Manufacturing Planning. Master Production Schedule. Material Requirements Plan. Work Order/ FPO Maintenance. Soft Bill Maintenance

Transcription

1 PRMS TM Manufacturing Planning SHOP FLOOR CONTROL Work Order/ FPO Maintenance Auto Allocation to Lots Pick Slip Print Master Production Schedule Material Requirements Plan Soft Bill Maintenance Stage Request Consolidated Pick Scheduling Workbench by Production Line RMS/Present Version 2.3 A Product of MXB - Managing the Business 100 N. Freeman Road Tucson, AZ (520)

2 RMS/Teachkit PRMS TM Manufacturing Planning Table of Contents Sample Agenda I Attendance Sheet II Introduction to PRMS TM Manufacturing 3 PRMS Planning Functions...4 PRMS Execution Functions...6 PRMS Manufacturing...8 Product Structure & Master Overview 11 Major Features...14 Primary Functions...16 System Control...18 Product Master Maintenance...20 Lot Sizing 26 Product Structure Definition...34 Product Structure Maintenance...35 Master Production Scheduling 39 Major Features...42 Entering Demand...44 Shipment Forecasts 44 Forecasting Planner Bills 45 Forecast Entry Process 46 Forecasting Setup Functions 48 Forecast Entry 50 Planner Bill Explosion 52 Forecast Inquiry 54 Forecast List 55 Demand Source Management...56 Setup Functions...64 System Control...66 MPS Management 67 Forecast Consumption Demand Source Rule Functions, Reports, Inquiries...76 MPS Generation 78 MPS Generation Report 84 MPS Generation Report Explained 85 Production Plan Report 88 Summarized MPS Valuation Report 90 Projected Inventory Report 92 MPS Order Maintenance 94 MPS Order Inquiry 96 MPS Order Report 97 MPS Inquiry/Pegging Available to Promise Inquiry 100 C MXB, 1993, 2000 Printed in the United States All Rights Reserved PRMS is a trademark of interbiz, a division of Computer Associates Inc.

3 RMS/Teachkit PRMS TM Manufacturing Planning Table of Contents Rough Cut Capacity Planning 103 Rough Cut - Demand vs. Resources Major Features Setting Up Resource Definition 110 Resource Definition Maintenance 112 Resource Definition List 113 Discrete and Flow Resources 114 Bill of Resource Maintenance 116 Resource Variance Maintenance 118 Resource Variance Maintenance Purge 120 Bill of Resource Report 121 Rough Cut Generation Rough Cut Analysis and Reporting Rough Cut Inquiry Rough Cut Load Reports Shop Floor Control Overview 129 Shop Data Maintenance Overview 133 Routings and Work Centers Major Features Operation Lead Times Work Center Maintenance Routing Maintenance Material Requirements Planning 147 What it Does Major Features Lead Time Planning for Discrete Items Lead Time Planning for Repetitive Products Functions System Control 160 MRP Generation 172 MRP Generation Reports 176 MRP Generation Report Explained 178 MRP Generation Report Explained 179 MRP Inquiry/Pegging 180 Suggested Work Order Report 182 Suggested PO Report 184 Dollars Committed Report 186 Exception Message Management C MXB, 1993, 2000 Printed in the United States All Rights Reserved PRMS is a trademark of interbiz, a division of Computer Associates Inc.

4 RMS/Teachkit PRMS TM Manufacturing Planning Table of Contents Capacity Requirements Planning 191 Load Versus Capacity Maintenance Programs and Functions CRP Generation 196 CRP Inquiry/Pegging 200 CRP Generation Reports 202 Work Center Variance Maintenance 204 Work Center Variance Batch Update 206 Manufacturing Planning in Multiplant 209 PRMS Multiplant Planning with Multiplant Using the Forecasting Workbench 214 Not Using the Forecasting Workbench 216 Managing Interplant Demand 218 Defining Interplant Demand 220 How it Works Inquiries and Maintenance Hands On Workshop 227 C MXB, 1993, 2000 Printed in the United States All Rights Reserved PRMS is a trademark of interbiz, a division of Computer Associates Inc.

5 PRMS TM Manufacturing Planning SHOP FLOOR CONTROL Work Order/ FPO Maintenance Auto Allocation to Lots Pick Slip Print Master Production Schedule Material Requirements Plan Soft Bill Maintenance Stage Request Consolidated Pick Scheduling Workbench by Production Line RMS/Present Version 2.3 A Product of MXB - Managing the Business 100 N. Freeman Road Tucson, AZ (520)

6 Sample Agenda Day 1 Morning Intro to PRMS Manufacturing Product Structure and Product Master Review Product Master/Structure Workshop Afternoon Master Production Scheduling Master Production Scheduling Workshop Day 2 Morning Master Production Scheduling Workshop Rough Cut Capacity Planning Afternoon Rough Cut Capacity Workshop Shop Floor/Shop Data Overview Shop Data Workshop Day 3 Morning Material Requirements Planning MRP Workshop Afternoon Capacity Requirements Planning CRP Workshop Day 4 Morning Manufacturing Planning in Multiplant Page I

7 Course Title RMS/Teachkit Manufacturing Planning Course Dates check (x) Name (printed) Job Function Day 1 Day 2 Day 3 Day 4 Page II

8 Introduction to PRMS TM Manufacturing SHOP FLOOR CONTROL Work Order/ FPO Maintenance Auto Allocation to Lots Pick Slip Print Master Production Schedule Material Requirements Plan Soft Bill Maintenance Stage Request Consolidated Pick Scheduling Workbench by Production Line RMS/Teachkit Page 3

9 TM PRMS Planning Forecasting Workbench Dist. Whse A Dist. Whse B Dist. Whse C Whse Fcst. Maint. R o u g h C u t C a p a c i t y Distribution Requirements Planning Suggested WRO's Posting Warehouse Master Production Suggested Scheduling MPS Orders Manufacturing Plant Material Requirements Planning Planned Order Releases Capacity Requirements Planning Forecast Maintenance MXB, 2000 Page 4

10 TM PRMS Execution Functions Dist. Whse A Dist. Whse B Dist. Whse C Warehouse Replenishment Orders Posting Warehouse MPS Orders/Scheduling Workbench/Work,Firm Planned Orders, Purchase Orders Manufacturing Plant Scheduling Workbench/ Work, Firm Planned Orders/ Requisitions, Purchase Orders/ Replenishment Orders MXB, 2000 Page 6

11 PRMS TM G e n e r a l L e d g e r I n t e r f a c e Distribution Requirements Planning Warehouse Replenishment Orders Capacity Requirements Planning Payroll/ Human Resources Customer Order Processing Accounts Receivable Master Production Scheduling Shop Data Forecasting Workbench Product Structure Material Requirements Planning Shop Floor Control Inventory Control Physical Inv./ Cycle Count PRMS is a trademark of interbiz, a division of Computer Associates, Int'l Planning Execution Vendor Managed Inventory 9.0 Rough Cut Capacity Planning Purchasing/ Receiving Accounts Payable Quality Control MXB,2000 Page 8

12 Product Structure & Master Overview SHOP FLOOR CONTROL Work Order/ FPO Maintenance Auto Allocation to Lots Pick Slip Print Master Production Schedule Material Requirements Plan Soft Bill Maintenance Stage Request Consolidated Pick Scheduling Workbench by Production Line RMS/Teachkit Page 11

13 Product Structure Functionality Product Master Engineering Change Control Product Structure Simulation Product Cost/ Lead Time Rollup Simulation Reporting Product Structure Maintenance Global Component 8.4 Replacement P/S Reorganization Assembly/Where-Used Reporting ECN Reporting Production Assembly Comparison Report 8.4 Product Costing Inventory Control Shop Floor Control Master Production Scheduling Material Requirements Planning MXB, 2000 Page 12

14 Product Structure Major Features PLANNER BILLS THREE QUANTITY REQUIRED FIELDS BATCH SIZES EFFECTIVITY DATES SUBSTITUTE/OPTIONS DESIGNATION ENGINEERING CHANGE TRACKING BY-PRODUCT DESIGNATION MATERIAL CONTROL BY COMPONENT BALLOON NUMBER DESIGNATION ENGINEERING, AND PRODUCTION TEXT POTENCY DESIGNATION DUPLICATE COMPONENTS ZERO QUANTITY REQUIRED Page 14

15 Product Structure Primary Functions SYSTEM CONTROL (WCMANT) UNIT OF MEASURE TABLE (MS0827) 8.3 PRODUCT MASTER MAINTENANCE (MS0825) PRODUCT STRUCTURE MAINTENANCE (PS0021) ENGINEERING CHANGE NUMBER (PS0800) GLOBAL COMPONENT REPLACEMENT (PS0203) 8.4 PRODUCT COST UPDATE (SC0060) PRODUCT STRUCTURE REORGANIZATION (PS0040) Page 16

16 Product Structure System Control ENGINEERING CHANGES SUPPORTED ENGINEERING CHANGE NUMBER REQUIRED SUBSTITUTES AND OPTIONS SUPPORTED EFFECTIVITY DATES SUPPORTED BALLOON NUMBERS SUPPORTED BATCH QUANTITIES SUPPORTED FOR ASSEMBLY FULL EDITING PERFORMED ON LINE PRINT PRODUCT STRUCTURE EDIT CHANGES NUMBER OF DAYS TO RETAIN DISCONTINUED COMPONENTS OMIT SETUP COSTS FROM ROLLUP FULL ABSORPTION OR DIRECT COSTING USED ALLOW FOR SHRINK IN COSTS USE ENG, MFG, OR BASE STD QTY In Base Costs In Current Costs In Actual Costs Page 18

17 Product Structure Product Master Maintenance (MS0825, MSPMP100) Key Fields for Manufacturing GENERAL PRODUCT INFORMATION ITEM TYPE DEMAND TYPE MODEL FLAG IMPORT FLAG LOTS REQUIRED LOCATIONS REQ. SHELF LIFE PRODUCT CLASS MAKE, BUY, PHANTOM, PLANNER I, C, D IS THIS A MODEL FOR F & O ALLOWS LANDED COST FOR BUYS REQUIRES FOR ALL TRANSACTIONS FOR CALCULATION OF EXPIRATION INVENTORY REPORTING UNIT OF MEASURE ALT. UNIT OF MEAS. FOR PURCHASED PARTS CONVERSION BUYER ID* ORDER PT ITEM ORDER PT & QTY INSP. REQUIRED TO DESIGNATE NON-MRP ITEMS WHEN AND HOW MUCH TO ORDER TO CONTROL THROUGH DOCK TO STOCK * indicates that the value used must be previously defined Page 20

18 Product Structure Product Master Maintenance (MS0825) PURCHASING Lead Times ORDER RELEASE DOCK TO STOCK DELIVERY LEAD TIME TO CREATE ORDER LEAD TIME TO PROCESS RECEIPT VENDOR LEAD TIME GENERAL MANUFACTURING PLANNER ID MRP & MPS SORTING AND CONTROL PROD PLAN GROUP CODE* MPS & RCC SORTING AND CONTROL POSTING WHSE* MPS ITEM MFG. METHOD SCHED LEVEL DEFAULT LINE* THE WAREHOUSE A MAKE ITEM IS POSTED TO OR THE WAREHOUSE A COMPONENT IS PICKED FROM DESIGNATES MPS ITEMS FLOW ORDERS OR WORK ORDERS FROM MPS OR MRP IN SCHEDULING WORKBENCH FOR WORKBENCH, WHICH LINE * indicates that the value used must be previously defined Page 22

19 Product Structure Product Master Maintenance (MS0825) GENERAL MANUFACTURING AUTO RESCHEDULE SCHEDULE TYPE 8.3 LAG TIME TYPE 8.3 MRP PROCESSING CONTROL DENOTES THE TYPE OF MANUFACTURING ORDER THAT IS NORMALLY USED IN THE MANUFACTURE OF THIS PRODUCT, 1-WORK ORDERS, 2-FLOW ORDERS, 3-OSF, 4-NOS WHETHER THE LAG TIME USED BY THE PRODUCTION SCHEDULING WORKBENCH IS IN CALENDAR DAYS OR LINE CALENDAR DAYS LEAD TIME OFFSET 8.3 THE NUMBER OF DAYS BETWEEN THE POR OF THE PARENT AND THE GROSS REQUIREMENT OF THE CHILD Page 24

20 Lot Sizing Lot Size Rule Lot Size POR before lot sizing POR after lot sizing 1 - Discrete Fixed w/disc Fixed Lot Not Used 5 - Fixed Period Length, FPL = 5 days Lot Size = 100 before lot sizing after lot sizing Lot Size = 500 before lot sizing after lot sizing Monday Tuesday Wednesday Thursday Friday Monday Tuesday Wednesday Thursday Friday MXB, 2000 Page 26

21 Product Structure Product Master Maintenance (MS0825) MANUFACTURING PLANNING SAFETY STOCK If Safety Stock is used by MRP or MPS, this is the projected on hand quantity that will be planned. MRP will issue exception messages to replenish whenever the projected or actual balance is below this level. MIN/MAX SUGGESTED ORDER QUANTITY MPS and MRP will plan to the minimum quantity and message if the planned order is over the maximum quantity. LEAD TIME FENCE RULE Determines which lead time value of the product is used to multiply by the Lead Time Multiplier to determine where a time fence is drawn. (1) Assembly lead time, (2) Assembly plus safety lead, (3) Manufacturing lead time, (4) Manufacturing with safety, (5) Cumulative, (6) Cumulative with safety MPS PHANTOM LEAD TIME If an item is a MPS Item and a Phantom, this lead time will be used by MRP. LEAD TIME MULTIPLIER 1 AND 2 The value here is multiplied by the appropriate lead time to determine the number of days plus the MPS Generation Date where a time fence is drawn. If no time fences are used then there is one time period, one fence equals two time periods, two fences equals three time periods. Page 28

22 Product Structure Product Master Maintenance (MS0825) MANUFACTURING PLANNING DEMAND SOURCE RULES 1, 2, 3 Determines what the MPS Generation considers as demand in the time periods determined by the lead time fences (1) Actual Forecasts, (2) Smoothed Forecasts, (3) Customer Orders, (4) Demand Smoothing, (5) DRP Information, (6) Forecast Consumption Lumpy 9.0, (7) Forecast Consumption Smoothed 9.0. (6) and (7) = Period Forecasts - (Shipped + Booked) + Booked - Past Due Postpones intra-period adjustments of suggested MPS/reschedules until forecast for period is consumed. AUTO ACCEPT MPS Defaulted from the System Control, determines if this item will be eligible for Auto Accept in MPS Generation after the Auto Accept Time Fence. AUTO ACCEPT MPS TIME FENCE The number of days from the MPS Generation date after which a Suggested MPS will be Auto Accepted into an Accepted MPS Order. Typically referred to as the 'firm' or 'frozen' schedule period. USE DRP PLAN ORDER FENCE A Yes indicates that your intention is to have Planned Replenishment Orders from DRP drive the demand to MPS after the number of days specified in the planned order time fence. This reduces the time horizon that Replenishment Orders are required to be managed. DRP PLANNED ORDER TIME FENCE The number of days after the MPS Generation Date in which Planned Replenishment Orders will drive demand in MPS. Page 29

23 Product Structure Product Master Maintenance (MS0825) MANUFACTURING PLANNING STANDARD LABOR AND STANDARD MACHINE User defined and not used in PRMS. CUM LABOR AND CUM MACHINE Used by the Production Plan Report (MP0110) and Summarized MPS Valuation Report (MP0170). This value is multiplied by the quantity of suggested and or accepted MPS orders to provide bucketed summaries. These values are not calculated from the routing file. LOT SIZING USED If lot sizing occurs during MPS, MRP, or not at all. System Control allows specification by demand type (I,C,D). LOT SIZING RULE The type of lot sizing that is performed (1) Discrete lot sizing, (2) Fixed lot with discrete quantities, (3) Fixed lot multiples, or (5) Fixed period length. FIXED PERIOD LENGTH For lot size rule 5 (fixed period length), the number of days of POR' s that will be consolidated into one POR. MRP will sum the POR's within this number of days, increase to the lot size and place the first POR on the first day of this period that the POR appears. MRP SAFETY LEAD TIME USED Determines is safety lead time will be considered in the POR offset. Safety lead time releases an order earlier than the scheduled release. Auto PO Create (PO0900), Requisition Entry (PO0010) and Batch Work Order Create (SF0019) all allow the specification of an upper release date which will accomplish this same functionality. Page 30

24 Product Structure Product Master Maintenance (MS0825) MANUFACTURING PLANNING SAFETY STOCK USED Will safety stock be planned during MPS, MRP, or neither. If safety stock is used, MRP will issue messages to replenish then inventory immediately (under lead time) when the actual or planned balances drop below the level. System Control allows specification by demand type (I,C,D). ON HAND INVENTORY USED Will on hand inventory be netted during MPS, MRP, neither or both 8.4. System Control allows specification by demand type (I,C,D). CONSIDER NEGATIVE ON HAND AS ZERO 9.0 MRP and the Shortage Report (SF0360) will consider negatives as zero if this flag is 'Y'. If negative inventory is due to timing of transactions, setting flag to "Y" will cause shortages to be planned. MRP MESSAGE FILTERS SUPPRESS RESCHEDULE IN DAYS AND AMOUNT The number of shop days OR base standard value that a Reschedule In message must exceed to generate an exception message. If set to 5 days and $100,000 then no item would be rescheduled in to the first 5 days unless the value exceeded $100,000. SUPPRESS RESCHEDULE OUT DAYS AND AMOUNT The number of shop days OR base standard value that a Reschedule Out message must exceed to generate an exception message. SUPPRESS PAST DUE REQUIREMENTS AND POR'S The number of days that a past due message is not considered past due and will not issue a message. Page 31

25 Product Structure Product Master Maintenance (MS0825) SUPPRESS SCHEDULED RECEIPT BEFORE GENERATION DATE The number of days that a Scheduled Receipt (PO, WO, RO, etc.) is past due without issuing a message. SUPPRESS ON HAND BELOW SAFETY STOCK The percentage of On Hand Below Safety Stock that is allowable without issuing an immediate replenishment message. MRP will still issue reschedule in or create messages. This filter is specifically for the "On Hand Below Safety Stock" message. SUPPRESS QUANTITY LESS THAN MINIMUM The percentage of Minimum that is allowable without issuing an exception message. SUPPRESS QUANTITY GREATER THAN MAXIMUM The percentage of Maximum that is allowable without issuing an exception message. PRODUCT INVENTORY TEST CYCLE DAYS FREQUENCY OF TESTING ACTIVE INGREDIENT HAVING ACTIVE QUANTITY POTENCY RANGE INV. METHOD STD POTENCY DEF. PHYS U/M WT TO WT FACTOR ACCEPTABLE RANGES FOR ALLOC. IN "ACTIVE" OR "PHYSICAL" DEFAULT POTENT VALUE FOR "ACTIVE" INV. METHOD FOR ALLOCATION OF FILLER Page 32

26 Product Structure Definition Make, Phantom, Model, Feature, Planner Parent By-Product Qty Req'd Child Child Child/Parent Make, Buy, Phantom, Feature, Planner Seq. No. Qty Req'd Eff. Dates Operation Bkflsh Stage Type ECN Balloon # Plan/Cost % Potency Text Line Init. Child MXB, 1998 Page 34

27 Product Structure Product Structure Maintenance (PS0021, PSPSP100) DEFINES COMPONENT TO PARENT RELATIONSHIP STATES THE ENGINEERING, MANUFACTURING AND BASE QUANTITY REQUIRED INDICATES IF COMPONENT IS SUBSTITUTE OR OPTIONAL DESIGNATES IF COMPONENT IS A BY-PRODUCT INDICATES EFFECTIVE DATES OF COMPONENT AND ECN NUMBER WHICH CAUSES THE CHANGE INDICATES THE FIRST OPERATION OF THE ROUTER THAT COMPONENT IS USED ALLOWS BALLOON NUMBER FOR DESIGNATION AND SORTING IDENTIFIES AND ALLOWS MAINTENANCE OF PRODUCTION AND ENGINEERING TEXT INDICATES IF COMPONENT IS ACTIVE, FILLER OR NOT DEFINES ALLOWABLE RANGE OF POTENCY FOR INVENTORY ALLOCATION Page 35

28 Product Structure Product Structure Maintenance (PS0021) DESIGNATES THE STANDARD POTENCY DESIGNATES IF COMPONENT IS USED BY CONSOLIDATED PICK DESIGNATES IF BACKFLUSH ISSUES TRANSACTIONS OCCUR AND WHERE THEY OCCUR FROM SPECIFIES QUANTITY TO INITIALIZE IN LINE INITIALIZATION Page 36

29 Master Production Scheduling SHOP FLOOR CONTROL Work Order/ FPO Maintenance Auto Allocation to Lots Pick Slip Print Master Production Schedule Material Requirements Plan Soft Bill Maintenance Stage Request Consolidated Pick Scheduling Workbench by Production Line RMS/Teachkit Page 39

30 The Production Planning Process Customer Orders Distribution Replenishment Customer Service Levels Forecast Master Production Scheduling Generation Rough Cut Capacity Planning Management Decision Shop Floor Determine Demand Consider Pending Supply Consider Inventory Determine Net Demand Propose Supply Test Against Resources Adjust Commit to Plan Execute Schedule Control MXB, 2000 Page 40

31 Master Production Scheduling Major Features Forecasting Input of a Shipment Forecast FIRM OR SPECULATIVE DESIGNATION MPS only recognizes Firm Forecasts PLANNER BILL EXPLOSION Generation of end item forecasts based on a parent and percentage relationships Master Production Scheduling Determination and commitment to build plan DEMAND SOURCE MANAGEMENT MPS GENERATION AUTO ACCEPT COMBINED DEMAND PRODUCTS AUTO ACCEPT BY TIME FENCE MULTI LEVEL MPS FOR BUILD TO ORDER MPS ORDER PURGE AVAILABLE TO PROMISE INQUIRY Page 42

32 Entering Demand Shipment Forecasts Forecasts Can be Entered or Generated Entering Forecasts FORECAST MAINTENANCE (MP0100) PRODUCT Widget BEG. DATE END DATE FIRM? QUANTITY 10/1/99 10/31/99 Y 1000 Only Firm Forecasts are Recognized by MPS Generation Quantity Expected to Ship between the Beginning Date and End Date SMOOTHED FORECAST If October has 20 Shop Days, forecasted shipment schedule of 50 per day LUMPY FORECAST Forecasted shipment of 1000 on October 1 Page 44

33 Each one of our RMS/Teachkit courses and training presentations are available for your selection. Choose the full color, 'Present' format for self-review or your presentation document for the class through your projection system. If you would like to print student manuals, select '+ Print' format. In addition to receiving the 'Present', you will receive an additional file specifically configured and optimized for two-sided student workbook production. Submit to your own laser printer or send outside. If you prefer, you can choose the 'Present' format only and order the student manuals from us! All our printing is crisp, laser printing, two-sided, soft bound and delivered on time 100% of the time. Education & Reference General Present + Print Present + Print Manufacturing Welcome to PRMS Product Definition PRMS Overview Manufacturing Planning Version 9 Enhancements Shop Floor Control 'Canned' Reports & Inquiries Router Training Distribution Inventory Forecasting Workbench Inventory Control Customer Order Processing Cycle Count & Phys. Inv Order Entry Training Lot Control RGA's & C/D Memos Financial Replenishment Orders Standard Costing Purchasing & Receiving Accounts Payable Online Tutorials The Keyboard & PRMS Navigating PRMS Purchasing Overview Requisition Processing Measuring Execution Performance Contact us: [email protected] u.s , , fax