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

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...)

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?

...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.

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.

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!

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.

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