New features added, version 7.5.2, 7.5.3, 8.1, 7.5.4, 8.4, 7.5.4 Patches, 8.4 Patches
Program ICPM, Inventory Planning Data Maintenance, is used to maintain material requirements planning (MRP) and master production scheduling (MPS) data for inventory items for both the logged in enterprise and logged in plant.
The ICPM_MODE parameter in program MURM, Initialization Parameter Maintenance, determines whether the user can modify information on both the enterprise and plant tabs, or only on the plant tab. The value of this parameter is displayed in the upper right corner of the screen.
If the parameter is set to A, then when the program is run, the user is given the option of modifying plants only or modifying both the plant and the manufacturing enterprise.
If the parameter is set to P, then the user can view the manufacturing enterprise information, but can only modify the plant information for the item.
Determining Item Planning Parameters
Creating Plant Records & Copying Manufacturing Enterprise Defaults
Entering Enterprise Item Planning Information
Entering Plant Item Planning Information
Planning parameters can be set up at the plant level on the Plant Tab in this program and those parameters override the parameters set up on the Default ME Tab in this program.. Most of this data is used by other parts of the system: material planning, master scheduling, reorder point calculations, work order release, and purchasing.
If any record exists on the Plant Tab for an item, the system will take all information from that tab over the information on the Default ME Tab. This includes fields that have been left blank on the Plant Tab.
The preferred vendor that is used in the purchasing module is set up in this program. The preferred vendor for an item is determined as follows:
The system first looks for a vendor quote in program VEQM, Vendor Quote Maintenance. If a quote exists, the system will use the quote information on the requisition.
If no quote exists, the system will look at the plant record for the item on the Plant Tab. If a preferred vendor exists in the plant record, the preferred vendor will be pulled into the requisition, and the unit cost from program ICCM, Inventory Cost Data Maintenance, will be used for the price.
If no preferred exists on the Plant Tab, the system will look at the enterprise record for the item on the Default ME Tab. If a preferred vendor exists in the enterprise record, the preferred vendor will be pulled into the requisition, and the unit cost from program ICCM, Inventory Cost Data Maintenance, will be used for the price.
If no preferred vendor exists for the item on the Default ME Tab, the system will not enter a preferred vendor.
If no unit price can be found for the item in program ICCM, Inventory Cost Data Maintenance, the system will look at the last purchase order or requisition entered for the item, and use that price.
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.
Inventory comments can be entered and maintained with this program. Comments entered for the item in program ICMM, Inventory Master Maintenance, program ICSM, Inventory Sales Data Maintenance, ICPM, Inventory Planning Data Maintenance, and ICCM, Inventory Cost Data Maintenance, will be displayed and can be maintained in this program.
When setting up planning information for proxy items for the Material Proxy Planning (PXM) Module, be sure to set the lead time information to match that of the set of items that the proxy item represents.
When you press the [Create Plant Record] button to create a plant planning record or the [Copy ME Defaults] button to replace the current values for the item, the defaults from program ICPD, Inventory Planning Data Defaults, are selected the in the following order of precedence. The X's and Y's indicates that the entries in the fields in program ICPD, Inventory Planning Data Defaults match the user's logged in manufacturing enterprise and plant. The A's and B's indicate that the entries in the field's match the manufacturing enterprise and plant code that are displayed at the top of this program in the Mfg Ent and Show Plant fields.
Def Unit Code |
Def Plant Code |
ME Code |
Plant Code |
Explanation |
X |
Y |
A |
B |
When the item planning record is created in this program, the defaults will come first from the ICPD record that has entries in the default unit code, default plant code, ME code, and plant code fields where the user's logged in manufacturing enterprise and plant match the default unit code and default plant code, and the ICPM manufacturing enterprise and show plant match the ME code and plant code. |
X |
blank |
A |
B |
If the previous record does not exist, the defaults will come from the ICPD record that has entries in the default unit code, ME code, and plant code fields, where the default unit code matches the user's logged in manufacturing enterprise and the ICPM manufacturing enterprise and show plant match the ME code and plant code. |
blank |
blank |
A |
B |
If the previous record does not exist, the defaults will come from the ICPD record that has no entries in the default unit code and default plant code fields, and has entries in the ME code and plant code fields, where the entries in the ME code and plant code fields match the ICPM manufacturing enterprise and show plant. |
X |
Y |
A |
blank |
If the previous record does not exist, the defaults will come from the ICPD record that has entries in the default unit code, default plant code, and ME code fields where the default manufacturing enterprise and default plant code match the user's logged in manufacturing enterprise and plant, and the ME code matches the ICPM manufacturing enterprise. |
X |
Y |
blank |
blank |
If the previous record does not exist, the defaults will come from the ICPD record that has entries in the default unit code and default plant code fields, but no entries in the ME code and plant code fields. The default unit code and default plant code must match the user's logged in manufacturing enterprise and plant code. |
X |
blank |
A |
blank |
If the previous record does not exist, the defaults will come from the ICPD record that has entries in the default unit code and ME code fields and no entries in the default plant code and plant code fields. The default unit code field must match the user's logged in manufacturing enterprise and the ME code must match the ICPM manufacturing enterprise. |
X |
blank |
blank |
blank |
If the previous record does not exist, the defaults will come from the ICPD record that has an entry in the default unit code field and no entries in the default plant code, ME code, or plant code fields. The default unit code must match the user's logged in manufacturing enterprise. |
blank |
blank |
A |
blank |
If the previous record does not exist, the defaults will come from the ICPD record that has an entry in the ME code field and no entries in the default unit code, default plant code, or plant code fields. The ME code must match the ICPM manufacturing enterprise. |
blank |
blank |
blank |
blank |
If the previous record does not exist, the defaults will come from the ICPD record that has no entries in the default unit code, default plant code, ME code, or plant code fields. |
You can only modify enterprise item planning information if the ICPM_MODE parameter is set to A for your user in program MURM, Initialization Parameter Maintenance, and you selected [Plants and Mfg Enterprise] when you ran the program.
1. In the Show Plant pop-list, select the desired plant for the logged in manufacturing enterprise.
2. In the Item No field, query the item for which you are entering planning information.
3. Click on the Default ME Tab. The background of the tab is dark gray to distinguish it from the plant tab.
1. In the Operations section, in the Planner Code field, enter the planner code for this item, if desired.
This is a user-defined planner code, used in selecting and sorting master schedule reports.
2. In the Buyer Code field, enter the buyer code for this item, if desired.
The buyer code is a user-defined code used for selecting and 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.
3. Set the Make or Buy pop-list to the desired setting. Choices are Manufactured or Purchased.
If you set this pop-list to Manufactured, you are indicating that this item is 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, you are indicating that this item is 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.
6. Set the Manufacturing Method pop-list to the desired setting. Choices are Work Order or Production Schedule.
If you set this pop-list to Work Orders, the programs that create work orders will create work orders for this item when a work order is released or created from the program.
If you set this pop-list to Prod Sched, the programs that create work orders will create production schedules when work orders are released or created from the program.
The programs that create work orders include program OEOE, Sales Order Entry Maintenance, program WOAR, Automatic Work Order Release, and program CMCP, Customer Contract Maintenance.
7. In the Preferred Vendor field, enter the vendor number that is the preferred vendor for this item.
You can enter a vendor in this program to be the enterprise preferred vendor for this item. The default is the enterprise preferred vendor from program VEPM, Preferred Vendor Maintenance.
If an enterprise preferred vendor is assigned to an item, the system will use this vendor as the primary source in purchasing unless overridden by a plant preferred vendor.
8. In the Order Policy field, enter the desired order policy for this item. The 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 order code. The order code indicates to the system whether the item is 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.
Order code F is a future feature of NDS.
10. In the Safety Factor field, enter the safety factor, if appropriate. The safety factor is used in program FCCP, Forecast Calculation, to calculate the safety stock quantity in statistical forecasts.
11. Set the Operation Scheduling pop-list to the desired setting. This will determine the type of scheduling, either forward or backward, that is to be used for this item in work order and production schedule releases. The default setting comes from program SPMM, System Parameters/Default Maintenance.
In Forward Scheduling, for the initial operation scheduling, the first operation due date is scheduled as the due date minus the production lead time entered in this program plus the manufacturing lead time. Each following operation is calculated as the due date of the preceding operation plus the manufacturing lead time.
In Backward Scheduling, the last operation start date is scheduled backward from the due date minus the manufacturing lead time (calculated from the routing operations) for that operation. Each preceding operation's start date is calculated backward from the start of its following operation.
12. Press [Commit].
1. In the Min Prod Rate field, enter the minimum production rate, if appropriate. This is the minimum production rate for the item, used for rate based items in master scheduling.
2. In the Max Prod Rate field, enter the maximum production rate, if appropriate. This is the maximum production rate for the item, used for rate based items in master scheduling.
3. In the Prod Period field, enter 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.
4. In the Safety Stock Qty field, enter the 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).
5. In the Shrinkage % field, enter the 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.
6. In the Max Stock Qty field, enter the 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.
7. In the Target Stock Qty field, enter the
quantity that should remain in the 'To Location' after the moves are completed
and the allocations are filled. This quantity is added to the move quantity
in program ICRC, Inventory Replenishment, when
inventory replenishment moves are calculated.
This field is also updated in program ICEM, Item Plant
Maintenance.
8. In the Reorder Point field, enter the 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
9. In the Min Order Qty field, enter the 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.
10. In the Order Multiple field, if appropriate enter 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.
11. In the Weeks Supply field, enter the 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).
12. In the EOQ field, enter the quantity for the standard EOQ calculation for lot sizing. However, this is only for reference purposes and not used by the system.
13. In the Mgmt Reserve field, if appropriate enter the extra quantity that is held aside in addition to the safety stock. It is treated by the system as an extra stock buffer and is used by material requirements planning (MRP) and master production scheduling (MPS). For serial control items, this must be an integer.
14. Press [Commit].
1. Set the SR Default Qty Rule pop-list to the desired setting. Choices are Order Quantity and Case Quantity.
If the pop-list is set to Order Quantity, the quantity received will be the order quantity.
If the pop-list is set to Case Quantity, the quantity received will be the case quantity. The number of units in a case is entered in the case quantity field below this field.
2. In the Case Qty field, enter the case quantity, if appropriate. If the SR Default Qty field is set to Case Quantity, this is the number of units equal to one case.
When sales orders are entered for this item and the order quantity is not an even multiple of the case quantity, a warning will be displayed.
3. In the Per Pallet field, enter the number of cases per pallet for the item, if appropriate.
When sales order lines with this item are automatically containerized during sales order staging, this determines the number of cases for each container.
4. In the Container Type field, enter the default container type, if appropriate.
When sales order lines with this item are automatically containerized during sales order staging, this is the default container type written to the container record.
5. Press [Commit].
1. Set the Statistical Option pop-list to the desired 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.
Forecasting for new items can be set to Track initially, and have the forecasting be automatically activated when enough data exists. If the forecast group to which the item is assigned has the Filter Enabled flag is set to on, and the FCCX_AUTO_FC_ACTIVATE is set to Y in program MURM, Initialization Parameter Maintenance, when the sample population of records for the item exceeds the minimum population for the forecast group, the setting of this pop-list will be changed to Yes automatically when program FCCX, Write Statistical Forecast Data to MPS, is run. See the Forecast Filter for Large Sales Spikes for more information.
2. In the Group field, enter the forecast group from program FCGM, Forecast Group Maintenance, to which the item belongs, if appropriate.
3. Set the Alpha pop-list to the desired 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.
4. Set the Base Option pop-list to the desired 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.
5. Press [Commit].
1. In the Lead Time 1, Lead Time 2, and Lead Time 3 fields, enter the lead times for the item, if appropriate. There are three fields for lead times in case you wish to categorize the lead times. The sum of the three are displayed in the Total Lead Time field.
If the item is assigned a lead time group in the Lead Time Group field, the lead time assigned to the group will override the lead times entered here.
2. In the Fixed LT field , the fixed lead time is the number of days to set up the item. It is calculated by the system from the routing, but it is not used by material requirements planning (MRP) or master production scheduling (MPS). You cannot maintain this field.
3. In the Variable LT field, the variable lead time is the runtime in days, calculated by the system. It is not used by material requirements planning (MRP) or master production scheduling (MPS). You cannot maintain this field.
4. In the Accum LT field, the accumulated lead time is the longest lead time path when exploding down the bill of material for the item. You cannot maintain this field.
If the MPS AC LT Override flag is set to on in program ICPM, Inventory Planning Data Maintenance for the enterprise or plant planning records, the accumulated lead time is allowed to override the demand time fence in master production scheduling (MPS).
Program MSLR, Planning Lead Time Rollup, calculates the accumulated lead time and automatically updates the field.
5 In the Item LT Group field, enter the lead time group for this item, if appropriate. Lead time groups are set up in program ICLT, Item Lead Time Group Maintenance, and the lead time assigned to the group overrides the individual settings for items to which the lead time group is assigned.
6. Press [Commit].
1. In the MPS Planner field, enter the MPS planner code for this item, if desired.
This is a user-defined master planner code, used in selecting and sorting master schedule reports.
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.
2. In the Round Method pop-list, select the forecast rounding method for this item, 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:
N - No Rounding. Forecasts are not rounded.
B - Roll 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.
F - Roll 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.
T - 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.
U - Round 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.
3. In the Round Qty field, enter the 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.
4. Set the MPS ATP Method pop-list for master scheduling to the desired 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.
5. In the MPS Trap % field, enter the master production schedule trap percentage for this item, 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.
6. Set the MPS ACC LT Override flag to the desired setting.
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.
7. Press [Commit].
1. Set the WO Costs are Elemental flag to the desired 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.
2. Set the Cascade WO Release in OE flag to the desired 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.
3. Press [Commit].
1. The User Ref 1 and User Ref 2 fields are for user-defined custom purposes. Enter the appropriate value.
2. Press [Commit].
1. In the Show Plant pop-list, select the desired plant for the logged in manufacturing enterprise.
2. In the Item No field, query the item for which you are entering planning information.
3. Click on the Plant Tab to view the plant planning information. If no plant planning record exists, the tab will be grayed out and you can press the [Create Plant Record] button to create the record for the logged in plant.
4. To copy the defaults for the item from the enterprise record on the Default ME Tab, press the [Copy ME Defaults] button.
1. In the Operations section, in the Planner Code field, enter the planner code for this item, if desired.
This is a user-defined planner code, used in selecting and sorting master schedule reports.
2. In the Buyer Code field, enter the buyer code for this item, if desired.
The buyer code is a user-defined code used for selecting and 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.
3. Set the Make or Buy pop-list to the desired setting. Choices are Manufactured or Purchased.
If you set this pop-list to Manufactured, you are indicating that this item is 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, you are indicating that this item is 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.
6. Set the Manufacturing Method pop-list to the desired setting. Choices are Work Order or Production Schedule.
If you set this pop-list to Work Orders, the programs that create work orders will create work orders for this item when a work order is released or created from the program.
If you set this pop-list to Prod Sched, the programs that create work orders will create production schedules when work orders are released or created from the program.
The programs that create work orders include program OEOE, Sales Order Entry Maintenance, program WOAR, Automatic Work Order Release, and program CMCP, Customer Contract Maintenance.
7. In the Preferred Vendor field, enter the vendor number that is the preferred vendor for this item.
If a plant preferred vendor is listing for an item, the system will use this vendor as the primary source in purchasing overriding the enterprise preferred vendor.
8. In the Order Policy field, enter the desired order policy for this item. The 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 order code. The order code indicates to the system whether the item is 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.
Order code F is a future feature of NDS.
10. In the Safety Factor field, enter the safety factor, if appropriate. The safety factor is used in program FCCP, Forecast Calculation, to calculate the safety stock quantity in statistical forecasts.
11. Set the Operation Scheduling pop-list to the desired setting. This will determine the type of scheduling, either forward or backward, that is to be used for this item in work order and production schedule releases. The default setting comes from program SPMM, System Parameters/Default Maintenance.
In Forward Scheduling, for the initial operation scheduling, the first operation due date is scheduled as the due date minus the production lead time entered in this program plus the manufacturing lead time. Each following operation is calculated as the due date of the preceding operation plus the manufacturing lead time.
In Backward Scheduling, the last operation start date is scheduled backward from the due date minus the manufacturing lead time (calculated from the routing operations) for that operation. Each preceding operation's start date is calculated backward from the start of its following operation.
12. Press [Commit].
1. In the Min Prod Rate field, enter the minimum production rate, if appropriate. This is the minimum production rate for the item, used for rate based items in master scheduling.
2. In the Max Prod Rate field, enter the maximum production rate, if appropriate. This is the maximum production rate for the item, used for rate based items in master scheduling.
3. In the Prod Period field, enter 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.
4. In the Safety Stock Qty field, enter the 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).
5. In the Shrinkage % field, enter the 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.
6. In the Max Stock Qty field, enter the 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.
7. In the Target Stock Qty field, enter the target stock quantity for the item.
8. In the Reorder Point field, enter the 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
9. In the Min Order Qty field, enter the 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.
10. In the Order Multiple field, if appropriate enter 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.
11. In the Weeks Supply field, enter the 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).
12. In the EOQ field, enter the quantity for the standard EOQ calculation for lot sizing. However, this is only for reference purposes and not used by the system.
13. In the Qty In Reserve field, if appropriate enter the extra quantity that is held aside in addition to the safety stock. It is treated by the system as a type of safety stock and is used by material requirements planning (MRP) and master production scheduling (MPS). For serial control items, this must be an integer.
14. Press [Commit].
1. Set the SR Default Qty Rule pop-list to the desired setting. Choices are Order Quantity and Case Quantity.
If the pop-list is set to Order Quantity, the quantity received will be the order quantity.
If the pop-list is set to Case Quantity, the quantity received will be the case quantity. The number of units in a case is entered in the case quantity field below this field.
2. In the Case Qty field, enter the case quantity, if appropriate. If the SR Default Qty field is set to Case Quantity, this is the number of units equal to one case.
When sales orders are entered for this item and the order quantity is not an even multiple of the case quantity, a warning will be displayed.
3. In the Per Pallet field, enter the number of cases per pallet for the item, if appropriate.
When sales order lines with this item are automatically containerized during sales order staging, this determines the number of cases for each container.
4. In the Container Type field, enter the default container type, if appropriate.
When sales order lines with this item are automatically containerized during sales order staging, this is the default container type written to the container record.
5. Press [Commit].
1. Set the Statistical Option pop-list to the desired 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.
Forecasting for new items can be set to Track initially, and have the forecasting be automatically activated when enough data exists. If the forecast group to which the item is assigned has the Filter Enabled flag is set to on, and the FCCX_AUTO_FC_ACTIVATE is set to Y in program MURM, Initialization Parameter Maintenance, when the sample population of records for the item exceeds the minimum population for the forecast group, the setting of this pop-list will be changed to Yes automatically when program FCCX, Write Statistical Forecast Data to MPS, is run. See the Forecast Filter for Large Sales Spikes for more information.
2. In the Group field, enter the forecast group from program FCGM, Forecast Group Maintenance, to which the item belongs, if appropriate.
3. Set the Alpha pop-list to the desired 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.
4. Set the Base Option pop-list to the desired 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.
5. Press [Commit].
1. In the Lead Time 1, Lead Time 2, and Lead Time 3 fields, enter the lead times for the item, if appropriate. There are three fields for lead times in case you wish to categorize the lead times. The sum of the three are displayed in the Total Lead Time field.
If the item is assigned a lead time group in the Lead Time Group field, the lead time assigned to the group will override the lead times entered here.
2. In the Fixed LT field , the fixed lead time is the number of days to set up the item. It is calculated by the system from the routing, but it is not used by material requirements planning (MRP) or master production scheduling (MPS). You cannot maintain this field.
3. In the Variable LT field, the variable lead time is the runtime in days, calculated by the system. It is not used by material requirements planning (MRP) or master production scheduling (MPS). You cannot maintain this field.
4. In the Accum LT field, the accumulated lead time is the longest lead time path when exploding down the bill of material for the item. You cannot maintain this field.
If the MPS AC LT Override flag is set to on for the enterprise or plant planning record in program ICPM, Inventory Planning Data Maintenance, the accumulated lead time is allowed to override the demand time fence in master production scheduling (MPS).
Program MSLR, Planning Lead Time Rollup, calculates the accumulated lead time and automatically updates the field.
5 In the Item LT Group field, enter the lead time group for this item, if appropriate. Lead time groups are set up in program ICLT, Item Lead Time Group Maintenance, and the lead time assigned to the group overrides the individual settings for items to which the lead time group is assigned.
6. Press [Commit].
1. In the MPS Planner field, enter the MPS planner code for this item, if desired.
This is a user-defined master planner code, used in selecting and sorting master schedule reports.
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.
2. In the Round Method pop-list, select the forecast rounding method for this item, 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:
N - No Rounding. Forecasts are not rounded.
B - Roll 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.
F - Roll 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.
T - 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.
U - Round 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.
3. In the Round Qty field, enter the 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.
4. Set the MPS ATP Method pop-list for master scheduling to the desired 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.
5. In the MPS Trap % field, enter the master production schedule trap percentage for this item, 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.
6. Set the MPS ACC LT Override flag to the desired setting.
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.
7. Press [Commit].
1. Set the WO Costs are Elemental flag to the desired 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.
2. Set the Cascade WO Release in OE flag to the desired 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.
3. Press [Commit].
1. The User Ref 1 and User Ref 2 fields are for user-defined custom purposes. Enter the appropriate value.
2. Press [Commit].
Press this button to create the plant planning record for an item when a plant item planning record does not exist for the item
Press this button to copy the defaults from the enterprise planning record for the item on the Default ME Tab.
Press this button to display the list of plants that have an item planning record for the current item.