We are on 405CD using AS/400 model 170 whose disk space is almost 80% consumed. Due to BOM complexity & prior MRP discussion here, we run several extra MRP500 on each facility ... I figure in aggregate maybe 15 runs of MRP500 MRP600 when all facilities and reruns into consideration. Currently we only run CAP600. We used to also run CAP500. We capture some data from CAP files for our own reports.

I have experimented with using multiple JOBQ running con-currently & concluded that is generally counter-productive to performance. Now we sometimes use alternate JOBQ for quicky tasks to get past heavy duty number crunching jobs placed in their own separate JOBQ.

Occasionally we have some high volume data entry by some customer whose requirements are extremely urgent, such that we try to schedule an MRP net change at approx lunch time for most of the office workers. Because there are always a bunch of people working throughout the day, doing a simple MRP500 600 one time each on one facility, in combination takes just over one hour.

When I run the full regeneration & extra net changes (due to BOM complexity) in evenings, it is just nite shift workers using some inquiry, and me for a few hours mainly in files unrelated to MRP.

The difference in speed I figure has to do with the volume of people making updates to the same files that are input to MRP work.

We have added some tasks to the normal job stream, such as after MRP's list any items with active MRP requirements, which are lacking in costs (null ... no entry in CMF). This is because we run a lot of query/400 reports that expect all relevant files to match on all contents.

By BPCS standards, there is an enormous volume of overlap in our operations, so CAP has only limited value. We have develioped our own modifications to get data like CAP functions the way our people want.

When the mass of co-workers leaves in the evening around 5 6 pm, I do Billing then post to General Ledger & get reports via Ops Nav to managers e-mail for first thing next morning, then load up JOBQ with MRP etc. Some nites I also include a Standard Cost Rollup. All of the MRPs are done in maybe 3-4 hours. A single cost rollup can take 3-4 hours. Sometimes we copy standard to simulation first, then afterwards can run a report showing what's different standard vs. simulation. I also have a simulation that is a copy of actual cost, to roll up the simulation, to see what the costs would be if we were allowed to roll up actual.

Off top of my head I figure we have maybe 3,000 customer order lines active, 5,000 shop orders, 500 PO's, over 1,000 inventory transactions a day, mainly from shop order reporting.

Another measure of our data volume.
If i run a SAVE-21 it takes about 2 3/4 hours.
There is something I call a SAVE BPCS which takes 1 hour, and uses GO BACKUP.
That saves all the data associated with BPCS files & software, including modifications.

On weekends I run a shop order purge (it takes 2-5 hours) followed by MRP & CAP600, along with a few other jobs. SYS120 can take an hour, but if run first, a lot of other stuff runs in more than 1 hour faster.

Before we had BPCS, our ERP was MAPICS, Except for MAPICS being Y2K compliant decades before any other ERP, it was vastly inferior to BPCS, especially in how long MRP took to run.

On an earlier version of BPCS (System 36), MRP was structured quite differently, such that it was only practical to run it on weekends, plus a human being had to be present for 1/2 a day, feeding it, so we made our own modifications to automate the process. Even so, it was impractical to do a regeneration during the week, because if we launched it when leaving the office in the evening, it would still be running when we returned the next morning. That is no longer a reality, thanks to using the siizng questionairre wisely, analysing & getting rid of dead orders, periodic updates to hardware speed, and being hard nosed about people who leave their work stations signed on when done for the day.

While modifying the process, I had to study the logic of MRP.
I was amazed at how much good work this software got accomplished in so little time.

Today we can load up the JOBQ with a ton of tasks, then leave the 400 running unattended. This is never a problem except end-fiscal month, which we just had last weekend. I got out of there Fri nite after midnite, while the JOBQ load did not complete until 9 am Saturday. Because co-workers sometimes work Saturday mornings, I was back there Saturday working 2 pm to 2 am, then back again Sunday for another 5 hours. How long the MRP takes is the least of my concerns.

I am still working on EOM stuff. Basically there are a ton of report modifications that I call "Excel friendly" which I am combining into Excels to deliver to various people: GL Dump; Commodity Content; Sales Analysis; Unused Inventory.

End Year will be a nightmare because we also do a physical inventory at that time, the company insists on year ending Dec-31 which is middle of week. I will be doing EOM thru INV900, then people will be working several days on physical inventory, plus I have a set of programs to replace the standard costs. The company grants workers some days off during holidays, which gives me just enough days to get the job done.

We use the GO CMDSCDE to run some standard reports waiting for people first thing in their morning. We do not have IBM advanced scheduler or ROBOT from HELP SYSTEMS so it has not been practical to put many BPCS tasks there.

Al Macintyre

We are running BPCS 8.0 and in the process of converting to LX. We are, however, using another program to run MRP, and re-evaluating it.

My question is - if you are running BPCS MRP nightly, how long does it take?

Dick Bailey
MCFA, Inc.



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