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Contents
List of Figures
Title and Copyright Information
Preface
Audience
Documentation Accessibility
Related Information
Conventions
1
Overview to Manufacturing and Distribution Planning
1.1
Resource and Capacity Planning
1.2
Material Planning Operations
1.3
System Integration
1.4
Terms and Concepts
1.5
Planning and Production Environments
1.6
Planning a Total Business Solution
1.6.1
People
1.6.2
Process
1.6.3
Technology
1.7
Tables for Manufacturing and Distribution Planning
1.8
Menu Overview
1.8.1
Fast Path Commands for Resource and Capacity Planning
1.8.2
Fast Path Commands for Material Planning Operations
Part I Item Master and Branch/Plant Review
2
Overview to Item Master and Branch/Plant Review
2.1
Objectives
2.2
About Item Entry
2.2.1
Before You Begin
3
Enter Item Master Information
3.1
Entering Item Master Information
3.1.1
What You Should Know About
3.2
Entering Basic Item Information
3.2.1
What You Should Know About
3.3
Entering Item Text
3.3.1
Before You Begin
3.4
Assigning Item Responsibility
3.5
Entering Item Classification Codes
3.6
Entering Item Unit of Measure Information
3.7
Entering Item Manufacturing Information
3.8
Entering Item Grade and Potency Information
3.8.1
What You Should Know About
3.8.2
Processing Options
4
Enter Branch/Plant Information
4.1
Entering Branch/Plant Information
4.1.1
What You Should Know About
4.2
Assigning an Item to a Branch/Plant
4.3
Working with Item Locations
4.3.1
What You Should Know About
4.3.2
What You Should Know About
4.4
Entering Item Tax Information
4.5
Locating Item Sources
4.6
Entering Item Reorder Quantities
4.7
Entering Item Branch/Plant Manufacturing Information
4.7.1
What You Should Know About
4.7.2
Processing Options
4.8
Duplicating Item Information for Multiple Branch/Plants
4.8.1
What You Should Know About
4.8.2
Processing Options
Part II Forecasting Review
5
Overview to Forecasting Review
5.1
Overview
5.2
System Integration
5.3
Features
5.3.1
Forecasting Levels and Methods
5.3.2
Demand Patterns
5.3.3
Forecast Accuracy
5.4
Forecast Considerations
5.5
Forecasting Process
5.6
Major Tables
5.7
Supporting Tables
5.8
Menu Overview
5.8.1
Fast Path Commands
6
Work with Detail Forecasts
6.1
Working with Detail Forecasts
6.2
Creating Detail Forecasts
6.2.1
Processing Options
6.3
Reviewing Detail Forecasts
6.3.1
Processing Options
6.4
Revising Detail Forecasts
6.4.1
Example: Revising a Detail Forecast
6.4.2
Processing Options
Part III Resource Requirements Planning
7
Overview to Resource Requirements Planning
7.1
Objectives
7.2
About Resource Requirements Planning
7.2.1
How Do You Use Demand Forecasting?
7.2.2
What Factors Should You Consider?
7.2.3
How Do You Determine Long-Range Capacity Plans?
8
Enter Work Centers
8.1
Entering Work Centers for Resource Requirements Planning
8.1.1
Before You Begin
9
Determine Available Capacity
9.1
Determining Available Capacity
9.1.1
Before You Begin
9.1.2
What You Should Know About
9.2
Entering Resource Units Manually
9.2.1
What You Should Know About
9.2.2
Processing Options
9.3
Generating Resource Units
9.3.1
Before You Begin
9.3.2
What You Should Know About
9.3.3
Processing Options
10
Determine Long-Range Load
10.1
Determining Long-Range Load
10.2
Defining Resource Profiles Manually
10.2.1
Before You Begin
10.3
Generating Resource Profiles
10.3.1
Before You Begin
10.3.2
Processing Options
11
Generate Resource Requirements Plans
11.1
Generating Resource Requirements Plans
11.1.1
Before You Begin
11.1.2
Processing Options
11.1.3
Data Selection for Critical Work Centers
11.1.4
Data Selection for Branch/Plant and Dispatch Group
12
Review Resource Requirements Plans
12.1
Reviewing Resource Requirements Plans
12.2
Reviewing Dispatch Groups for Resource Requirements Planning
12.2.1
Processing Options
12.3
Reviewing Work Center Load for Resource Requirements Planning
12.3.1
Before You Begin
12.3.2
What You Should Know About
12.3.3
Processing Options
12.3.4
What You Should Know About
12.3.5
Processing Options
12.4
Reviewing Period Summaries
12.4.1
Processing Options
12.5
Reviewing Message Detail
12.5.1
What You Should Know About
12.5.2
Processing Options
12.6
Validating Resource Requirements Plans
13
Set Up Resource Requirements Plans
13.1
Setting Up Resource Requirements Plans
13.2
Setting Up Resource Requirements Display
13.3
Setting Up Unit Types
14
Set Up Resource Requirements Planning
14.1
Setting Up Resource Requirements Planning
14.2
Resource Profile
14.2.1
Calculating the Resource Profile
14.2.2
Using the Resource Profile
Part IV Single Level Master Scheduling
15
Overview to Single Level Master Scheduling
15.1
Objectives
15.2
About Single Level Master Scheduling
15.2.1
Master Scheduling Applications
16
Understand Time Fences and System Messages
16.1
About Time Fences
16.1.1
What Are Time Fence Rules?
16.1.2
What Are the Time Series Calculations?
16.2
About System Messages
17
Generate Single Level Master Schedules
17.1
Generating Single Level Master Schedules
17.1.1
Before You Begin
17.1.2
Net Change Flag Update
17.1.3
Net Change Flag Control
17.2
Generating a Master Schedule for All Items
17.2.1
Data Selection
17.2.2
Data Sequence
17.2.3
Processing Options
17.3
Reviewing Items for Master Schedule Selection
17.3.1
Processing Options
17.4
Generating a Master Schedule for Selected Items
17.4.1
Data Selection Values
18
Working with Forecast Consumption
18.1
About Forecast Consumption
18.2
Setting Up Forecast Consumption
18.2.1
Adding Planning Fence Information
18.2.2
Setting Up UDCs
18.2.3
Setting Up a Customer/Item Relationship
18.2.4
Defining Monthly Forecast Consumption Periods
18.2.5
Setting Up for Planning Generation
18.2.6
Setting Up for Time Series
18.3
Working with Forecast Consumption by Customer
18.4
Forecast Consumption Example
19
Work with Master Schedules
19.1
Working with Master Schedules
19.2
Reviewing DRP/MPS Time Series
19.2.1
Quantity Types for DRP and MPS
19.2.2
What You Should Know About
19.2.3
Processing Options
19.3
Reviewing Planning Families
19.3.1
Processing Options
19.4
Working with Messages
19.4.1
What You Should Know About
19.4.2
Reviewing Detail Messages
19.4.3
Processing Work Order Messages
19.4.3.1
What You Should Know About
19.4.4
Processing Purchase Order Messages
19.4.4.1
What You Should Know About
19.4.5
Processing Options
19.5
Adding a Freeze Code to a Purchase Order
19.6
Adding a Freeze Code to a Work Order
20
Validate Master Schedules
20.1
Validating Master Schedules
20.1.1
What You Should Know About
20.2
Generating Rough Cut Capacity Plans
20.2.1
Before You Begin
20.2.2
What You Should Know About
20.2.3
Processing Options
20.3
Reviewing Work Schedules on Production Status
20.3.1
Processing Options
20.4
Reviewing Rate Schedule and Work Center Loads
20.4.1
Processing Options
21
Set Up DRP, MPS, and RCCP
21.1
Setting Up DRP, MPS and RCCP
21.2
Setting Up Supply and Demand Inclusion Rules
21.2.1
Processing Options
21.3
Setting Up Message Types for DRP, MPS and RCCP
21.4
Setting Up Time Fence Rules for DRP, MPS and RCCP
21.5
Setting Up Forecast Consumption Periods
21.5.1
Before You Begin
21.6
Setting Up a Rough Cut Capacity Display
22
Process Orders
22.1
Processing Orders
22.1.1
Before You Begin
22.1.2
Processing Options
23
Plan Bills in the MPS/DRP System
23.1
Purpose
23.2
Demand Structure
23.2.1
Component Item Master/Item Branch Plant Information
23.2.2
Bill of Material Record
23.3
Gross Regeneration
Part V Multi-Level Master Scheduling
24
Overview to Multi-Level Master Scheduling
24.1
Objectives
24.2
About Multi-Level Master Scheduling
24.2.1
What Are Planning Bills?
24.2.2
Example: Exploding Planned Orders
25
Set Up Multi-Level Master Schedules
25.1
Setting Up Multi-Level Master Schedules
25.1.1
Before You Begin
25.2
Setting Up Order Policy Rules
25.2.1
What You Should Know About
25.3
Setting Up Stocking Types
25.4
Setting Up Feature Planned Percents
26
Generate Multi-Level Master Schedules
26.1
Generating Multi-Level Master Schedules
26.1.1
Before You Begin
26.1.2
What You Should Know About Processing Options
Part VI Manufacturing and Distribution Environments
27
Overview to Manufacturing and Distribution Environments
27.1
Objectives
27.2
About Manufacturing and Distribution Environments
27.2.1
Discrete Manufacturing
27.2.2
Batch Manufacturing
27.2.3
Rate-Based Manufacturing
27.2.4
Process Manufacturing
27.2.5
Distribution
27.2.6
What You Should Know About
28
Work with Batch Manufacturing
28.1
Creating Batch Bills of Material
28.1.1
Before You Begin
28.1.2
Processing Options
28.2
Creating Batch Routings
28.2.1
Before You Begin
28.2.2
Processing Options
28.3
Processing Batch Work Orders
28.4
Generating MPS for Batch Bills
28.5
Reviewing Batch Output from the MPS Generation
28.5.1
Example: Reviewing the Time Series for Batch Output
28.5.2
What You Should Know About
29
Work with Repetitive Manufacturing
29.1
Working with Repetitive Manufacturing
29.2
Defining Order Policy for Repetitive Items
29.3
Creating Repetitive Routings
29.4
Creating Line/Item Relationships
29.5
Creating Rate Schedules
29.5.1
Before You Begin
29.5.2
What You Should Know About
29.6
Generating MPS for Repetitive Items
29.6.1
What You Should Know About
29.7
Reviewing Repetitive Rate Scheduled Output from MPS Generation
29.7.1
What You Should Know About
29.7.2
What You Should Know About
29.8
Validating Load on Lines or Cells
29.8.1
Processing Options
30
Work with Process Manufacturing
30.1
Working with Process Manufacturing
30.2
Defining the Stocking Types for Processes
30.3
Defining Co- and By-Products
30.4
Generating MPS for the Process Industry
30.4.1
What You Should Know About
30.5
Reviewing Process Output from MPS Generation
30.5.1
What You Should Know About
30.5.2
Example: Reviewing Time Series for Pacing Co-Products
30.5.2.1
What You Should Know About
30.5.3
Processing Options
Part VII DRP/MPS Multi-Facility Scheduling
31
Overview to DRP/MPS Multi-Facility Scheduling
31.1
Objectives
31.2
About DRP/MPS Multi-Facility Scheduling
31.2.1
What Are the Different Types of Multi-Facility Scheduling?
32
Set Up Multi-Facility Schedules
32.1
Setting Up Multi-Facility Schedules
32.1.1
Before You Begin
32.2
Setting Up Supply and Demand Relationships
32.2.1
What You Should Know About
32.2.2
Processing Options
32.3
Reviewing Branch Relationships on the Relationships Chart
32.3.1
Processing Options
33
Generate Multi-Facility Schedules
33.1
Generating Multi-Facility Schedules
33.1.1
Before You Begin
33.1.2
Processing Options
34
Work with Multi-Facility Planning Output
34.1
Working with Multi-Facility Planning Output
34.1.1
Before You Begin
34.2
Reviewing Multi-Facility Time Series
34.3
Processing Multi-Facility Transfer Order Messages
34.4
Reviewing Transfer Messages
34.4.1
Processing Options
34.4.2
Batch Process to Create Transfer Orders
Part VIII Single Facility Material Requirements Planning
35
Overview to Single Facility Material Requirements Planning
35.1
Objectives
35.2
About Single Facility MRP
35.2.1
How Do You Use Bills of Material in MRP?
35.2.2
What Are the Differences Between MRP and MPS?
35.2.3
How Do You Run MRP Effectively?
36
Generate Material Requirements Plans
36.1
Generating Material Requirements Plans
36.1.1
Before You Begin
36.1.2
What You Should Know About
37
Work with Material Requirements Plans
37.1
Working with Material Requirements Plans
37.2
Reviewing MRP Time Series
37.2.1
Before You Begin
37.3
Reviewing Planning Families for MRP
37.4
Working with Messages for MRP
37.4.1
Reviewing MRP Detail Messages
37.4.1.1
What You Should Know About
37.4.2
Reviewing Quantity Types for MRP
37.4.3
Processing Work Order Messages for MRP
37.4.4
Processing Purchase Order Messages for MRP
37.5
Working with Scheduling Information
37.5.1
Reviewing MRP Pegging Demand
37.5.1.1
Processing Options
37.5.2
Reviewing MRP Supply and Demand
37.5.2.1
Processing Options
37.5.3
Reviewing Shop Floor Workbench for MRP
37.5.3.1
What You Should Know About
37.5.3.2
Processing Options
37.5.4
Reviewing Leadtime for MRP
37.5.4.1
Processing Options
38
Validate Material Requirements Plans
38.1
Validating Material Requirements Plans
38.1.1
What You Should Know About
38.2
Generating Capacity Requirements Plans
38.2.1
Before You Begin
38.3
Reviewing Capacity Requirements Plans
38.3.1
Reviewing Dispatch Groups for Capacity Requirements Planning
38.3.2
Reviewing Work Center Load for Capacity Requirements Planning
38.3.2.1
Before You Begin
38.3.3
Reviewing Period Summaries for Capacity Requirements Planning
38.3.3.1
Processing Options
38.3.4
Reviewing MRP Work Schedules on the Dispatch List
38.3.4.1
What You Should Know About
38.3.5
Reviewing MRP Rate Schedule and Work Order Loads
38.3.6
Validating Capacity Requirements Plans
39
Set Up Material & Capacity Requirements Planning
39.1
Setting Up Material and Capacity Requirements Planning
39.2
Setting Up MRP Supply and Demand Inclusion Rules
39.3
Setting Up Message Types for MRP
39.4
Setting Up Time Fence Rules for MRP
39.5
Setting Up Forecast Consumption Periods for MRP
39.5.1
Before You Begin
39.6
Setting Up the Capacity Requirements Display
40
Process Orders for MRP
40.1
Processing Orders for MRP
Part IX MRP Multi-Facility Scheduling
41
Overview to MRP Multi-Facility Scheduling
41.1
Objectives
41.2
About MRP Multi-Facility Scheduling
42
Set Up Multi-Facility Requirements Plans
42.1
Setting Up Multi-Facility Requirements Plans
42.1.1
Before You Begin
42.2
Setting Up MRP Supply and Demand Relationships
42.3
Reviewing MRP Branch Relationships on the Relationships Chart
43
Generate Multi-Facility Requirements Plans
43.1
Generating Multi-Facility Requirements Plans
43.1.1
Before You Begin
43.1.2
What You Should Know About
44
Work with MRP Multi-Facility Planning Output
44.1
Working with MRP Multi-Facility Planning Output
44.1.1
Before You Begin
44.2
Reviewing the Time Series for MRP Multi-Facility
44.3
Processing MRP Transfer Order Messages
Part X Supplier Scheduling
45
Overview to Supplier Scheduling
45.1
Objectives
45.2
About Supplier Scheduling
45.2.1
What Is the Effective Date Range?
45.2.2
What Is a Blanket Purchase Order?
45.2.3
What Is a Blanket Order Release?
45.2.4
What Are the Steps for Creating a Supplier Schedule?
46
Define Supplier Contracts
46.1
Defining Supplier Contracts
46.2
Defining Supplier Contract Information
46.2.1
Before You Begin
46.2.2
What You Should Know About
46.2.3
Processing Options
46.3
Generating and Revising Shipment Dates
46.4
Defining Supplier Split Percentages
46.4.1
Processing Options
47
Generate Supplier Schedules
47.1
Generating Supplier Schedules
47.1.1
Before You Begin
47.1.2
What You Should Know About
47.1.3
Processing Options
48
Revise Supplier Schedules
48.1
Revising Supplier Schedules
48.1.1
What You Should Know About
48.1.2
Processing Options
49
Release Supplier Schedules
49.1
Releasing Supplier Schedules
49.1.1
Before You Begin
49.1.2
What You Should Know About
49.1.3
Processing Options
50
Print Supplier Schedules
50.1
Printing Supplier Schedules
50.1.1
Before You Begin
50.1.2
Processing Options
Part XI Processing Options
51
Item Master and Item/Branch Review Processing Options
51.1
Item Master Revisions (P4101)
51.2
Branch/Plant Item Information (P41026)
51.3
Item / Branch Duplication (P41015)
52
Forecasting Review Processing Options
52.1
Forecast Generation (P34650)
52.2
Forecast Review (P34201)
52.3
Forecast Revisions (P3460)
53
Resource Requirements Planning Processing Options
53.1
Work Center Resource Units (P3007)
53.2
Work Center Resource Units Refresh (P3007G)
53.3
Resource Profile Regeneration (P3365)
53.4
Resource Requirements Planning (P3380)
53.5
Message Inquiry (P3301)
53.6
Load (P3313)
53.7
Load Bar Graph (P3313B)
53.8
Period Summary (P3312)
53.9
Message Detail (P3311)
54
Single Level Master Scheduling Processing Options
54.1
Master Planning Schedule - Plant Maintenance (P3482)
54.2
Net Change Review (P3402)
54.3
Time Series (P3413)
54.4
Multi-Facility - Gross Regeneration (P3483)
54.5
Planning (P3382)
54.6
Work Center Schedule Review (P31224)
54.7
Production Status (P31226)
54.8
Supply/Demand Inclusion Rules (P34004)
54.9
Review Planning Family (P3401)
54.10
Generate and Print Work Orders (P31410)
55
Manufacturing and Distribution Environments Processing Options
55.1
Bill of Material Revisions (P3002)
55.2
Routing Master Revisions (P3003)
55.3
Schedule Review (P3152)
55.4
Message Detail (P3411)
56
DRP/MPS Multi-Facility Scheduling Processing Options
56.1
Branch Relationship Revisions (P3403)
56.2
Branch Relationships Chart (P34031)
56.3
Multi-Facility - Gross Regeneration (P3483)
56.4
Transfer Order Review (P3421)
57
Single Facility Material Requirements Planning Processing Options
57.1
Pegging (P3412)
57.2
Supply & Demand (P4021)
57.3
Manufacturing Scheduling Workbench (P31225)
57.4
Lead Time Inquiry (P30207)
57.5
Period Summary (P3352)
58
Supplier Scheduling Processing Options
58.1
Supplier/Blanket Information (P4321)
58.2
Supplier Split Percentages (P43211)
58.3
Generate Supplier Schedule (P34400)
58.4
Supplier Schedule Revisions (P34301)
58.5
Release Supplier Schedule (P34410)
58.6
Print Supplier Schedule (P34450)
59
Z File Processing Options
59.1
Bill of Material Master - Z File (P3002Z)
59.2
Routing Master Revisions - Z File (P3003Z)
59.3
Work Center Revisions - Z File (P3006Z)
59.4
Manufacturing Work Order Entry - Z File (P48013Z)
A
Action Messages
A.1
About Action Messages
B
Functional Servers
B.1
About Functional Servers
B.1.1
Example: Voucher Processing Functional Server
C
Time Series Quantity Types
C.1
About Time Series Quantity Types
D
Import Mass Data into Manufacturing Systems
Index
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