New features added, version 7.5.2, 7.5.3, 8.1
Program MPPP, Material Requirements Planning, is used to select material requirements planning (MRP) parameters and to perform Material Requirements Planning for your manufacturing enterprise and plant.
* Before you can successfully run the material requirements planning (MRP), the shop calendar must be set up for one year before the material requirements planning (MRP) run start date.
* When considering transfer orders, if a due date has been entered on the transfer order, the due date will be used when calculating material requirements planning, instead of defaulting to the system date.
You can select the number of buckets for displaying period requirements and the number of work days in each bucket. You can also specify the number of days after an order due date that the inventory is available.
You can set the run start time so that processing will take place during an off-peak period or at night.
While program MPPP, Material Requirements Planning, creates planned orders as necessary to meet requirements, the orders are held in the Material Planning (MP) Module. Use program MPPX, MRP Planned Order Transfer, to transfer the orders to the work order management modules.
Multiple Plant Material Requirements Planning
Using Materialized Views in MRP for Performance
Material Requirements Planning Process
This feature should not be used if the Yes flag is set to on in program MSSP, Master Production Scheduling, for the question Is planned orders in other plants demand in this plant?
Multiple plants can be selected for the same material requirements planning (MRP) run. The Include Plant in MRP flag must be set to on and the desired plants must be selected under on the Plants tab. The plant in which material requirements planning (MRP) is being run is the current plant in the following explanation.
* Item planning parameters for the current plant are used to determine requirements when material requirements planning (MRP) is run. Item planning parameters are first used for the current plant the Plant Tab in program ICPM, Inventory Planning Data Maintenance. If no record exists on the Plant Tab, the item planning parameters for the manufacturing enterprise are used from the Default ME Tab in program ICPM, Inventory Planning Data Maintenance.
* The item plant record from program ICEM, Item Plant Maintenance, is used to determine the manufacturing plant when the planned orders are transferred with program MPPX, MRP Planned Order Transfer.
After material requirements planning is run, when the results are transferred with program MPPX, MRP Planned Order Transfer, the planned orders in the current plant and the planned orders in the plants selected on the Plants tab will be deleted.
Each MRP item's default manufacturing plant will be retrieved from program ICEM, Item Plant Maintenance, for the current plant. When new planned orders are written or existing planned orders are updated, they will be written or updated in the item's default manufacturing plant, as long as that plant was included in the material requirements planning (MRP) run.
If the item's default manufacturing plant is not included in the material requirements planning (MRP) run, or if it is blank, the current plant will be used.
For example:
ICEM, Item Plant Maintenance, setup
The default manufacturing plant in program ICEM, Item Plant Maintenance, for each item included in the material requirements planning (MRP) run, in the current plant.
|
Current |
MRP Item |
MRP Item |
MRP Item |
MRP Item |
MRP Item |
|
10 |
10 |
20 |
30 |
40 |
blank |
Non-Firm Planned Orders
Before material requirements planning (MRP) is run, this is the number of non-firm planned orders in each plant for each item included in the run.
|
Plant |
MRP Item |
MRP Item |
MRP Item |
MRP Item |
MRP Item |
|
10 |
10 |
10 |
10 |
10 |
10 |
|
20 |
5 |
5 |
5 |
5 |
5 |
|
30 |
3 |
3 |
3 |
3 |
3 |
|
40 |
1 |
1 |
1 |
1 |
1 |
MPPP, Material Requirements Planning, Setup
Include Plant in MRP set to on, and plants 10, 20, and 30 selected.
Planned orders after material requirements planning (MRP) run and the orders have been transferred with program MPPX, MRP Planned Order Transfer.
|
Plant |
MRP Item |
MRP Item |
MRP Item |
MRP Item |
MRP Item |
|
10 |
18 |
0 |
0 |
18 |
18 |
|
20 |
0 |
18 |
0 |
0 |
0 |
|
30 |
0 |
0 |
18 |
0 |
0 |
|
40 |
1 |
1 |
1 |
1 |
1 |
If you have a large number of sales order entry lines records to be considered when MRP is run, then you have the option of using a materialized view to increase the performance of the MRP run. In order to use the materialized view, set up the MRP_USE_FAST_OE parameter in program MURM, Initialization Parameter Maintenance.
If you are using this parameter, then the materialized view needs to be refreshed immediately before MRP is run by adding a job parameter in program MUJM, Menu and Job Parameter Maintenance. Once this step has been added, the MRP run with program MPPP, Material Requirements Planning, must be done as the database schema owner.
To add the job parameter in program MUJM, Menu and Job Parameter Maintenance, complete the following steps:
* Run program MUJM, Menu and Job Parameter Maintenance, from the menu.
* Click on the Job Definitions tab.
* In the Menu Option field, enter MPPP.
* Press [Execute Query].
* The MPPP Menu Option should have 4 records. Go to the last one.
* In the Seq field, change the 4 to a 5.
* Press [Commit].
* Click on [New Record].
* In the Menu Option field of the new record, enter MPPP.
* In the Seq field, enter 4.
* Leave the OK to run flag set to off.
* In the Seq On Success field, enter 5.
* In the On Error and On Not Ok fields, enter 0.
* In the Menu Selc field, enter MPPV.
* In the Proc Type field, enter 1.
* In the Prog Name field, enter mppp_mvw.
* In the Scrn Head field, enter Material Requirements Planning.
* Press [Commit].
1. In the MRP Past due time fence field, enter the past due time fence date for the material requirements planning (MRP) run.
* This is the end date for the past due bucket.
* Supply and demand items dated on or before this date are past due.
2. Set the MRP Startup Flag to the desired setting. The choices are In Progress, New Run, Restart, and No Run.
* If this pop-list displays In Progress, a material requirements planning (MRP) run is currently in progress or has been halted due to a processing error.
* Set the pop-list to New Run to indicate a normal startup. This will reset a multi-plant selection to be a single plant selection. You must then click on the Plants tab to set up the multi-plant selection, if desired.
* Set the pop-list to Restart to indicate that is a restart. A restart is necessary only under extraordinary circumstances, such as a power outage. In such a case, a restart saves processing time since processing is resumed at the point of interruption.
* Set the pop-list to No Run, if a material requirements planning (MRP) run will not be started at this time.
3. In the Run start date/time field, enter the calendar date and time for activation of the MRP Process. The default is for an immediate start.
4. Set the Non-firm Shop Order Reschedule pop-list to the desired setting. This pop-list controls the re-planning of non-firm order dates and how to reschedule. The choices are out only, in only, in and out, or do not reschedule.
* In only allows the order dates to be moved up.
* Out only allows the order dates to be moved back.
* In and out allows the order dates to be changed as needed.
* Do not reschedule will prevent the order dates from being changed.
5. Set the Enable Transition Planning flag to the desired setting. When this flag is set to on, firm replenishments that do not match the Make or Buy pop-list from item planning will not be rescheduled. Planned orders will be generated for any previous project shortages.
6. Set the Transfer Planned Orders flag to the desired setting. When this flag is set to on, then transferring the planned orders for all items will be performed as part of the material requirements planning (MRP) run.
7. In the No of Buckets field, enter the number of buckets for displaying period requirements.
* At least three buckets must be specified - past due, one current bucket, and future.
8. In the Work days in each bucket field, enter the number of work days to be included in each bucket.
9. In the Days after due field, enter the number of days after the order due date that the inventory is available.
10. If you are using the multiple plant feature, set the Include Plant in MRP flag to on, and click on the Plants Tab.
* On the Plants tab, set the Include in MRP flag to on for all plants that you wish to include in the material requirements planning (MRP) run.
* This feature should not be used if the Yes flag is set to on in program MSSP, Master Production Scheduling, for the question Is planned orders in other plants demand in this plant?
10. Press [Commit], and exit the program.
* The program will run some other processes and then open program MPPW, MRP Progress Monitor.
* If you do not exit program MPPP, Material Requirements Planning, the information will not process correctly. The netting and grossing processes will complete before the loading process, and the material requirements planning run will go no further. You will then have to re-run the material requirements planning process.
11. When program MPPW, MRP Progress Monitor, is open, go to the server. There is an MRP icon on the server.
12. Make sure that the target field in the icon's properties is set up for the database for which you are running Material Requirements Planning. The target field should be similar to the following example. In the following example, the NDS Home Directory is N:\
* Target: N:\NDS\MRP.EXE userid/password@server
* There are additional parameters that you can pass to the material requirements planning program. The string allows the following parameters.
MRP.EXE <oracle login> <debug switch> <silent mode> <debug item>
<oracle login> = the oracle connect string (in the above example, this is userid/password@server)
<debug switch> = optional switch setting for controlling debug output. 0 or omitted = no debug, 1 = debug all processes, C = debug loader process, D = debug netting process, E = debug grossing process
<silent mode> = optional switch for suppressing dialog boxes. 0 or omitted = normal mode with dialogs, 1 = suppress dialogs
<debug item> = optional item number to debug, only used when debug switch setting is other that 0.
* You must pass all parameters that are listed in front of the one that you wish to pass. For example, if you need to indicate that you would like to have dialogs suppressed, you would need to also send in the oracle login and the debug switch values. N:\NDS\MRP.EXE userid/password@server 0 1
13. Use the icon to start the Material Requirements Planning run.
* The server will give you an application error and the material requirements planning process will not run if the target field is not set up for the correct database.
14. You can view the progress of the run in program MPPW, MRP Progress Monitor, using the [Execute Query] button. When the run has completed, both the next item for netting field and the next item for grossing field will be filled with right brackets - ]]]]].