MFG/PRO 9.0 User Guide Volume 3: Manufacturing - QAD.com

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240 MFG/PRO USER GUIDE — MANUFACTURING Ï See User Guide Volume 5: Supply Chain Management. Ï See Chapter 11, “Forecasting/ Master Schedule Planning,” for more detail. Introduction Material requirements planning (MRP) balances supply and demand for purchased and manufactured items. Given a set of demands or requirements, MRP automatically calculates a time-phased schedule of planned supply orders or replenishments to satisfy those demands. MRP looks at demand for finished items and uses product structure information to calculate demand for component items. For each item, MRP looks at the ordering information, the amount currently on hand, and lead times, and generates planned orders suggesting how many of that item to buy or make and when to do so. MRP and Sites MRP’s planning activity is performed by site. Each site’s material plan is completely independent from inventory, demand, and supply at other sites. You can run MRP for several sites in succession, but it does not plan for these sites as a group. For organizations with multiple sites, MRP can be used in conjunction with distribution requirements planning (DRP), which balances supply and demand among sites. Sources of Demand and Supply MRP uses the master production schedule (MPS) to calculate dependent component demand. Dependent demand is directly derived from the demand for other items, and includes demand for components items, raw materials, and subassemblies. Independent demand is demand that cannot be calculated or derived from demand for other products. It is represented through forecasts and sales orders, and includes demand for end products and replacement items. Independent demand generally passes to MRP through the master production schedule.
Sources of Demand MRP considers the following as sources of demand: • Forecasts • Sales orders • Customer scheduled orders from a required ship schedule • Intersite orders, generated by DRP • Component requirements from manufacturing • Production forecasts • Safety stock requirements MRP does not consider unconfirmed sales orders or component requirements from batch firm planned orders as sources of demand. Sources of Supply MRP considers the following as sources of supply: • Nettable quantity on hand (QOH) • Purchase orders • Intersite requests, generated by DRP • Manufacturing orders (work orders and repetitive schedules) • Quality orders • Supplier scheduled orders MATERIAL REQUIREMENTS PLANNING 241 MRP does not consider blanket purchase orders or non-nettable inventory as sources of supply. Setting Up MRP Before running MRP, set up the following data in your system: • Control file parameters in the MRP Control File. • Item planning parameters • Inventory status codes • Product structures and formulas
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User Guide Volume 3 MANUFACTURING P
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Contents ABOUT THIS GUIDE . . . . .
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CONTENTS V Defining Processes . . .
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CONTENTS VII Lead Time Calculations
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CONTENTS IX Common Transaction Data
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CONTENTS XI Maintaining Master Sche
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What Is in This Guide? 2 Windows Ke
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QAD Web Site or MFG/PRO users with
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Navigation Commands User Menu F6 Ct
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CHAPTER 1 Introduction to Manufactu
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Formula/Process The Formula/Process
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CHAPTER 2 Product Structures This c
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If a single company manufactures th
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Alternate Structures/Formulas An it
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Setting Up a Product Structure Defi
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equired, consider changing the comp
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Relationship with Configured Produc
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Assembly or Component Lead Time Sun
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CHAPTER 3 Routings/Work Centers Thi
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Some of these capabilities are espe
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Account Type Use Burden Usage Var E
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Machines. Enter the number of machi
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Yield %. Enter the order percentage
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Planning Maintenance (1.4.7) or Ite
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Work Center Routing Standards Somet
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If you examine this formula, severa
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Set the work center labor and burde
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CHAPTER 4 Formula/Process The Formu
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The Formula/Process module works in
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BOM/Formula as an alternate using A
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Use this frame to specify which scr
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CHAPTER 5 Co-products/ By-products
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Overview A base process is a manufa
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More About Co-products and By-produ
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Setting Up Mix Variance Accounts If
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Order Policy. Enter POQ or FOQ. MRP
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Qty Type. Enter B for batch, P for
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To set up a structure for a recycla
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Only a base process can have altern
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Although prune juice is a significa
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Rolling Up Costs Roll up lower-leve
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Allocation by Price The percentage
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• Closed. Co-product costs are re
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ecord for its base process. This de
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When a planned purchase order is ap
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Accessing and Modifying Joint Order
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Mix Variance Acct. Enter the accoun
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Backflush Calculation Methods Speci
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Receiving Unplanned Items Use Unpla
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(Supplier) Schedule Update from MRP
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CHAPTER 6 Work Orders The Work Orde
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• Schedule operations with Capaci
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Creating Work Orders Work orders ar
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Table 6.2 lists work order type cod
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Scheduled Work Orders Scheduled wor
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Planned Bills Bill created Routings
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Released A released order is like a
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• The release date is the date wh
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the average order quantity, the les
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Modifying Work Order Routings Use W
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Creating Picklists After you releas
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Issues are not restricted to what t
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Subcontract Operations Work orders
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Receiving and Backflushing When you
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Example Ten phantoms are in stock.
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Generating Reports Many of the Work
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Closing Work Orders To close a work
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6 Print Work Order WIP Cost Report
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CHAPTER 7 Shop Floor Control The Sh
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You can calculate employee efficien
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Times You can enter setup times, ru
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You can review recorded downtime us
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Downtime Review recorded downtime b
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CHAPTER 8 Advanced Repetitive Repet
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• Batches can overlap and visibil
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Setting Up Advanced Repetitive Repe
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• PO Shipper Receipt (5.5.5.5) Wh
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production lines. To set up multipl
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is 700 units per shift. If a second
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Milestone and Non-Milestone Operati
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In the first, there is a primary st
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Whenever you create or modify a seq
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Creating Repetitive Schedules A rep
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The schedule explodes automatically
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The Net Available is the material a
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Transfer the Inventory Use Repetiti
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• Cumulative Order Close (18.22.1
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Processing Steps Cumulative Order C
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Common Transaction Data All repetit
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Rate Variance All transactions cons
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Repetitive Transaction Programs The
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The component backflush logic looks
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Scrap Transaction Use Backflush Tra
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cumulative order. The amounts to po
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Generating Repetitive Reports Table
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Using Scheduled Orders You can hand
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If there is no WIP item number ente
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CHAPTER 9 Repetitive The Repetitive
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Defining Control File Settings Sett
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Operation Reporting The reporting o
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Page 203 and 204: CHAPTER 10 Quality Management MFG/P
Page 205 and 206: Setting Up Quality Management Befor
Page 207 and 208: A comparative symbol (, =) and a nu
Page 209 and 210: Defining Sampling Patterns Define s
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Page 213 and 214: Conducting Process Inspections When
Page 215 and 216: Use inventory sampling patterns to
Page 217 and 218: CHAPTER 11 Forecasting/Master Sched
Page 219 and 220: 6 Load the detail forecast records
Page 221 and 222: FORECASTING/MASTER SCHEDULE PLANNIN
Page 223 and 224: Forecast Methods FORECASTING/MASTER
Page 229 and 230: Copying and Combining Forecasts FOR
Page 233 and 234: Generating Reports FORECASTING/MAST
Page 241 and 242: Fully Automatic Scheduling FORECAST
Page 243 and 244: Available-to-Promise FORECASTING/MA
Page 249 and 250: Generating Master Schedule Reports
Page 251: CHAPTER 12 Material Requirements Pl
Page 255 and 256: Item Planning Data MATERIAL REQUIRE
Page 257 and 258: Order Policy Description Order Modi
Page 259 and 260: Time Fence MATERIAL REQUIREMENTS PL
Page 261 and 262: Component Effective Dates MATERIAL
Page 263 and 264: MRP Pegged Requirements MATERIAL RE
Page 265 and 266: MATERIAL REQUIREMENTS PLANNING 253
Page 267 and 268: Message Meaning Shipment Past Due I
Page 269 and 270: CHAPTER 13 Capacity Requirements Pl
Page 271 and 272: CAPACITY REQUIREMENTS PLANNING 259
Page 273 and 274: Generating Load Reports You can gen
Page 275 and 276: Adjusting Capacity and Load If a wo
Page 277 and 278: Numerics 1.1.5 58 1.1.13 57 1.2.1 5
Page 279 and 280: A Account Code Maintenance co-produ
Page 281 and 282: defined 53 demand for 77 material r
Page 283 and 284: Formula Maintenance 45 co-products/
Page 285 and 286: MPS. See master production scheduli
Page 287 and 288: epetitive 154, 183-189 completions
Page 289 and 290: sources for MRP 241 System/Account
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MFG/PRO 9.0 User Guide Volume 3: Manufacturing - QAD.com

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