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  1.  Home
  2. BPCS-L
  3. August 2005

MRP -> Shop Orders

Managers are questioning the level of clerical support needed to launch paperwork to our shop floor, so I'm reviewing what alternatives may be available to 405 CD. * Do we really need to report actual time for the labor, since the quantity done is good enough for the dispatch report? What is the cost to the company tracking that, and what is the benefit knowing performance and actual costs, when we don't track everything anyway, such as setup time? And if we can eliminate actual time, then we not need to know which employee did it, just plug in a dummy clock # for everything. * We have a proposal for discussion on the table to alter the sequence of shop paperwork from by shop order to by shop dept, then item, then shop order. * I have rejected several requests to have MRP250 sub-assembly data by end item customer, because no one in the company seems willing to enter and maintain correct info by item what customer it is for, figure out which is the right customer for components that are common to several customers, and other variations
We do full MRP500 600 CAP600 regen nitely, then production planning uses MRP250 (a several hundred page report which we have modified), MRP540, SFC550. If there's a rush item (which happens a lot): SFC500, SFC520. The only JIT we do is JIT600 series. 

Is anything obviously missing from this picture?

I think what we'd like to have is
1. A way to put a stop order on MRP requirements we not want to make right now, with optional reasons 1.1 Engineering Change in the works, hold off on production start until this done 
1.2 Onsies uneconomical, live without them
1.3 Tooling down for repair, hold off on adding to the bottleneck until they get done 
1.4 Serious shortage, don't aggravate
1.5 This work is to be moved to another factility, wrap up what is here
2. Then when we have flagged stop on everything MRP says we need, that production planning says we not gonna make, at this time, have something that will automatically release & print 100% planned orders in some date range, whose MRP251 conclusions would be "Ok to release" 100% because we have all the raw materials needed, and where there are multiple requirements for same item within the selected date range, aggregate the whole thing into a single shop order ... this would replace production planning now having to individually release stuff ... which is several thousand new shop orders each week 
3. Full regen would not undo the "stop flag"
4. Reports listing stuff with the "stop flag" for review which to take off that condition 5. This way we shift focus from manual effort getting the non-exceptions paperwork on its way, to managing the stop conditions that we never seem to have time to deal with, and thus they tend to pile up, complicating the task of selecting what to release 

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Al Macintyre  http://www.ryze.com/go/Al9Mac
BPCS/400 Computer Janitor ... see
http://radio.weblogs.com/0107846/stories/2002/11/08/bpcsDocSources.html

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