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Evo-ERP and DBA Classic >> Manufacturing >> MRP Help and clarifications
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Message started by cmsk on 11/08/05 at 04:17:01

Title: MRP Help and clarifications
Post by cmsk on 11/08/05 at 04:17:01

Hi,

We're in the process of diving into utilizing MRP and need some feedback being that we've never used it before. For one, the forecast part of MRP I don't see us using, as for us to guess what our sales will be a month from now is nearly impossible. One thing we really could use some good examples on, is how Expedite and Delay buffers work. The example of Expedite in the help file is pretty clear, but I wouldn't mind another one. The Delay buffer wording is rather confusing and I'm not sure how that works. This in particular :

Any order due to arrive within the delay buffer period prior to a requirement is assumed by the MRP program to be designated for that requirement and will receive a DELAY action message on reports. Any order that arrives prior to the delay buffer period is assumed to be for some other requirement and will receive a REVIEW action message.

Both sentances sound like they're sayin the same thing... to me anyway. Can anyone clarify this with a comprehensive example?

Many thanks

Title: Re: MRP Help and clarifications
Post by shadowcaster on 11/08/05 at 06:57:18

if its going to come early it will tell you to delay

if it comes really early it will tell youi to review

so

if the delay buffer is 30 days and it going to come in 29 days early it will tell you to delay it

if its going to come in 31 days early it will tell you to review the whole situation.

j Dub

Title: Re: MRP Help and clarifications
Post by Tim Keating on 11/08/05 at 07:26:09

And that is a very clear and simple answer to how the Delay Buffer works.

There is another parameter called Delay Sensitivity which controls the printing of the Delay message.

Using the example above, if you set the Delay Sensitivity at 7 days :

If the item is set to arrive 0 to 7 days early you will get no message at all.

If it is set to arrive between 8 and 30 days early you will get a Delay message.

If it is set to arrive 31 or more days early you will get a Review message.

(you said Expedite Tim but I know you meant to say Review so I edited it - Lynn...)

Title: Re: MRP Help and clarifications
Post by cmsk on 11/10/05 at 04:44:49

That was helpful, thank you very much.

Title: Re: MRP Help and clarifications
Post by cmsk on 11/23/05 at 04:32:17

Greetings,

Could someone shed some light on the best way to start implimenting MRP -- a good model outlay would be helpful. Getting into this with all of our existing products and part numbers already in place seems a bit overwhelming. One thing we've decided to do is create a faux product along with applicable subassemblies and parts and running MRP tests utilizing that part along with generating faux orders for the product and for individual parts; just to see how the reports look / work and to overall get a feel for things. I figure this way, we won't have to battle with creating fake orders for "real" products only to mess up our already screwed up inventory. Does this make sense to do?

What are the key 'ducks' that need to be in a 'row' for MRP to be usable?

Title: Re: MRP Help and clarifications
Post by Karen Mason on 11/23/05 at 05:36:21

Some areas of the MRP need "shoring-up". There are many errors in the reports that are generated. I use it as a "guide" and review each and every item before ordering (requirements, current orders, etc). I use it extensively for purchased items.

You may want to create a Test Company. You can transfer all your existing data to the test company and use it to "tryout" different things. One problem: make sure you are in your "real" company when doing real work. It's easy to forget you are in your test company and merrily go along and do a bunch of work that will need reentered.

Title: Re: MRP Help and clarifications
Post by Karen Mason on 11/23/05 at 05:38:46

...further to my last post. If you create a test company and transfer your data, you must be careful who has access to the test co and modules.

Title: Re: MRP Help and clarifications
Post by cmsk on 11/23/05 at 06:11:29

Well that doesn't sound very comforting... :(

We're trying to impliment MRP to aid with our inventory problems. Right now, we're monitoring just about everything manually because when a WO is generated for a product, it doesn't take into account any of the items on lower levels of the BOM or if an item is used elsewhere on another product. This makes life extreamly difficult for the person who's monitoring shortages. Being that MRP 'drills down' to through all subassemblies and individual items, it seems to be the best option, but obviously we'll need to monitor it... which is why I wanted to create a 'dummy' product and run with that -- to hopefully understand the workings and gain some faith. The test company is a good idea, but I think using all of our existing information would be seriously overwhelming to my staff.

Thanks again for the input Karen.

Title: Re: MRP Help and clarifications
Post by Tim Keating on 11/23/05 at 07:33:31

It's easy enough to limit access to the test company through the password security module.

I also always name the company "***Test Company - Do Not Use***" so that shows at the top of the window (in Classic anyway).

About MRP - I think you will find it very valuable and a huge time saver once it is set up.

My initial advice is to make sure all your data is good - assigned vendors, reorder levels, reorder amounts, lead times, BOM's, buffers etc...

Make sure all parts are selected to be included in MRP in IN-B screen.

Comb through your data and be sure there are no errors and that all numbers are accurate.

It will be a process of evolution so you might implement in stages to begin with. We have been using it for years and we still generate WOs and POs manually with my close oversight.

We drive from forecast though raw material purchasing each month in a build to stock environment with over 250 active Finished Goods and over 2000 part numbers. Whole process takes about 2-1/2 days for me and an assistant.

Title: Re: MRP Help and clarifications
Post by cmsk on 11/23/05 at 07:57:11

Tim Keating wrote:

It will be a process of evolution so you might implement in stages to begin with. We have been using it for years and we still generate WOs and POs manually with my close oversight.

Thanks for the feedback Tim,

This is what I'm looking for at this point... what the process would be to 'implement in stages.' Could you elaborate on what you mean by that? Is this to say, pick a product line and implement MRP with those products and then move on to the next? Or do you mean something else? I'm looking for a 'layout' of how someone started with this and maybe what 'gotcha's' to look out for along the way.

Thanks again

Title: Re: MRP Help and clarifications
Post by Karen Mason on 11/23/05 at 13:26:41

Sorry Chris, didn't mean to be negative. We use the MRP module, it just could use some help.

You can start with a given segment. Pick something easy to implement and something you are closely attuned to. In my case, it is purchased parts for a given product line and steel. Steel is something I know inside out-I know when something seems right or wrong and can investigate it fully.

The BOM's have to be accurate. In our first attempt we added a scrap % to the BOM, then our sales dept added a % to the work orders, then the purchasing dept added another %. All of a sudden 20% more products were being ordered then were needed. We removed all scrap from BOM, and used WO only to add on any overages we want to produce.

If you aren't tied to specific reorder levels and amounts, they can be worked on or added later. We only have them on some products.

Order entry and work orders must be done on a very timely basis, as that will drive your mrp if you do not use forecasts. Must generate the MRP after entering orders.

I have only recently started using the assigned vendors. We were recently ISO certified and as part of that process we are trying to tighten the control on purchases.

We have some assemblies/subassemblies we make month in and month out for a customer. I have tried to get the planner to use MRP but it has been kind of an uphill battle on using it to plan work orders.

You can generate the MRP any time. Then pick one or two items you have to order (either PO or WO) and see how MRP differs from what you would have done in your system. Check out why there are differences-is it due to the BOM or something else?

It just takes some practice and getting used to what reports you want to use. I use MR-H the most, sometimes I use MR-G.

Guess this is long winded so I better quit, go scrap the snow off my car, and start my Thanksgiving weekend!

Title: Re: MRP Help and clarifications
Post by cmsk on 11/28/05 at 03:05:49

I hope you had a great holliday weekend Karen.

Thanks for the "long-winded" responce... :-) Actually, that and even the negativity is what I'm looking for. My personnel spend alot of time doing so much of this manually and right now everyone is a bit leary on potentially spending an absorbent amount of time trying to get MRP up and running, only to find out it doesn't do what we expect or want it to... and feel comfortable with it. So, the "real" examples and input is what I need... the good, bad, and ugly.

Title: Re: MRP Help and clarifications
Post by Nancy_SP on 11/28/05 at 04:33:13

This is how we have used MRP the past 3 years. I set all items that I buy on expedite 360 day and delay on 180 days. Without any sensitivity because some of my vendors take a long while to deliver or my plannned purchase orders take longer than MRP will see. If my po is not within the range of buffer days MRP will not see it and will put it on my buy list. If you set your buffers like on 30 and 20 days sequences . You will get a lot of more items on your list. You cannot keep up with manufacturing in that short of a time frame, not even purchasing. I set finished items on 60 & 30 days and the lower manufacturing levels on 120 & 90 or 90 & 60.
This is something you have to massage over time to your needs. You still have to review all. We have approxmently 2000 part number and the reorder list can be mind bogging . Start a little on low side and as you see unnessary items on list then raise the buffers. Hope this info helps.

Title: Re: MRP Help and clarifications
Post by cmsk on 11/28/05 at 08:15:51

Every little bit helps Nancy, thank you. However, I would think that setting some of those numbers that high, would defeat the purpose of MRP altogether... No?

I'm actually toying with the idea of going to Phoenix to do some "networking" as I feel that's always the best way to learn (that and practical knowledge). I can't see spending $800 for the overall training however, we know the other parts of DBA pretty well at this point. Parts of the Symposium could be informative, but I think the discussion sessions would be the most advantageous to us at this point.

Title: Re: MRP Help and clarifications
Post by shadowcaster on 12/01/05 at 08:19:15

I wouldn't waste time with the test company.

set reorder levels on everything you want to stock
reorder levels should be set by a formula and intuition

I used a spreadsheet to get the initial numbers based on number of turns I wanted Lot size ect.

So if I use 12 a year of x item and I want 4 turns I make 3 at a time when I get to 1 or zero depending on replenishment time the system reorders

set some lead times on items this can be done by range or type so its fairly quick to get basic numbers in the system.

Once items have lead times use the lead time generator to generate lead-times for assemblies and finished goods.

after this

what I would do is run the mrp ON everything in the system MR-F

run the report MR-G to a file only for M items and get the data in excel.

using M will make a list of things you need to make to make the MRP happy. You need to get M type items in shape 1st before you can get purchased items working.

Do you need these items do you need to set the reorder levels so the mrp wont want to make them.

Look at this list adjust items as necessary you may have many items to adjust.

OLD work orders outside the buffer date range will need to be fixed too fix the dates on them or cancel them.

I use wintask to adjust the items by using the data in the spreadsheet and having wintask automate the dba data entry process. Even if I had to adjust 3000 items wintask could do it in a few hours.

rerun the MRP MR-F
rerun the report MR-G m type items
you rerun a lot

don't worry about buying stuff until the m type items look clean.

don't worry about delay and expedite messages Until later.

Do the same thing for with MR-G on B items these are things you need to buy.

if you need them buy them !
If not fix them so they fall off the report.

mostly this involves fixing min levels
fixing dates on old work orders

I got my system mostly clean in a week using this method. over 10,000 items

It will never be totally automatic but it automates 99 % of work order generation and purchasing.

We have cut stock and maintained good deliveries with the MRP its not hard to use it just takes some persistence to set it up.

if the system is calling to make of buy something and you cant figure out why use MR-G on that item to see why it wants some more.

set the expedite and delay buffers wide to start with
Exp Bufr: 360 Del Bufr: 360
Exp Sens: 1 Del Sens: 30

I have mine set like the above for all items

I run the MR-H to an excel sheet look thru the items fix and adjust rerun MR-F / MR-G until the list looks good and then issue work orders.

same with PO's
run fix run fix ect. run issue po's

once po's are issued we review the qty one more time beat up the vendor on price and issue the po's
we use as many as 50 po's in a week.

couldn't live w/o the MRP

I'm sure there is something I'm missing here but it should get you started.

J Dub

Title: Re: MRP Help and clarifications
Post by cmsk on 12/05/05 at 10:54:06

WOW, thanks for that shadow -- some very useful info here. This is the information you simply can NOT get from books / manuals and why we're hoping planning on heading out to Phoenix in February.

Title: Re: MRP Help and clarifications
Post by cmsk on 12/06/05 at 06:17:19

shadowcaster wrote:

set the expedite and delay buffers wide to start with
Exp Bufr: 360 Del Bufr: 360
Exp Sens: 1 Del Sens: 30

I have mine set like the above for all items

With the Buffers set to such high values, do you ever get any messages on the MRP reports?

Title: Re: MRP Help and clarifications
Post by shadowcaster on 12/06/05 at 07:56:22

Yes we get plenty of mrp messages

That's why I only print out the order action report using M or B only once in a while do we used delay or expedite but that's coming soon.

I just took over the purchasing job. (in my spare time) :-) actually I just issue the po's and do the 1st review.

other people follow up manually by job to make sure we get stuff in ect they usually use shortage reports.

once you get the M and B reports clean the system is very useful and performs a cross check on what everyone is doing in the system.

Delay expedite and review would be great if we had that much time maybe by changing the buffers and stuff I could do better but right now the system is getting stuff in here at the right time and all my work orders are issued for what I need. the only hard part is getting people to complete the work orders !!

see you in pheonix

J Dub

Title: Re: MRP Help and clarifications
Post by cmsk on 12/06/05 at 08:54:37

This is starting to make some sense. At least I feel I have a place to start.

Thanks again so much for your input, and yes we'll most likely see you in AZ.

Title: Re: MRP Help and clarifications
Post by cmsk on 12/12/05 at 08:13:45

Hey again,

Question on lot size. It referrs to a "typical production run," which would seem to indicate that it's related to made parts as opposed to purchased parts, but from what I can tell, we need a lot size on everything that would be run through the 'generate lead times.' Is this true?

How does this relate to reorder amounts?

Thanks

Title: Re: MRP Help and clarifications
Post by Lynn Pantic on 12/12/05 at 10:00:36

Generate Lead Times uses the Routing so it is only Make parts.

Title: Re: MRP Help and clarifications
Post by shadowcaster on 12/13/05 at 16:05:11

To set lead times for purchased goods you need to do it manually BUT you can do it via an import or use something like wintask to do the data entry for you if there are a lot of items.

J Dub

Title: Re: MRP Help and clarifications
Post by Lynn Pantic on 12/13/05 at 17:36:31

You can also use MR-D to globally set the lead time for ranges of items that are similar.

Title: Re: MRP Help and clarifications
Post by cmsk on 12/16/05 at 03:05:40

Thanks again. Lynn, I didn't know about MR-D -- that's going to be quite helpful.

Title: Re: MRP Help and clarifications
Post by shadowcaster on 12/16/05 at 14:16:55

I was looking for that I forgot to look under MR
I thought lead time was only adjustable under In-B
My leadtimes are a mess I need to work on them.

also I just noticed the forum icon in EVO Nice !

however my unit converter wont work Its always something

J Dub

Title: Re: MRP Help and clarifications
Post by cmsk on 12/19/05 at 07:16:03

The lead times are understandably easy to miss, as the lead time input box is on the secondary screen. So upon a quick view, chances are you'd not see it right away.

Title: Re: MRP Help and clarifications
Post by shadowcaster on 01/11/06 at 22:06:32

getting any results ?

J dub

Title: Re: MRP Help and clarifications
Post by cmsk on 01/24/06 at 06:42:17

shadowcaster wrote:

getting any results ?

J dub

We are, slowly but surely, working towards implementing. We've created a test product and will be running MRP on it with fake PO's and WO's. When we're comfortable and acclimated with the reports, we'll move to "real" products. Part of the delay in moving ahead faster with this, has been due to some large bigs we've been trying to pull together... so everyone has had their focus on other things for the past several weeks.

I'm sure I'll have some other questions as we move forward and I'll keep you up to date as well. Thanks again for all of your "real world" input... always the best kind.

Title: Re: MRP Help and clarifications
Post by shadowcaster on 01/24/06 at 08:17:23

I kept waiting for others to do things
for a few years I waited
then I did the whole thing myself
no tests no more waiting
best thing I ever did because we got really slow and the people I was waiting on are now gone and when things picked up I didnt need them because the MRP was working.

All you need are good BOM's and routings generate lead times on things you make set leadtimes on what you buy.

what do you get when you run MR-G for B and M types ?

J Dub

Title: Re: MRP Help and clarifications
Post by shadowcaster on 03/15/06 at 16:13:22

anyone making any progress with getting mrp to work.

I could not live with out it

J Dub

Title: Re: MRP Help and clarifications
Post by cmsk on 03/22/06 at 06:17:27

I've / we've been picking away at it.

I'm currently running details on a sample part. Question when running MR-G.

I've set up my On Hand, Reorder Level's and Amounts for the Main part, subassemblies, purchased parts, and raw materials. If I run a reorder report, IN-D, it shows the over/under amounts; some of which are negative -- which is fine. When I run MR-G, shouldn't those negative items show up on the MR-G report? OR, does MRP only start action suggestions with the creation of W/O's and P/O's?

Let me know if any of this isn't clear...

Many thanks

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/22/06 at 09:19:53

MR-G generates "planned" orders for required actions. If you are short an assembly, a planned work order will be suggested and the subassemblies and purchased items pegged to it.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/23/06 at 05:14:42

Tim Keating wrote:

MR-G generates "planned" orders for required actions. If you are short an assembly, a planned work order will be suggested and the subassemblies and purchased items pegged to it.

Thanks for the response.

So, if I create a SO for the Main part, and I'm short on purchased parts, subassemblies, whatever... the MR-G should suggest actions on the items I'm short on?

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/23/06 at 08:19:29

Yes, just try it and you'll see. There is no harm to running MR-F, G, I. Nothing in the system is affected until you start generating Work Orders or Purchase Orders which, by the way, we only do manually.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/23/06 at 08:43:13

Tim Keating wrote:

Yeah, I sucked it up and did some experimenting. :) Luckily we don't have THAT many items -- soooo running MR-F doesn't take forEVER!!!

Anyway:

I generated a SO for the main part. I have some items (subassemblies, parts, and raw material) that need to be made or purchased to complete the order. I ran MR-F and then MR-G and the only thing I get on the report are several of the main parts' items -- but I don't see what those items correlate too. There are no messages or actions listed. According to my numbers, I should be having to make and purchase many of the sub-items to complete the order. I'm under the assumption that MRP would suggest WO's and PO's (planned orders), but I'm not getting any suggestions on items that I either don't have, or will fall short on to complete the SO.

Manually creating orders is fine (we're doing that now anyway), but what I need the system to do, is let us know (suggest) when we need to make or buy items based on orders placed without manually monitoring the inventory on everything.

(edited to fix the PO / SO confusion... if hope)

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/23/06 at 09:46:32

cmsk wrote:

I generated a PO for the main part.

What inventory type is the main part?

Does it have a Bill of Material?

Are you assembling components to create the main part?

Maybe you should you be creating a Work Order for the main part.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/23/06 at 09:57:39

Tim Keating wrote:

What inventory type is the main part?

Does it have a Bill of Material?

Are you assembling components to create the main part?

Maybe you should you be creating a Work Order for the main part.

It's a type F. I've set it up to have several subassemblies, which in turn have purchased parts along with made parts from raw materials. I pretty much set it up like many of our actual products, only a bit more scaled down, so that monitoring of it wouldn't become a monumental endeavor and so that we could get a realistic view of how things work.

So, yes, it has as BOM, purchased, made, and assembled components.

I can try generating a WO, but shouldn't MRP "suggest" a WO, if I don't have enough stock to cover the SO???

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/23/06 at 11:52:04

You had me confused because your previous post indicated you had generated a PO for the part. I assume you meant Sales Order.

So, yes, if you have an SO quantity exceeding the O/H quantity and you don't have any otherwise "on order", MRP should suggest a Work Order.

Check IN-B for the Parent Part. There is a button on the bottom of the screen called "MRP". In this screen you should have the "Include in MRP..." box marked "Y".

You should also have a reorder amount entered, either here or on the first IN-B screen.

When you run MR-F, be sure to include Sales Orders in MRP Generation and run for all inventory types.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/24/06 at 04:48:34

Tim Keating wrote:

Sorry 'bout that Tim... yes I meant SO not PO. I was thinking from a purchasing point of view when I wrote that, not a sales POV... Stupid mistake and sorry for the confusion.

ANYway.

Yes, I'm set up the way you suggested, but I went through -- double checked -- and ran everything again (MR-F, that is). I have an O/H quantity of 10 items, I'm creating a SO for 15, and I get nothing suggested when MR-G is run. With the way I have it set up, I should be short on A. five pieces of the main part, and B. a variety of raw materials, purchased parts, and subassemblies. The only thing the report lists, are five items total with no details of why they are listed or suggestions of what to do... Shouldn't it at least be suggesting that I generate a WO for the five main parts that I'm short? Again, with the way I have my inventory numbers, I should be short on EVERY component of the finished main item.

p.s., I really wish this forum would notify me of replies... I have it checked but it doesn't, not has never worked...

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/24/06 at 08:09:55

What is the Ship Date of the Sales Order you entered?

What are the buffer settings for the Parent Part? (Check MR-D, there a 4 buffers.)

Can you see the units on Sales Order in IN-A for the Parent Part?

Title: Re: MRP Help and clarifications
Post by cmsk on 03/24/06 at 08:28:16

Tim Keating wrote:

The ship date is set for 3/31/06.

I have the MRP settings for the items at Exp Buff 30, Sensitivity at 1
Delay Buff at 30 and Sensitivity at 7.

Yes, the SO is showing up in IN-A, under SO's.

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/24/06 at 08:55:54

I'm getting close to stumped. I'm sure something isn't set right.

Just to be sure, even though I asked before. In MR-F screen, is Include Sales Orders? set to "Y"?

Can you post, email or fax an image of the MF-G printout and IN-I printout for the parent part? Maybe BM-B as well?

tim@motorguard.com
Fax 209-239-5301

Title: Re: MRP Help and clarifications
Post by cmsk on 03/24/06 at 11:00:55

Tim Keating wrote:

Well, I guess I don't feel so dumb now... :) I'm more than stumped at this stage.

Yes, I most definately chose 'Y' to include SO's.

I've put together a PDF of the reports ... here http://homepage.mac.com/WebObjects/FileSharing.woa/wa/default?user=asrai&templatefn=FileSharing10.html&xmlfn=TKDocument.10.xml&sitefn=TKSite.5.xml&aff=consumer&cty=US?=en for any one who cares to take a look. I'm also emailing this to you.

Greatly appreciated Tim!!!!

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/24/06 at 12:11:54

I'm concentrating on the Parent Part, (TP-MRP) because whatever is hanging that up is likely hanging up everything downstream.

The MR-G report shows balances that don't agree with IN-I so I would run SM-J-C, Master Level Reconciliation, on TP-MRP only and see what you get.

Title: Re: MRP Help and clarifications
Post by shadowcaster on 03/24/06 at 18:30:59

I only use mr-g when Im haveing a problem with some planed item

MR-h is where you get what you need to get wo's and po's ready to go.

run mr-g with only type M selected

generate wo's for those items or fix them to get them off the list.

then run mr-g for B types to see what the system wants to buy.

I now generate all po's right from mrp

J dub

Title: Re: MRP Help and clarifications
Post by cmsk on 03/27/06 at 05:37:54

Tim Keating wrote:

Ok, did that, and it deleted blank records from several files (BKICMSTR, BKICLOC, INVTXN). I re-ran MRP, and still get the same results.

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/27/06 at 08:06:49

Bring up IN-A for the Parent Part (TP-MRP). Hit the Locations button, I'd like to see what is there.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/27/06 at 08:10:20

Looks like the same as the IN-I. On hand 10, SO/BO 15.

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/27/06 at 09:46:11

???

I think the gene pool on this thread is getting too shallow.

Hopefully someone will jump in and show us what we're missing.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/27/06 at 10:59:48

Yeah, quite honestly I'm a little surprised that some of the IS guru's haven't chimed in here.

How about it gods of the application code world. It appears that my "issue" has even stumped those who are familiar and confident with MRP. In turn, this isn't instilling much confidence in yours truly.

Let's have some additional input on this.

Title: Re: MRP Help and clarifications
Post by Lynn Pantic on 03/27/06 at 15:34:51

I tried looking at the PDF of reports but the link doesn't work anymore. If you send it to me or post another link that works I will take a look.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/28/06 at 04:12:54

Lynn Pantic wrote:

I tried looking at the PDF of reports but the link doesn't work anymore. If you send it to me or post another link that works I will take a look.

Hmmm, so it doesn't !?!? Rather odd, anyway, try this one:

http://homepage.mac.com/asrai/.cv/asrai/Sites/.Public/DBA-Reports.pdf-zip.zip

Thanks Lynn...

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/28/06 at 10:19:27

Page 13 of your printout tells the whole tale. Because the MRP Beginning Balance is 15.00*** and the Sales Order is for 15.00, no action is required and no Work Orders suggested.

For laughs, you might try issuing another Sales Order for, like 8 parts and see what happens.

Check values in Maintain Database for TP-MRP part:
BKICMSTR File BKIC_PROD_UOH Field =
BKICLOC File BKIC_LOC_UOH Field=

UT-K-E can be used to consolidate multiple locations and rebuild BKIC_LOC_UOH to single value.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/28/06 at 11:11:09

Tim Keating wrote:

I guess the main question is, how did that MRP beginning balance end up at that value? I don't even know what that is. I'll try another SO and the other suggestions, but I'm not too familiar with the Maintain Database section of DBA.

Continued:

Okay, I was able to work through the Maintain DB areas and the fields in those files don't show anything much different than the reports show. Again, I have no idea what that MRP beginning balance number is or how it was set to 15.00***.

Issuing another SO did nothing except add another line to the TP-MRP report with the negative quantity of the new SO.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/29/06 at 04:33:04

Tim Keating wrote:

UT-K-E can be used to consolidate multiple locations and rebuild BKIC_LOC_UOH to single value.

I am not even slightly familiar with what this is or does. I looked into it this morning, and from the Notice it presents, it seems like it's going to alter much more than I need. Until I have a better understanding of what's happening with this utility, I'm not going to run it.

Still can't find any reference to the MRP beginning balance number...

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/29/06 at 08:35:37

I'm going to stop posting here after this so someone else will hopefully jump in, but check this old thread anyway:

http://www.istechforum.com/cgi-bin/YaBB.pl?board=DBA_MFG;action=display;num=1080938716;start

Title: Re: MRP Help and clarifications
Post by cmsk on 03/29/06 at 10:40:14

Tim Keating wrote:

Thanks again Tim, and yes I wish some others would get involved here.

From the thread you linked, it appears to be a similar situation and I may need to run UT-K-E, but I still need to know what else this affects??

I also don't understand how a new item that I just generated and have basically no transactions on, other than a simple SO, would be in error with multiple locations... makes me wonder about the status of the rest of my data.

I'm beginning to think that this whole MRP thing is going to be more headaches then I, or my staff, have time for or are willing to deal with.

Lynn, someone, how about some input here.

Title: Re: MRP Help and clarifications
Post by shadowcaster on 03/29/06 at 10:46:09

DBA cant count

Run consolidate to one location if thats all you have.

then try the mrp again

its really worth it when it works

are your leadtimes adding to to longer than expidite delay times ?

JW

Title: Re: MRP Help and clarifications
Post by cmsk on 03/29/06 at 10:46:51

...oh and Tim and I already went down the Locations route (as shown a few posts back) and I'm not showing a discrepancy there (unlike the issue in the other thread)... same numbers as in IN-A.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/29/06 at 11:02:02

shadowcaster wrote:

I don't know or understand what the UT-K-E, consolidate does or affects... however, it doesn't appear that I need to run it, as my item isn't showing in mulitple locations -- from locations in IN-A.

Not sure what you mean about the "lead times adding to longer than expidite delay times." I wouldn't think so, but all of the details and numbers are in the PDF file that I posted. In any event, this appears to be off the mark, as there are other anomalies going on here.

The item I created is a perfect and simple model of exactly how we have our products set up... only a bit simpler and more straight forward to monitor. I just created it, have no transactions on it, other than a SO that should generate suggestions from MRP -- understanding it as I do. I see that some have gotten MRP to work and have some faith in it, however with what I'm seeing on my end it's going to be a waste of time, as I can't even get a simple test to yield any results.

There's something wrong somewhere...

UPDATE FYI: I just did some more research into Locations -- bottom line is we don't use them... never have. We only have one, so I don't see how this is a locations issue, or how the consolidation will do anything.

Title: Re: MRP Help and clarifications
Post by Lynn Pantic on 03/29/06 at 15:47:39

In your test assembly and top level subassemblies, change the on hand and reorder levels to 0 and keep your Sales Order for 10 of the top assembly and run MR-F again. Then look at the MR-G report.

Title: Re: MRP Help and clarifications
Post by shadowcaster on 03/29/06 at 20:42:17

>>I'm beginning to think that this whole MRP thing is going to be more headaches then I, or my staff, have time for or are willing to deal with.

lets not get silly
for me its the grail

once you have this working you have a window into whats going on with your material.

its like getting the sand out of your eyes.

J Dub

Title: Re: MRP Help and clarifications
Post by cmsk on 03/30/06 at 04:58:41

Lynn Pantic wrote:

In your test assembly and top level subassemblies, change the on hand and reorder levels to 0 and keep your Sales Order for 10 of the top assembly and run MR-F again. Then look at the MR-G report.

Ok, same exact result. I did try something that wil hopefully shed some light. After doing the above and not getting any different output. I tried changing the SO quantity. Whatever quantity I changed it to, also changed the MRP beginning balance to that same number, only with the "***" at the end. If I add another SO, the MRP beginning balance number becomes whatever the new SO amount is, with the "***" at the end -- again, still MRP makes no suggestions.

Title: Re: MRP Help and clarifications
Post by Lynn Pantic on 03/30/06 at 07:29:27

Are you running the MR-G report with a date range? Do not enter any dates. The On Hand and MRP On Hand should always be the same if you re-run MR-F and use no date filters on the report.

And you always need to re-run MR-F after entering orders or any other transactions so that it recalculates everything.

Title: Re: MRP Help and clarifications
Post by shadowcaster on 03/30/06 at 07:47:35

what dio you get on mr-h

pirint and post it

JW

Title: Re: MRP Help and clarifications
Post by cmsk on 03/30/06 at 07:48:07

Lynn Pantic wrote:

Yes, I always re-run MR-F after any changes I've done, and no, I'm not touching the date range.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/30/06 at 07:53:10

shadowcaster wrote:

what dio you get on mr-h

pirint and post it

JW

Nothing:

ORDER ACTION REPORT Page: 1
Thursday March 30, 2006 10:47 AM

Action Types : MBEDOR Start Date From : 00/00/00 Category From : Primary Vendor Code From:
Thru 00/00/00 Thru Thru:
Part Number From: TP-MRP Finish Date From00/00/00 Product Class Fr Planner Code From:
Thru: TP-MRP Thru00/00/00 Th Thru:

Part Number Description Order No Start Dt Due Dt Quantity Action Pegged to Vendor Req Dt Quantity
------------------------------------------------------------------------------------------------------------------------------------

Total records printed: 0

Title: Re: MRP Help and clarifications
Post by shadowcaster on 03/30/06 at 07:54:59

Looks like its not working.

what if you run it for all items not just the 1
and limit it to type B and M

J Dub

Title: Re: MRP Help and clarifications
Post by cmsk on 03/30/06 at 08:04:33

Tried that too, no difference, still nothing.

Title: Re: MRP Help and clarifications
Post by shadowcaster on 03/30/06 at 08:22:21

print/post the mrp parameters for the test range of items

J

Title: Re: MRP Help and clarifications
Post by cmsk on 03/30/06 at 08:29:47

Date: 03/30/06 MRP PARAMETERS Page: 1
Time: 11:24:13 AM brookfield industries

Item Number Desc T MRP RD? R Lvl R Amt Lead ExpS ExpB DelS DelB
-----------------------------------------------------------------------------------------------
TP-MRP FINISHED TEST PRODUCT F Y Y 0 20 4 1 30 7 30
TP-P3 PURCHASED PART 3 R Y Y 5 50 1 1 30 7 30
TP-S1 SUBASSEMBLY 1 A Y Y 0 20 4 1 30 7 30
TP-S1P1 PURCHASE PART 1 R Y Y 5 5 5 1 30 7 30
TP-S1P2 PURCHASE PART 2 R Y Y 10 50 10 1 30 7 30
TP-S1P3 Made part A Y Y 5 20 2 1 30 7 30
TP-S1P3-R1 RAW MATERIAL 1 R Y Y 25 100 7 1 30 7 30
TP-S1P3-R2 RAW MATERIAL 2 R Y Y 15 80 3 1 30 7 30
TP-S2 SUBASSEMBLY 2 A Y Y 0 30 14 1 30 7 30
TP-S2P1 PURCHASED PART R Y Y 5 25 7 1 30 7 30
TP-S2P2 Made Part A Y Y 25 75 10 1 30 7 30
TP-S2P2-R1 RAW MATERIAL 1 R Y Y 10 20 4 1 30 7 30

Total records printed: 12

Yowsa, I guess the alignment doesn't stay very neat during copy & paste.

Title: Re: MRP Help and clarifications
Post by cmsk on 03/30/06 at 08:34:28

This may be better for viewing....

http://homepage.mac.com/asrai/.cv/asrai/Sites/.Public/MR-E.TXT-zip.zip

Title: Re: MRP Help and clarifications
Post by shadowcaster on 03/31/06 at 10:42:54

can you print the inventory info for the test items

IN-D
IN-E
IN-F

JW

Title: Re: MRP Help and clarifications
Post by cmsk on 03/31/06 at 11:04:04

Sure, here they are.

http://homepage.mac.com/asrai/.cv/asrai/Sites/.Public/IN-D.TXT-zip.zip

http://homepage.mac.com/asrai/.cv/asrai/Sites/.Public/IN-E.TXT-zip.zip

http://homepage.mac.com/asrai/.cv/asrai/Sites/.Public/IN-F.TXT-zip.zip

Title: Re: MRP Help and clarifications
Post by Tim Keating on 03/31/06 at 13:49:12

cmsk wrote:

I tried changing the SO quantity. Whatever quantity I changed it to, also changed the MRP beginning balance to that same number, only with the "***" at the end.

I wouldn't look any farther than this. With this behavior, which does not happen on my system or anyone else's that I've heard of, you will never get MRP to run.

Maybe a run file is corrupt or maybe a database is. Either way, you are going to need some direct help from IS Tech.

Title: Re: MRP Help and clarifications
Post by cmsk on 04/03/06 at 05:19:55

Yeah I kinda figured that's the place I'm at, at this point.

Staying true to form... I always end up with the "unique" problems... :-/

Title: Re: MRP Help and clarifications
Post by shadowcaster on 05/01/06 at 14:13:41

Is it fixed yet

You really need this to work

maybe try with a few new items / assembly numbers ?

JW

Title: Re: MRP Help and clarifications
Post by cmsk on 06/01/06 at 04:00:47

Seems to be. There was a problem with 1 or 2 items' BOM and it wasn't allowing MRP to finish it's run. I didn't see / know this, as I've never ran MRP before. Thanks to Lori at TS, we got it sorted.

Now comes the fun of cleaning up all of the mess that's built up over the years, but at least the test part proved the functionality. Thanks for everyones input. I'm sure there will be more questions down the road...

Title: Re: MRP Help and clarifications
Post by shadowcaster on 06/02/06 at 20:09:46

We Love lorie Too !!!

have Fun cleaning up :-(

j dub