New features added, version 7.5.2
Program ICPD, Inventory Planning Data Defaults, is used to enter the default material requirements planning (MRP) and master production scheduling (MPS) data for inventory items. The information entered here will be the default for item planning parameters in program ICPM, Inventory Planning Data Maintenance.
Defaults are set up according to several parameters. Parameters include the log in manufacturing enterprise and plant and the manufacturing enterprise and plant for which the record is being created. This is explained in further detail below.
You must have one default template record set up with blanks in the Default Unit Code, Default Plant Code, ME Code, and Plant Code fields. This is the record that will be used when no other records meet the enterprise/plant criteria.
When a default parameter record is entered for a plant, the plant record will be created for the item automatically when the item is created.
Information entered in this program will be displayed for each item in program ICPM, Inventory Planning Data Maintenance. If a field is left blank in this program, the default for that field will be blank in program ICPM, Inventory Planning Data Maintenance.
If a vendor is entered in this program, it will be the default preferred vendor for all items unless an item has a different vendor entered in program ICPM, Inventory Planning Data Maintenance, or program VEPM, Preferred Vendor Maintenance.
The enterprise preferred vendor for the item in program VEPM, Preferred Vendor Maintenance, will override the vendor entered here.
A vendor entered for the item in program ICPM, Inventory Planning Data Maintenance, will override the vendor entered in program VEPM, Preferred Vendor Maintenance, or program ICPD, Inventory Planning Data Defaults.
In order for the reorder point feature to operate, the order code must be set to R and a reorder point quantity must be entered in the reorder point field.
Planning Parameters by Log In Manufacturing Enterprise and Plant
Entering Default Planning Information
Planning parameters can be entered according to the log in enterprise and plant for the person creating the items. This means that a user that is logged into enterprise 100 will have different defaults applied to the items he enters than the person logged into enterprise 200. In each case, the item planning parameter will be created in all manufacturing enterprises, but the defaults applied will be different.
The most obvious application of this functionality is a company that has two plants, one that manufactures the items and the other that sells the finished goods.
For example, when a user in the Selling plant enters a packaging item, that item is going to be of no concern to the Manufacturing plant. When a user in the Manufacturing plant enters a component item, it is going to be of no concern to those in the Selling plant. The log-in plant determines these parameters for each.
The selling user's parameters might be set up as follows:
Def Unit Code |
Def Plant Code |
ME Code |
Plant Code |
Order Code |
100 |
10 - Selling |
100 |
10 - Selling |
R - Reorder Point |
100 |
10 - Selling |
100 |
40 - Manufacturing |
NULL - Unplanned |
100 |
40 - Manufacturing |
100 |
10 - Selling |
NULL - Unplanned |
100 |
40 - Manufacturing |
100 |
40 - Manufacturing |
MRP - MRP Planned |
When the Selling user enters the item, the plant planning record for plant 10 will indicate that the packaging item entered is a reorder point item, and the Manufacturing plant record 40 will not contain an order code for the item.
When the Manufacturing user enters the item, the plant planning record for plant 40 will indicate that the component item entered is an MRP item, and the Selling plant record 10 will not contain an order code for the item.
This is a larger application of the same functionality, using multiple enterprises and multiple plants.
The example company has the following manufacturing enterprise plant setup:
Enterprise 100, plants 10, 40
Enterprise 200, plants 20, 25
Enterprise 300, plant 30
The following records are set up in program ICPD, Inventory Planning Data Defaults, using the Default Unit Code, Default Plant Code, ME Code, and Plant Code fields, with different Planner Codes.
Def Unit Code |
Def Plant Code |
ME Code |
Plant Code |
Planner Code |
100 |
10 |
200 |
|
ABC |
100 |
|
200 |
|
DEF |
200 |
20 |
100 |
40 |
GHI |
200 |
20 |
100 |
|
JKL |
200 |
20 |
200 |
25 |
MNO |
200 |
20 |
|
|
PQR |
200 |
|
200 |
|
STU |
|
|
|
|
VWX |
User 1 logs into 100, 10. User 2 logs into 100, 40. User 3 logs into 300, 30. User 4 logs into 200/20. User 5 logs into 200, 25.
For User 1 logged into 100, 10:
There is one default record for the user's log in unit code and plant.
The default record is for enterprise 200. This means that the other enterprises will use the default template record. (Manufacturing enterprise planning records are created in ICPM, Inventory Planning Data Maintenance.)
There is no plant
code assigned to the record, no plant planning records will be created.
(Plant planning records are created on the Plant Tab in program ICPM,
Inventory Planning Data Maintenance.)
User 1
100, 10 |
ICPM
ME |
100 |
VWX |
200 |
ABC |
300 |
VWX |
For User 2 logged into 100, 40:
There is no default record for the user's log in unit code and plant.
There is one default record for the user's log in unit code.
The default record is for enterprise 200. This means that the other enterprises will use the default template record. (Manufacturing enterprise planning records are created in ICPM, Inventory Planning Data Maintenance.)
There is no
plant code assigned to the record, no plant planning records will
be created. (Plant planning records are created on the Plant Tab
in program ICPM, Inventory Planning Data Maintenance.)
User
2 100, 40 |
ICPM
ME |
100 |
VWX |
200 |
DEF |
300 |
VWX |
For User 3 logged into 300, 30:
There is no default record for the user's log in unit code and plant.
There is no default record for the user's log in unit code.
The default
template record will be used for all enterprises (the Default
ME Tab in program ICPM, Inventory Planning Data Maintenance).
Plant records will not be created (the Plant Tab in program
ICPM, Inventory Planning Data Maintenance).
User
3 300, 30 |
ICPM
ME |
100 |
VWX |
200 |
VWX |
300 |
VWX |
For User 4 logged into 200, 20:
There are four records for the user's log in enterprise and plant.
There is one record for enterprise 100, plant 40. A plant planning record will be created in this enterprise and plant for the item (the Plant Tab in program ICPM, Inventory Planning Data Maintenance).
There is one record for enterprise 200, plant 25. A plant planning record will be created in this enterprise and plant for the item (the Plant Tab in program ICPM, Inventory Planning Data Maintenance).
There is one record for enterprise 100, no plant. This default record will be used to create the unit planning record in program ICPM, Inventory Planning Data Maintenance.
There is one other record with no enterprise and no plant assigned. All other enterprises will use this record (Manufacturing enterprise planning records are created in program ICPM, Inventory Planning Data Maintenance).
No other
plants (besides 100, 40 and 200, 25) will have plant records
created.
User
4 200, 20 |
ICPM
ME |
ICPM
Plant |
100, 40 |
|
GHI |
200, 25 |
|
MNO |
100 |
JKL |
|
200 |
PQR |
|
300 |
PQR |
|
For User 5 logged into 200, 25:
There is no default record for the user's log in unit code and plant.
There is one default record for the user's log in unit code.
The default record is for enterprise 200. This means that the other enterprises will use the default template record. (Manufacturing enterprise planning records are created in ICPM, Inventory Planning Data Maintenance.)
There
is no plant code assigned to the record, no plant
planning records will be created. (Plant planning
records are created on the Plant Tab in program ICPM,
Inventory Planning Data Maintenance.)
User 5 200, 25 |
ICPM ME |
100 |
VWX |
200 |
STU |
300 |
VWX |
1. In the Default Unit Code field, enter the log-in manufacturing enterprise for this item planning default record.
For more information on this feature, see the Planning Parameters by Log In Manufacturing Enterprise and Plant section.
2. In the Default Plant Code field, enter the log-in plant for this item planning default record.
For more information on this feature, see the Planning Parameters by Log In Manufacturing Enterprise and Plant section.
3. In the ME Code field, enter the manufacturing enterprise for which you are defining default planning information. This is the default record for use in program ICPM, Inventory Planning Data Maintenance.
If you leave this field blank, the default record will be used for all manufacturing enterprises for which a default record has not been entered.
4. In the Plant Code field, enter the plant for which you are defining default planning information, used for defaults on the Plant Tab in program ICPM, Inventory Planning Data Maintenance.
If you enter a default record for a plant, then a plant planning record for each plant default record will be created for the item automatically upon item creation.
5. In the Mstr Planner field, enter the default Master Planner code, if desired.
This is a user-defined master planner code, used in selecting and sorting master schedule reports.
6. In the Planner Code field, enter the default Planner code, if desired.
This is a user-defined planner code, used in selecting and sorting master schedule reports.
7. In the Buyer Code field, enter the default Buyer code, if desired.
The buyer code is a user-defined code used for selecting a sorting various inquiries and reports. Buyer codes are entered in program POBM, Buyer Maintenance. However, the entry in this field is not validated against those entered in program POBM, Buyer Maintenance.
8. In the Order Policy field, enter the desired order policy. The default order policy determines the type of orders created by material requirements planning (MRP) and master production scheduling (MPS).
L - Lot for Lot - Each day's unsatisfied demand results in a single planned order for the demand quantity.
M - Lot Multiples - Total unsatisfied demand results in as many planned orders of the order multiple quantity as necessary to meet the demand. If the order multiple is zero, material requirements planning (MRP) and master production scheduling (MPS) create a single planned order for the demand quantity.
Q - Minimum Order Quantity - Total unsatisfied demand results in a single planned order for the minimum order quantity plus increments of the order multiple quantity as required to meet the demand. If the order multiple is zero or null (blank), order multiple will be considered to be 1 (or lot for lot).
R - Rate Based - Rate based scheduling is used in material requirements planning (MRP) and master production scheduling (MPS). For each group of shop calendar days represented by a production period, where there is any demand greater than the existing supply, an order will be scheduled for receipt on the first day of the production period. The order quantity will be at least the minimum production quantity and not greater than the maximum production quantity. Demand greater than the maximum production quantity is rolled back to the previous production periods, if possible. If maximum and minimum production rates are not found, Lot for Lot is used. For more information, see the Material Requirements Planning (MRP) and Rate Based Items or Master Production Scheduling (MPS) and Rate Based Items section.
9. In the Order Code field, enter the default order code to indicate to the system whether the default is for items to be manually or automatically planned and the type of planning to be done. It is also used to cover the generation of stock transfer orders.
M - MRP Planned - Items are planned by material requirements planning.
R - Reorder Point - Reorder Point items.
P - MPS items - Master schedule items.
F - FAS items - Final assembly schedule items.
Material requirements planning (MRP) occurs for items with codes M and R but planned orders are created only for items with code M.
Master production schedule (MPS) forecasting and scheduling occurs only for items with code P.
Program IXAR, Create Stock Transfer Orders, will only generate stock orders for items with code R.
Order code F is a future feature of NDS.
10. In the Preferred Vendor field, enter the default enterprise preferred vendor, if appropriate.
The enterprise preferred vendor for the item in program VEPM, Preferred Vendor Maintenance, will override the vendor entered here.
If a vendor is entered in this program, it will be the default preferred vendor for all items unless an item has a different vendor entered in program ICPM, Inventory Planning Data Maintenance, or program VEPM, Preferred Vendor Maintenance.
A vendor entered for the item in program ICPM, Inventory Planning Data Maintenance, will override the vendor entered in program VEPM, Preferred Vendor Maintenance, or program ICPD, Inventory Planning Data Defaults.
11. Set the ATP Method pop-list for master scheduling to the desired default setting. The choices are Cumulative and Periodic.
If
you set the pop-list to Periodic, for the first
period, ATP is calculated as the on hand quantity
plus the new master production schedule supply
minus total demand (production forecast, customer
orders, manufacturing demand, and inter-plant
demand).
For subsequent periods, ATP is the new master production
schedule supply minus total demand (production
forecast, customer orders, manufacturing demand,
and interplant demand).
If you set the pop-list to Cumulative, the period ATP is calculated. Then starting with the lowest period, the ATP is added to the following period.
If the order code is P - MPS Planned - and you leave this field blank, the program supplies the value for this plant from program ILPM, Plant Code Maintenance, when you commit the record.
12. In the MPS Trap Percent field, enter the default MPS Trap Percentage, if appropriate.
The trap percentage is used to highlight individual customer demands that are greater than this percentage of the master production schedule (MPS) within a period.
When a customer order exceeds the trap percentage in a period, it is flagged on the master production schedule report.
If the order code is P - MPS Items, and you leave this field blank, the program supplies the value for this plant from program ILPM, Plant Code Maintenance, when you commit the record.
13. Set the default MPS Accum LT Override flag.
Set this flag to on to indicate that accumulated lead time is allowed to override shorter demand time fences in master production scheduling (MPS).
If the order code is P - MPS Items and you leave this field blank, the program supplies the value for this plant from program ILPM, Plant Code Maintenance, when you commit the record.
14. In the Fcst Round method pop-list, select the default forecast rounding method, if appropriate.
The forecast rounding method operates with the forecast round to quantity to determine the rounded daily forecast actually used in master production scheduling (MPS) calculations.
If the order code is P - MPS Items, and you leave this field blank, the program supplies the value for this plant from program ILPM, Plant Code Maintenance, when you commit the record.
The system includes the following forecast rounding methods:
None. Forecasts are not rounded.
Backward. The round to quantity is used as the rounded forecast for the period containing the first day with any forecast. The rounded forecasts for subsequent periods are zero until the period in which the sum of the existing forecasts exceeds the round to quantity. In this period, the round to quantity is again used as the rounded forecast, and any excess is added to the existing forecasts for subsequent periods until their sum again exceeds the round to quantity.
Forward. The rounded forecasts for the first and subsequent periods are zero until the period in which the sum of the existing forecasts reaches or exceeds the round to quantity. In this period, the round to quantity is used as the rounded forecast, and any excess is added to the existing forecasts for subsequent periods until their sum again reaches or exceeds the round to quantity.
Truncate. If the existing forecast is not an exact multiple of the round to quantity, then it is rounded down to the nearest lower multiple of the round to quantity.
Up. If the existing forecast is not an exact multiple of the round to quantity, then it is rounded up to the round to quantity.
15. In the Fcst Round To Qty field, enter the default forecast round to quantity, if appropriate.
The forecast round to quantity is used with the forecast rounding method to determine the quantity to round to for this item.
If the order code is P- MPS Items and you leave this field blank, the program supplies the value for this plant from program ILPM, Plant Code Maintenance, when you commit the record.
16. Set the Statistical Forecast pop-list to the desired default setting. The choices are Yes, No, and Track.
This pop-list indicates whether statistical forecasts will be created for this item.
Set the pop-list to Yes to indicate that they will be calculated and used.
Set the pop-list to No to indicate that they will not be used.
Set the pop-list to Track to indicate that they will be calculated, but not used.
17. In the Forecast Group field, enter the default forecast group from program FCGM, Forecast Group Maintenance, to which the item belongs, if appropriate.
18. Set the Forecast Alpha pop-list to the desired default setting, if appropriate. The choices are low, medium, and high.
This pop-list indicates which alpha smoothing constant from program FCGM, Forecast Group Maintenance will be used for this item.
The higher the value is, the more significance is placed on the newer data. The lower the value is, the more significance is placed on the older data.
This value is used for calculating statistical forecasts in program FCCP, Forecast Calculation.
19. Set the Forecast Base pop-list to the desired default setting, if appropriate. Choices are Orders and Shipments.
This pop-list indicates what the forecast for the item will be based on, orders or shipments.
Program FCCP, Forecast Calculation, will use this information in calculating statistical forecasts.
20. In the Safety Factor field, enter the default safety factor, if appropriate. The safety factor is used in program FCCP, Forecast Calculation, to calculate the safety stock quantity in statistical forecasts.
21. Set the Work Order Costs are Elemental flag to its default setting.
When this flag is set to on, material costs are issued to work orders with the material cost, labor cost, overhead cost, and service cost added to the corresponding elemental cost in the work order summary.
For example, suppose an item had two component items, and the material cost for the first item was $1, while the material cost for the second one was $2. Suppose also, that the labor cost for the first one was $1.50, while the labor cost for the second one was $0.75. To create the parent item, it takes $1.
When this flag is set to on, the material cost is calculated as the material cost for the first item + the material cost for the second item. The material that will be added to the material cost in the work order summary in this case is $3.00.
The labor cost is calculated as the labor for the first item + the labor for the second item + the labor to create the parent item. The labor that will be added to the labor in the work order summary in this case is $3.25.
When this flag is set to off, the unit cost is added to work order summary material cost.
For example, in the example above, the material and labor of the two component items would be combined for a total of $5.25, which will be added to the material cost in the work order summary. The only cost that would be added to the labor in the work order summary is the $1.00 that it cost to assemble the parent item.
22. Set the Cascade WO Release in OE flag to its default setting.
When this flag is set to on, when the [Write WO] button is pressed for the item in program OEOE, Sales Order Entry Maintenance, the work orders for the item and all of the components of the item are created.
When this flag is set to off , the work order is created for only the ordered item, and not its components.
The work order cascade does not look at the available to promise inventory. If the [Write WO] button in program OEOE, Sales Order Entry Maintenance, is pressed, the work orders are created for the ordered item and for the components of the order item regardless of the available to promise inventory.
If the flag is also set to on for the item's component items, work orders will be created for the component items' component items as well. This allows work orders to be created for items from the lowest level to the highest level of the item's routing.
For example, you have an order line for item A. Item A has two components, B and C. Item B has two components, D and E.
All of these items have the Cascade WO Release in OE flag set to on.
Items A, B, C, and D have the Make or Buy pop-list set to Manufactured.
Item E has the Make/Buy pop-list set to Purchased.
Items C, D, and E do not have bills of material.
The [Write WO] button is pressed for item A on the sales order line.
A work order for A is created. The Cascade WO Release in OE flag is set to on for A, so work orders are also created for items B and C. This occurs even though item C has no bill of material because the Make or Buy pop-list for C is set to Manufactured.
The Cascade WO Release in OE flag is set to on for item B, so a work order is created for D. This occurs even though item D has bill of material because the Make or Buy pop-list for D is set to Manufactured.
No work order is created for item E because the Make or Buy pop-list is set to Purchased.
There are no components for item C, so no work orders are created.
There are no components for item D, so no work orders are created.
23. Set the Make or Buy pop-list to the desired default setting. Choices are Manufactured or Purchased.
If you set this pop-list to Manufactured, the default will be that items are manufactured. The system will create manufacturing orders for the item during the planning and order release cycle.
If you set this pop-list to Purchased, the default will be that items are bought. The system will create purchase requisitions during the planning and order release cycle.
If the setting of this pop-list is Null and a bill of material exists for the item, the Null setting is interpreted by the system as Manufactured.
If the setting if this pop-list is Null and a bill of material does not exist for the item, the Null setting is interpreted by the system as Purchased.
24. In the Lead Time fields, enter the default lead times for the item, if appropriate. There are three fields for lead times, in case you wish to categorize the lead times.
25. In the Min Prod Rate field, enter the default minimum production rate, if appropriate. This is the minimum production rate for the item, used for rate based items in master scheduling.
26. In the Max Prod Rate field, enter the default maximum production rate, if appropriate. This is the maximum production rate for the item, used for rate based items in master scheduling.
27. In the Production Period field, enter the default production period, if appropriate.
This is the production period for the minimum and maximum rates. If you have entered either the minimum or maximum production rate and leave this field blank, the program supplies "1" as the default when you commit the record.
28. In the Econ Order Qty (EOQ) field, enter the quantity for the standard EOQ calculation for lot sizing. This field is used only for reference purposes and not used by the system.
29. In the Safety Stock Quantity field. enter the default safety stock quantity, if appropriate.
Safety stock is a minimum on hand balance that is carried by inventory to compensate for uncertainty in forecast and lead time.
This field is used by material requirements planning (MRP) and master production scheduling (MPS).
30. In the Shrinkage Percent field, enter the default shrinkage percent, if appropriate.
The shrinkage percent is used by material requirements planning (MRP) and master production scheduling (MPS) to increase order quantities to allow for shrinkage during manufacturing.
31. In the Max Stock Quantity field, enter the default maximum stock quantity, if appropriate.
This is the maximum number of units that should be kept in stock. This field is only used by reorder point.
32. In the Reorder Point field, enter the default reorder point quantity, if appropriate.
When the quantity on hand plus the on-order quantity falls below the reorder point level, replenishment orders need to be issued. The order code must be R for reorder point transactions
33. In the Minimum Order Qty field, enter the default minimum order quantity, if appropriate.
The minimum order quantity is the smallest quantity that material requirements planning (MRP) and master production scheduling (MPS) can use in creating an order for the item. This quantity is used in conjunction with the order policy.
34. In the Order Multiple field, enter the default order multiple, if appropriate.
The order multiple is the increment used by material requirements planning (MRP) and master production scheduling (MPS) in creating orders. This is used in conjunction with the order policy.
35. In the Weeks Supply field, enter the default week supply, if appropriate.
Orders for this item should include this many weeks of requirements. This is not used by material requirements planning (MRP) and master production scheduling (MPS).
36. In the Case Quantity field, enter the default case quantity for items.
All items created after this field is entered will have the case quantity set to the quantity entered here.
When the SRFE quantity rule field is set to Case Quantity for an item, this is the default number of units equal to one case.
When sales orders are entered for the item with a quantity that is not an even multiple of the case quantity, a warning is displayed.
37. In the Cases Per Pallet field, enter the default number of cases per pallet for items.
All items created after this field has been entered will have the cases per pallet set to the quantity entered here.
When sales orders are containerized during sales order staging, this field is used to determine how many cases are shipped in the same container.
38. In the Container Type field, enter the default container type for items.
All items created after this field has been entered will use this container type.
When sales orders are containerized during sales order staging, this is the default container type that will be used on the container record.
39. Press [Commit].