFP. If not, it will create KMR & then KFP for such items which are unaddressed during MPS run such as Level 6 MPS item above. i.e. in the above example, it will create first KFP for Level 4. then based on this KMR for Level 5 which in turn will create KFP for Level 5 & so on. Is this correct ? Regards, Prashanth On Thu, 18 Aug 2005 Frederick C Davy wrote : >MRP500 will plan ALL items flagged as Master Schedule Items (CIC/ICMRP >field equal "M"), regardless of its position in the bill-of-material. This >is done so that an item that is at a third level in the B/M but is also >sold as a service part, can recognize external demand (forecast/customer >orders), as well as internal (dependent demand from B/M) demand. Also, if >an MPS item appears at the third level in the B/M, when MRP500 is run it >will pass KMR requirements to its first level childern, if any exist (if >it is a purchased part, it would have no childern). The term "Finished >Product", as I have used it, is anything that is sold directly to a >customer, or is a Planning B/M item.The rest of your logic is correct. > > > > >"p d" <prd2005@xxxxxxxxxxxxxx> >Sent by: bpcs-l-bounces+amkavoulakis=sealinfo.com@xxxxxxxxxxxx >08/17/2005 08:08 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] 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. > > > > > > > > > > > > > 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 : > > >Send BPCS-L mailing list submissions to > > > bpcs-l@xxxxxxxxxxxx > > > > > >To subscribe or unsubscribe via the World Wide Web, visit > > > http://lists.midrange.com/mailman/listinfo/bpcs-l > > >or, via email, send a message with subject or body 'help' to > > > bpcs-l-request@xxxxxxxxxxxx > > > > > >You can reach the person managing the list at > > > bpcs-l-owner@xxxxxxxxxxxx > > > > > >When replying, please edit your Subject line so it is more specific > > >than "Re: Contents of BPCS-L digest..." > > > > > > > > >Today's Topics: > > > > > > 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 > > > >To post a message email: BPCS-L@xxxxxxxxxxxx > > > >To subscribe, unsubscribe, or change list options, > > > >visit: http://lists.midrange.com/mailman/listinfo/bpcs-l > > > >or email: BPCS-L-request@xxxxxxxxxxxx > > > >Before posting, please take a moment to review the archives > > > >at http://archive.midrange.com/bpcs-l. > > > > > > > >Delivered-To: prd2005@xxxxxxxxxxxxxx > > > > > >-- > > >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, > > >visit: http://lists.midrange.com/mailman/listinfo/bpcs-l > > >or email: BPCS-L-request@xxxxxxxxxxxx > > >Before posting, please take a moment to review the archives > > >at http://archive.midrange.com/bpcs-l. > > > > > >Delivered-To: amkavoulakis@xxxxxxxxxxxx > > > > > > > > > > > >------------------------------ > > > > > >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 ââ?¬Ë?0ââ?¬â?¢ 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 ââ?¬â?? Inventory Available ââ?¬â?? > > >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 itemââ?¬â?¢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 > > > > ââ?¬Ë?0ââ?¬â?¢ 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 Ã? Inventory Available Ã? 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 itemââ?¬â?¢s KF as > > > > itââ?¬â?¢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 Ã? 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, > > > >visit: http://lists.midrange.com/mailman/listinfo/bpcs-l > > > >or email: BPCS-L-request@xxxxxxxxxxxx > > > >Before posting, please take a moment to review the archives > > > >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/ > > > > > > > > >------------------------------ > > > > > >-- > > >This is the SSA's BPCS ERP System (BPCS-L) digest list > > >To post a message email: BPCS-L@xxxxxxxxxxxx > > >To subscribe, unsubscribe, or change list options, > > >visit: http://lists.midrange.com/mailman/listinfo/bpcs-l > > >or email: BPCS-L-request@xxxxxxxxxxxx > > >Before posting, please take a moment to review the archives > > >at http://archive.midrange.com/bpcs-l. > > > > > > > > > > > >End of BPCS-L Digest, Vol 3, Issue 173 > > >************************************** > > > >-- > >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, > >visit: http://lists.midrange.com/mailman/listinfo/bpcs-l > >or email: BPCS-L-request@xxxxxxxxxxxx > >Before posting, please take a moment to review the archives > >at http://archive.midrange.com/bpcs-l. > > > >Delivered-To: amkavoulakis@xxxxxxxxxxxx > > > > > >-- > >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, > >visit: http://lists.midrange.com/mailman/listinfo/bpcs-l > >or email: BPCS-L-request@xxxxxxxxxxxx > >Before posting, please take a moment to review the archives > >at http://archive.midrange.com/bpcs-l. > > > >Delivered-To: prd2005@xxxxxxxxxxxxxx > >-- >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, >visit: http://lists.midrange.com/mailman/listinfo/bpcs-l >or email: BPCS-L-request@xxxxxxxxxxxx >Before posting, please take a moment to review the archives >at http://archive.midrange.com/bpcs-l. > >Delivered-To: amkavoulakis@xxxxxxxxxxxx > > >-- >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, >visit: http://lists.midrange.com/mailman/listinfo/bpcs-l >or email: BPCS-L-request@xxxxxxxxxxxx >Before posting, please take a moment to review the archives >at http://archive.midrange.com/bpcs-l. > >Delivered-To: prd2005@xxxxxxxxxxxxxx
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