User Manual Mrp

Material Requirements PlanningUSER REFERANCE MANUAL

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Material Requirements Planning

USER REFERENCE MANUAL

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Page 1 of 21 Revision: Baseline

© Nalco Saudi Co. Ltd. 2010


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Baseline 20.01.10



Table of Contents

Content PageDocument History LogTable of Contents

Purpose of Document

ScopeDefinitions

…………. Planning Parameters…………. Warehouse Replenishment

Chapter 1: FORECAST 4Scenario 1: Create New Forecast 4Scenario 2: Amend/Adjust Forecast 5Scenario 3: Print Forecast 6Scenario 4: Insert Forecast into Plan 7Scenario 5: Remove Forecast from Plan 8Scenario 6: Delete Forecast 9

Chapter 2: MASTER PRODUCTION SCHEDULE [MPS] 10Scenario 1: Create MPS 10Scenario 2: Print MPS 12Scenario 3: Print Action List 14Scenario 4: Validate MPS 16Scenario 5: Amen/Adjust MPS 18Scenario 6: Delete/Clean MPS 11

Chapter 3: MATERIAL REQUIREMENTS PLANNING [MRP] 20Scenario 1: Create MRPScenario 2: Print Action ListScenario 3: Validate MRP Outputs/ProposalsScenario 4: Release Work Order Proposal to Work OrderScenario 5: Release Purchase Order Proposal to Purchase Order

Chapter 4: FULL CYCLE CHART 21



Notes: To enter another row, just press ENTER after entering the quantity required To enter another item, keep pressing ESC tell you reach the “segment” field.

Chapter 1: FORECAST

Functionality

This function gives a forecast Line Item Display. User can enter/adjust forecast data.

Scenario 1: Create New Forecast

In case you are going to create a new forecast, you have to do the following:

Open the forecast entry/adjust form:

Menu Path Material Production Control Master Planning Forecasting Enter/Adjust Forecast Forecast Stock Control

Update the following fields:

Forecasted Item General Data:

Field Name Field Description Values

Forecast Number identifying a given forecast.

0 to 9999

Segment The factory/plant for which the forecast belongs

1001: For Dammam Plant,2001: For Yanbu Plant

Stock Code The YSLD code for which forecast to be entered.

Any of NALCO SAUDI codes, press F4 to see the full list.

Forecasted Item Details:


Row A sequential line number Provided automatically by the system

Date The date at which the forecasted quantity in the specified row is required to be delivered.

The monthly format Myymm will be followed,Example: use M1012 for Dec 2010

Quantity The forecasted quantity to be delivered at the specified date

As provided by sales forecast.



Scenario 2: Amend/Adjust Forecast

In case you are going to amend or adjust an existing forecast.


Menu Path Material Production Control Master Planning Forecasting Enter/Adjust Forecast Forecast Stock Control

Select the forecast you are going to amend by either: Pressing F4, and selecting the specific item immediately, or by Selecting the forecast parameters one by one, started from selecting the forecast number, followed

by selecting the segment, then selecting the specific item

Do the required amendment either by adding new row, adjusting or deleting an existing one The screen will automatically assume you are going to “ADD” a new row, and provided an auto row

number and date, you can adjust the date, and enter the quantity you need. If you are going to adjust an existing row, then press “ESC” once to go to the row field, enter the

row number to be adjusted in the row field, followed by pressing TAB, the existing parameters of this row (date and quantity) will appear so that you can adjust whatever you want.

If you are going to delete the forecast row, then select the row as in . then just enter a “ZERO” quantity in the quantity field, followed by pressing “Enter” or “TAB”

For adding new item to the forecast, repeat step . and enter the new required item after selecting the forecast number and segment, then continue as if you are creating new forecast.



Scenario 3: Print Forecast

In case you are going to get a printout of a specific forecast, you have to do the following:

Open the forecast print form:

Menu Path Material Production Control Master Planning Forecasting Print Forecast/Budget Forecast Stock Control

Enter the parameters of the forecast to be printed:


Forecast Number of the forecast to be printed.

0 to 9999



Stock Code The YSLD code(s) for which forecast to be printed.

Stock items range to be included in the print out.

- If full set of all items required in the forecast is required then leave both fields empty,

- If forecast of specific item only is required, then enter the item code in both fields.

Date The period for which the forecast to be printed.

Period range in format of ddmmyy.

- If all period included in the forecast required to be printed, then leave default values (which are: 000000 as start from date and 999999 as end date),

Type of Date Type of date required All

Distributed Distribution required Select “Total”, as NALCO will not use forecast distribution.

Select/confirm report format, you can also change printer and page setups by clicking proper button:



Notes: Moving Forecast into a plan is helping in understanding and analysing the results

of the master plan, it has nothing to do with the processing of the master plan calculations which is based on the parameters entered in the “create plan form” which are explained into chapter 2, scenario 1.

Scenario 4: Insert Forecast into Plan

You want to insert the content of a specific forecast into the master plan, to be appeared into the master plan reports for enabling you countercheck the master plan output:

Open the move forecast to item plan form:

Menu Path Material Production Control Master Planning Forecasting Move Forecast to Item Plan

Enter the parameters of the forecast to be inserted into (moved in) the master plan:


Forecast Number of the forecast to be moved in plan.

0 to 9999



Forecast Date The period for which the forecast to be moved in plan.


- If all period included in the forecast required to be moved in plan, then adjust start date to be: 000000 and leave end date as default: 999999.

Note: By default the starting date is today’s date, which can be obtained also by pressing F6.

Stock Code The YSLD code(s) for which forecast to be moved in plan.

Stock items range to be “appeared as forecasted items” in the plan.



Warehouse Warehouse identification number, the warehouse number “to which plan” the forecast will be moved in.

Use mainly:

01: For Dammam main warehouse,

02: For Yanbu main warehouse



Notes: This is not a deletion of the forecast or any part of it, it is jus a “move-out”

function, which disable forecast parameters from appearing into the master plan report, this is a useful tool to clean forecast from the plan in case of having multi plans, in order to avoid analysis confusion.

Deleting forecast or part of it, is explained in chapter 1, scenario 6, you can click here to check it.

Scenario 5: Remove Forecast from Plan

You want to remove a specific forecast from the master plan.

Open the move forecast to item plan form:

Menu Path Material Production Control Master Planning Forecasting Delete Forecast in Item Plan

Enter the warehouse for which forecast(s) are going to be deleted from (moved out) its master plan:


Warehouse Warehouse identification number, the warehouse number “from which plan” the forecast will be moved out.

Use mainly:

01: For Dammam main warehouse,

02: For Yanbu main warehouse

OK to Delete A confirmation question for completing the deletion process

Yes.(Default is “NO” in case if last minute decision was not to move it out the plan)



Scenario 6: Delete Forecast

As you can create upto 9999 forecasts, you may not require to delete anyone of them, just In case you are going to delete a specific one, you have to do the following:

Open the forecast delete form:

Menu Path Material Production Control Master Planning Forecasting Delete Forecast/Budget Forecast

Enter the parameters of the forecast to be deleted:


Forecast Forecast(s) range to be deleted from the database.

If one forecast only to be deleted, then enter forecast number twice (as from and as to), other wise enter the range of forecasts to be deleted.

If you need to delete several forecasts that cannot be selected as one range, you have to run this function more than once, to get the un-wanted forecasts deleted.

Date The period range to be deleted from the forecast.


- If all period included in the forecast required to be deleted, then leave default values (which are: 000000 as start from date and 999999 as end date),

Stock Code The YSLD code(s) to be deleted from the forecast.

Stock items range to be deleted from forecast(s) can be selected by pressing F4.



Section The factory/plant for which the forecast belongs

1001: For Dammam Plant,

2001: For Yanbu Plant

Once a forecast is deleted it cannot be recovered, and should be re-created if required.



Chapter 2 MASTER PRODUCTION SCHEDULE [MPS]

Functionality

This function gives a supply/demand statement (on the parents level), which includes the following inputs:

Demand inputs:Forecast,Undelivered Sales orders,Work orders demand

Supply inputs:Stock on Hand,Undelivered Purchase orders,Existing in-complete work orders supply

The output of this statement could be expedite/release/delete/forward/backward the completion/delivery of parent level items.

Accuracy of MPS outputs is highly dependent on the accuracy of supply/demand data, as well as the items planning parameters, l ike as lead-time, EOQ, Safety Stock and packaging size.

NALCO system will consider demand as work orders demand plus maximum of forecast and undelivered sales orders.

Scenario 1: Create MPS

You want to create a master plan.

Prerequisites

Before running the MPS, you have to have the forecast entered into the plan, click here to see chapter 1 – scenario 4.

Procedures

Open the Create MPS form:

Menu Path Material Production Control Master Planning Master Planning Schedule Create MPS

Enter the parameters of required to run the MPS:

Scenario 2: Print MPS

You want to enter a master plan.

Procedures




Reservation Date Period of reservations (sales orders and opened work orders) to be considered.

If you are in a steady state situation, period should start by today’s date, press F6 to get it, otherwise you can start by date 000000 or any proper date.

Forecast Forecast number for which MPS is to be run.

0001 – 99999, the forecast number under concern

Segment Plant for which MPS to be run You can select a specific plant or both, based on your requirements1001: Dammam Plant2001: Yanbu Plant

Forecast Date Forecast Span/Period of forecasted items to be considered.


Safety Stock Level Confirmation request if safety stock to be considered from MPS calculations.

Yes.

Stock Code The YSLD code(s) to be deleted from the forecast.

Stock items range to be deleted from forecast(s) can be selected by pressing F4.




Use mainly:01: For Dammam main warehouse,02: For Yanbu main warehouse

Scenario 6: Delete MPS

You want to delete/clean master plan.

Open the Create MPS form (same one used for creating MPS, click here to review it):

Menu Path Material Production Control Master Planning Master Planning Schedule Create MPS



Enter the following parameters:

Field Name Values Field Name Values

Reservation Date From 000000 to 999999 Safety Stock Level Leave as default

Forecast Select forecast number relate Stock Code Enter from “Dummy”

Segment From 1001 to 2001 To “Dummy”

Forecast Date From 000000 to 999999 Warehouse Leave as default

Repeat the cycle again, open the form, and re-enter the same parameters with “Dummy” item again.

Scenario 2: Print MPS

Open the Print MPS form:

Menu Path Material Production Control Master Planning Master Planning Schedule Print MPS

Enter the parameters of required to print the MPS:

Item select:


Which Selection Term The system allow to enter a selective fields by entering the field number here, you can enter its parameters, for example, if you entered “1” then “Enter” you will be able to enter “stock code” range, and so on.

Recommended to press “Enter” any continue without any narrow selections.

Sorting, select report-sorting parameters, Just press “ENTER” no need to select any special sorting.



Enter final MPS-report parameters


Gross Requirements from

Period of MPS report demand presentation.


Type of Period Type of period for supply presentation:T: Transactions,D: Days,W: Weeks,M: Months,Y: Years.

You can select the most suitable period for supply presentation, recommended inputs are: T or M




Sample output could be like:



Scenario 3: Print Action List

You want to print the action list recommended by the MPS. Open the Print Action List report:

Menu Path Material Production Control Master Planning Master Planning Schedule Print Action List



Which Selection Term Select a number from 1 to 11 to select which parameter/field to be entered.

Press Enter to go for next screen, do not select any field.- Select 1 only if you are interested in

checking MPS for specific item or range of items.

Stock Code The items code which appeared in MPS

Stock items range to be considered for MPS calculations.


Stock Code Range of stock items for which action

Leave it as default

Warehouse Warehouse number, for which MPS proposals to be checked.


Planner Planners name, for whom MPS proposals to be checked.

Leave it as default

Status Code Items status code, 0 to 7 Leave it as default

Start Date Period for which MPS proposals to be checked.


Expedite Confirmation request if MPS proposals for “expediting” order completion/delivery is required

Select Yes/No based on your requirement, recommended to select YES always.

Release Confirmation request if MPS proposals for releasing new orders.


Delete Confirmation request if MPS proposals for deleting existing orders.


Forward Confirmation request if MPS proposals for “forwarding” order completion/delivery is required


Backward Confirmation request if MPS proposals for “back wording” order completion/delivery is required








Scenario 4: Validate MPS

You want to enter a master plan.

Prerequisites

If you did not move the forecast into the plan yet, you should enter it at this step, click here to see chapter 1 – scenario 4.

Procedures

Open the Planning List per Transaction:

Menu Path Material Production Control Analyse Material Other Demands Report Planning List per Transaction



Which Selection Term The system allow to enter a selective fields by entering the field number here, you can enter its parameters, for example, if you entered “1” then “Enter” you will be able to enter “stock code” range, and so on.

Recommended to press “Enter” any continue without any narrow selections.

Sorting, select report-sorting parameters, Just press “ENTER” no need to select any special sorting.

Sorting, select report-sorting parameters, Just press “ENTER” no need to select any special Page 16 of 21 Revision: Baseline


sorting.


Warehouse Warehouse number/range, for which MPS required to be verified.


From Del. Date The period required for MPS validation

Enter the period suitable to you to confirm the MPS output.

With Forecast A confirmation request if forecast to be printed with the master plan.

Select “YES”, this is the important field to be able to validate the MPS.

Select/confirm report format, you can also change printer and page setups by clicking proper button.




Scenario 5: Amend/Adjust MPS

You want to amen/adjust/add/delete MPS proposal.

Open the Enter/Adjust MPS form:

Menu Path Material Production Control Master Planning Master Planning Schedule Enter/Adjust MPS

Enter the parameters of the MPS to be amended:


Procedures



Stock Code Range of Stock items to be checked

Enter item code (range of codes) to be amended),

If you want to add a new item to the plan, leave the range as default.

Warehouse Warehouse number/range, for which MPS required to be verified.


Stock Items with MPS only?

Confirmation request from the system regarding if the items to be shown are those with recommended work orders to be released only, or to show all items in the plan

Preferred to select “NO”

Show Forecast A confirmation request if forecast to be printed with the master plan.

Select “YES”

Forecast Date Enter forecast range to be presented.

Leave it as default.

Type of Display Type of transactions to be display

Leave it as default. “T”





Chapter 3 MATERIAL REQUIREMENTS PLANNING [MRP]

Functionality


Scenario 1

You want to enter a new forecast.

Procedures




Chapter 4 FULL CYCLE CHART

Functionality


Scenario 1

You want to enter a new forecast.

Procedures



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