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MRP/MPS User Manual - Maynard Software Solutions

1. ADMIN Print Inventory Quantities On Hand The first period displays the Item s on hand quantity as pulled directly from Sage PFW s Inventory Location File Each period following the first period displays the forecasted On Hand Quantity or the On Hand quantity if the planned quantity is ordered On Order The On Order quantity is derived from the quantity remaining on purchase orders that are open and the Assembly items that are posted using BOMP commit transactions An example would be if you had an open PO with an item key of widget with a quantity remaining of 9 and one BOMP commit transactions for the assembly item widget with 5 committed You would show 14 on order on in this field Open PO s would decrease the amount available and be stored in the on order row On Order Show Detail This option will show the PO detail In other words if we have an open order on a certain date it will show what purchase order created that need This list will print following the data for each raw material Material Requirement Planning e 45 Commit to Sales Prints the Item s committed to sales quantity as pulled directly from Sage PFW s Inventory Location File Open Sales orders would decrease the amount available and be stored in the Commit to Sales row Commit to Production This field is calculated from open Commit transactions that haven t been completed and closed through a Manuf
2. J NP Work Order Printed I Np Invoice Printed I BN Back Order Not Printed J BP Back Order Printed TF Bp Back Order Invoice Printed Process Clear Save Exit ADMIN test Order Entry Preload e 23 Filters 24 e Order Entry Preload Assembly Key The magnifying glass icon located to the left of the Beginning and Ending fields will allow a search of available data Search Value 100 000 100 003 FLRDA Sub Assembly 3 Level 1 100 003 CALIF Sub Assembly 3 Level 1 300 001 FLADA Sub Assembly 1 Level 2 300 007 CALIF SubAssemblyiLevel2 400 001 FLADA Component level 3 Component level 3 Select Cancel The user may search for a specific item or location by pressing the magnifying glass icon entering part or all of the value in the Search Value box and then pressing the lt ENTER gt key Once the desired record is highlighted press lt ENTER gt or the select button The value will be inserted into the entry field Beginning To search for orders with a specific Assembly Item or range of Assembly Items then enter the first item in this field If this field is left blank the program will assume that you want to start with the first record Ending Enter the last Assembly Item to search for in the sales order files If this field is left blank the program will assume that you want to end with the last re
3. Prints the Item s minimum stock quantity as pulled directly from Sage PFW s Inventory Item Location File The MPS report will calculate and print the quantity required be ordered for each item If this field is selected the calculation used to determine the required order quantity will include the minimum stock quantity In addition if the Reorder Quantity field is selected the purchase quantity will be 46 e Material Requirement Planning limited to quantities divisible by the reorder amount The create purchase orders option will use the purchase quantity when generating Purchase orders Maximum Order Quantity Prints the Item s maximum order quantity as pulled directly from Sage PFW s Inventory Item Location File Reorder Quantity Prints the Item s reorder quantity as pulled directly from Sage PFW s Inventory Item Location File The MPS report will calculate and print the quantity required be ordered for each item If this field is selected the calculation used to determine the required order quantity will include the minimum stock quantity In addition if the Reorder Quantity field is selected the purchase quantity will be limited to quantities divisible by the reorder amount The create purchase orders option will use the purchase quantity when generating Purchase orders Calculate Requirements Raw level Computes the report quantities by using the lowest level component items therefore the inventory quantities for the
4. This allows for a single BOM to be used for multiple finished goods locations when importing via Open Order Commitment This option is to be used for companies that have multiple finished goods warehouses that make product in one location and then move it to others Also the product is shipped from the other locations They want to track what is in the other locations and also want to sell from those locations Normally you would have to maintaining multiple BOMs for each item one for each location This feature avoids this by triggering a translation table to be used by Open Order Commitment and Order Entry Preload When either of those programs reads the sales order files and brings in the records the locations on the records will be changed This same functionality can be found in the BOMP OOC Advanced features section of the BOMP Manual Combine Production Schedule Location Maintenance e 19 Drop In Order Maintenance Overview 20 e Drop In Order Maintenance The Drop In Maintenance program allows the user to print a Net Change MRP report You can select sales orders over a range of dates and or order numbers to Drop In to the MRP Report The MRP program would take the output from a previous MRP report include the requirements from the drop in orders and report the additional requirements The report will NOT re read the item location file or any other file to reflect the current status of inventory usage It will assume that
5. VV VV VV V WV Remove Previous Preload Selecting this check box will overwrite previously loaded plans The user may leave the check box unselected to append orders from multiple order status codes to the current pre loaded totals Process This option will begin the MPS Order Pre load The sales order module will be searched using the parameters entered into the screen Cancel This option will exit the screen to the main menu without processing the pre load Order Entry Preload e 25 Production Schedule Maintenance Production Schedule Maintenance Overview This screen allows the entry and maintenance of the Production Forecasting Schedule The Production Schedule Maintenance Grid Format screen allows you to enter and view the same information in a grid format The user may run the Pre load Orders utility and then use this screen to adjust pre loaded quantities add forecasting quantities and or add additional planned items If your Production Schedule is not order driven then this screen should be used to enter the schedule and forecasting This program only allows planning of inventory items with an associated BOM in the Bill of Materials Processor program If you want to use this screen to view and modify pre loaded schedule items you must have the allow modifications to pre load option selected in the Default screen To Plan for Independent Demand on Component Items create a planning BOM that includes all items th
6. 0 Minimum Stock Quantity 300 Reorder Quantity 720 PERIOD END O7 01 200 07 08 200 07 15 200 07 22 200 07 29 200 08 05 200 08 12 200 08 19 200 08 26 200 09 02 200 09 09 200 ON HAND 1705 305 895 335 455 975 975 525 495 415 885 ON ORDER 0 COM SLS 0 COM PRD 0 REQUIRED 250 PURCHASE 720 PERIOD END The ending dates for each of the planning periods These dates are the dates set in the Period Parameter section of the Print Parameters tab for the Production Schedule Report ON HAND The number of the Item that is on hand in inventory This information is taken from the Sage PFW Inventory files ON ORDER This field shows the number of the Item that is on order This information is taken from Sage PFW COM SLS This field shows the number of the Item that has been committed to sales in BOMP 52 e Material Requirement Planning COM PRD This field shows the number of the Item that has been committed to production by commit BOMP transactions REQUIRED This field shows the total number of Items needed on the date based on the options chosen in the MRP report parameters PURCHASE This field shows the number of the Item that has been purchased through purchase transactions in Sage PFW Production Schedule Report Production Schedule Report Overview The Production Schedule Report is generated for all finished good items that need to be manufactured in order to fulfill the production plans formulated in
7. Grid File Edit Help ADMIN 1 14 53 037 127200 ATLA SSET M STE M i 03 16 200 ATLA SSET M STE M 04 05 2007 ATLA SSET M STE M dl 05 12 200 HELI 4093 M B0R M 03 23 2007 On Hand 1 182 00 Minimum Stock 300 00 Committed to Prod 0 Reorder Quantity 720 00 Committedto Sales 0 00 Maximum Order 1 500 00 On Order 0 00 Lead Time 300 00 Description Atlantic Pro Iron Set 3 Pw Men steel ADMIN Demo T Production Schedule Maintenance Grid Format 31 Edit Menu Lookup F9 This option allows you to zoom on all available Assembly Keys or Locations depending on the column that is selected Copy Line F3 This option will copy the entire row that is above the selected row Restrict F6 Selecting the Restrict option allows you to schedule production for a selected inventory item Only the selected item will be displayed in the grid Show All F8 Select this option to view all items in the production schedule 32 e Production Schedule Maintenance Grid Format Forecast Sales Listing Forecast Sales Listing Overview Filters This report will list the Production Schedule plans that have been entered and or pre loaded between a specified range of dates items and locations The listing will also show who entered the plan and when it was entered If the Default Maintenance option to have a user specified plan has been selected then only plans entered by the user cur
8. Print Items with quantities that have changed Print if quantities have changed in the first Columns Clear Save Exit ADMIN test 50 e Material Requirement Planning Tool Bar Drop In Tab Field Definitions Print Net Change Drop In Report If this checkbox is checked then when the process button is selected then either a Net Change or a Drop In report will be run showing the change from the original MRP report The original report is the one selected as the base material requirements file Both the Drop In and Net Change programs use a base MRP report and compare to that The difference is that the Drop in adds only sales orders in our drop in file The Net Change report looks at the current BOMP files committed to production net available etc and recalculates the required to purchase based on those changes To print a Net Change report go into the Material Requirements Planning program and select the Print Net Change Drop In report checkbox also check the Net Change Report checkbox To print a Drop In report go into the Material Requirements Planning program and select the Print Net Change Drop In report checkbox but DO NOT check the Net Change Report checkbox Base Material Requirements File The original MRP file that the Net Change Drop In orders will be compared against To save this file go to MRP Advanced Features and check the Save report file for the Net Change re
9. atico 39 00 0 50 A R 39 RR O 39 Disk its 005550 E A 50005 ais 39 Print OPUONS anson 0 0 070 0 39 Open POSi era ondas craneo tierra pilas 39 FREQUITEMCNIS nnn a as aE a aE O A R a 39 Purchase Need 0 500700 0 RRS 39 Material Requirement Planning 40 Material Requirement Planning OvervieW seessesseeseeseereerssrsresresrestesrestesreresresresrestenresresrnees 40 Printed Fields Definitions iii dl tata ia ta 40 Prirchase 7 lio dia 40 Print 41 Assembly Key iii 41 1 42 Period Parameter int ta roda iia 42 Print 05 a ON aE EERS 42 0 2 43 Component Ranger 43 Component Keita ia 43 Local i 44 R E A ONES 44 Print Inventory Quantities iz enera naa O REN ORS 45 Print Additional Pl ldsi iii dd NSS 46 47 7 Component TI ypestinttd id lit 47 stduvsceduadcevdensesetvenss 48 Processing Options Calculate Requirements Using oooonocccononononononononnnonanonanonnnnoncnnncnn ocn no nono nn nora ncnn con concen 49 Print Components vistosidad iris 49 Drop liinda aladas 50 OVELVIEW EEEE EE RE O NER E E SE 50 Drop In Tab Field Definitions 51 Net Change Report Differences oooocnoncnonnnonononconnconncononononnonnnonnnonn nono nonnnnnn cnn nnnn cnn 51 Tool Barinitas 51 00 A E E 52 Production Schedule Report 53 Production Schedule Report OvVervieW oooooonoccoocconcconononononconcconocono 000 20 53 Print 54 Assembly Ky inde caries 5
10. daa aa aiii 28 Planned Quantity solitos sitial fai 29 View Only Field Definitions seasessapdazesdcsaibease suas esdeseadesoapies 29 PL OOM a r EEEE staves deve tscsss teased dovetves sedi agusdccnanessiadedea a a oi 29 File Men Lia Lo thee oido 30 Production Schedule Maintenance Grid Format 31 Production Schedule Maintenance Grid Format Over Vie W oooocccnnooccnononcnononnnnnnnonncnnonncnnnnnns 31 TORO 32 Forecast Sales Listing 33 Forecast Sales Listing OVerview 33 SES 33 EE Eaa A EAEE AE EERS 33 Assembly E AN E EE 34 0 Dates ai ds a 34 Print Destination A dia 34 Tol i 35 Move Sales History to Forecast 35 NR 35 Ranee O TO 36 Range of tem Keys 0 36 Range of Item Class Keys cuore alli reia 36 Range of Commodity 1 36 Range of Product Keys sz cuotas 00 00 a 36 Range Of Locations cistitis 36 Range OF ABC Keys 00 5 00500 0 E 36 Date Ram ge i siiyciicsdcalesssbisstacodcetas 050 E 37 Transaction Type Options sitio ese ote E hae eee Ea R 37 Include Adjustments 5 6 eg ee tea Pe 37 Increase Options ann es ee 37 i HS eo at 37 Increase Da ysis ii Hees pe es SE eet adie el eee 37 Item Type OplONS it ea 5 ee Re 38 MRP Action Report 38 Paw Sed A eS 38 7 38 Component Ke Vicio dias 38 Dit iaa A sade gab tg eSEE UES ates e sven Gav o iT 39 Assembly Key 0 00 olla 39 Print Destination 00
11. date entered in this field Purge Pre Load Items Selecting this check box will purge all pre loaded items within the specified Item Key and Location ranges Standard Report Information Standard Report Overview Our reports are written using Crystal Report Writer so additional fields additional decimal places and customizations may be easily added to the reports by modifying the report file Please see the Advanced Features Chapter for more information on using custom reports Custom report changes may be purchased through IndustriOS for a minimal programming fee For a quotations please call 866 275 9028 or 905 829 2525 Crystal Reports Window The Crystal Reports screen contains the following tool bar 4 4 1of1 gt Al 100 y Total 3 100 lolx Scrolls to first page of the report Scrolls to previous page of the report Scrolls to the next page of the report Scrolls to the last page of the report Cancels the report and returns to report parameters screen Prints the report to the printer specified in Printer Setup located in the File drop down menu Exports report to a specified file type Microsoft export DLL Files are required to use this options Please see the Exporting a File section of this document for more information Changes the size of the report Exporting to a File 1 Select the Format and Destination for the report export The format types available depend
12. everything has been and or will be built to plan except for the added drop in orders Both the Drop In and Net Change programs use a base MRP report and compare to that The difference is that the Drop in adds only sales orders in our drop in file The Net Change report looks at the current BOMP files committed to production net available etc and recalculates the required to purchase based on those changes To use this program you must first go to the MRP Advanced Features program and check the Save report file for Net Change Report checkbox in the MRP tab If this option is not checked then the standard MRP report will be run To use this feature first run the MPS report a base MRP report and then a series of drop in or net change MRP reports If another MPS report is run then you MUST run another base MRP report 3 Drop In Order Maintenance lol x Order Number 004 p Sequence By Beginning Order Number 00001 P Order Date Ending C Customer Name 00027 Order Status M Order Date Beginning 9 12 2002 Ending Process Clear Save Exit ADMIN test IV Clear previous drop in selections Drop In Order Maintenance Field Definitions Order Number Here the user can select a range of order numbers to use in the Net Change Report Order Date Here the user can select a range of dates to use in the Net Change Report
13. option is selected then all components with a purchase quantity will print on the report Material Requirement Planning 49 With Activity This option will print only items with activity Activity would be defined as anything on the REQUIRED or PURCHASE line If On Order commit to sales or commit to production are checked than any non zero quantity on any of those lines would also be activity Drop In Overview The Drop In tab allows users to print a Net Change MRP report The sales orders selected in Drop In Maintenance will Drop In to the MRP Report The MRP program would take the output from a previous MRP report include the requirements from the drop in orders and report the additional requirements The report will NOT re read the item location file or any other file to reflect the current status of inventory usage It will assume that everything has been and or will be built to plan except for the added drop in orders To use this program you must first go to the MRP Advanced Features program and check the Save report file for Net Change Report checkbox in the MRP tab Then run the MRP report that you want the Drop In report to be compared against If the Save report file for Net Change Report option is not checked then the standard MRP report will be run E Material Requirements Planning 3 loj xi Drop In rop In parameters Base Material Requirements File CAPLATINUM TEST MRO2031 O mdb gt
14. record Ending Enter the last Location that the program will search for in the sales order files If this field is left blank the program will assume that you want to end with the last record Report Options 44 e Material Requirement Planning a Material Requirements Planning Print Parameters E Print Inventory Quantities On Hand On Order Vi TF Commit to Production Show Wetall r Print Additional Fields IV Lead Time TF Planner Code 4 Minimum Stock Oty Maximum Order Qty Y Reorder Quantity m Calculate Requirements gt Raw level Top level 10 x r Processing Options JV Include Order Entry preload items JV Create Purchase Orders for requirements Number of Periods 7 JV Include plans dated prior to start date IF Include Labor Capacity in Gn Order Number work days per Period Include Lead Time in Calculations TF Page Break after each Item J Include only components with R trans types m Calculate Requirements using Forecasted quanitities Production quantities generated from production schedule report Scheduled Jobs F Show Detail Open Transactions m Component Types Include Inventory J Include Additional Cost TF Include Non Stocking Include Sub 4ssemblies m Print Components All Components With Required Quantity With Purchase Quantity C With Activity Cem ces Save Est PremGL
15. report Note The Drop In Report will save automatically as a temp file with the name MRyymmdd mdb if you do not select anything in the MRP advanced features temporary file name field If a quantity on the sales order has changed as long as you checked the committed to sales option in the original run of the report then the change in the quantity on the sales order would be noted on the report Drop In Order Maintenance 21 Order Entry Preload Order Entry Preload Overview The Order Entry Preload utility allows users to populate the Production Schedule using orders that have been entered into Sage PFW This utility is useful to companies that manufacture items on a make to order basis The program reads the sales order module for orders with the specified order status and fills the assembly s planned quantity with the quantity remaining on the order If the user has selected the Allow modifications to pre load check box in the Defaults screen then pre loaded item quantities can be modified in the Production Schedule Maintenance screen 33 Order Entry Preload x Assembly Key Beginning EQUIP CLUBS ATLA S Ending m Location Beginning Ending m Options Start Date End Date Remove Previous Preload m Include Status Codes M ON New Quote QP Quote Printed 5 Fully Shipped NN New Order Not Printed
16. scheduler is different on different versions of Windows The user is responsible for determining how it works on their system This means that the user must be able to successfully create a scheduled job for a different task and have the system start that program on schedule We tested the task scheduler using the Acrobat Reader After we got this program to run as scheduled we then scheduled the MRP program As we tested this on an XP system our most common error was that we had an incorrect user name or password You need to get pass this and other scheduler errors prior to contacting us for assistance The first step is to go into the MRP program and save the desired parameters There are 10 choices for the name of the parameter set BATCH and BATCH through BATCH9 We strongly recommend that you run the program to insure that the parameters give you the desired results We strongly recommend that the output goes to the printer and that you save the temporary report see MRP Advanced Features Do not output to a disk file as the program requests a file name when it is run with this option For XP Go to the Control Panel Select Schedule Tasks Click on Add Scheduled Task Go through the setup wizard When you get to the screen where you are to choose the program to be run click on the Browse button 61 Go to the drive and then the folder where the MSS from IndustriOS programs are installed Select the MRPREP exe program
17. sub assemblies will not be considered when processing the report This report shows purchasing which raw material items need to be ordered for each production planning period Top level Computes the report quantities by using the top level component items and sub assemblies therefore any components that are used to build the sub assemblies will not be considered in the report This report displays the top level components and sub assemblies that are needed to be ordered built for each production planning period Component Types Include Inventory If this option is selected then valid inventory items will print on the report Include Non Stocking If this option is selected the report will display Sage PFW items that are defined as non stocking Include Sub Assemblies If this option is selected then sub assemblies will be included in the report Material Requirement Planning 47 Processing Options Include Order Entry Preload Items Selecting this option will print all of the Order Entry Preload Assembly Items Create Purchase Orders for Requirements Selecting this option will generate purchase orders from the MRP reports The purchase order cost is calculated using the cost field specified in the Purchase Order Application Setup program Unit Cost Default Method The purchase orders can be viewed modified and posted through Sage PFW s Purchase Order module Please see the Sage PFW PO Interface chapter of this m
18. 2l Print Clear Default Exit ADMIN Demo T Component Key The magnifying glass icon located to the left of the Beginning and Ending fields will allow a search of available data Search Value Assembly Item 1 Sub Assembly 3 Level 1 Sub Assembly 3 Level 1 Sub Assembly 1 Level 2 Sub Assembly 1 Level 2 Component level 3 Component level 3 Material Requirement Planning 43 The user may search for a specific item by pressing the magnifying glass icon entering part or all of the value in the Search Value box and then pressing the lt ENTER gt key Once the desired record is highlighted press lt ENTER gt or the select button The value will be inserted into the entry field Beginning If you want to print the report for a specific Component Item or range of Component Items then enter the first item in this field If this field left blank the program will assume that you want to start with the first record Ending Enter the last Component Item that the program will include in the report If this field is left blank the program will assume that you want to end with the last record Location Beginning If you want to search orders for a specific Location or range of Locations then enter the first location in this field If this field left blank the program will assume that you want to start with the first
19. 31 99 The lead time is configured using actual days not workdays Create Commit Transactions in BOMP Selecting this option will generate BOMP transactions for all Assemblies with a planned quantity The transactions are imported into BOMP s Transaction Entry screen where they can be viewed and or modified then posted to Sage PFW See the BOMP Interface Chapter for more information Print Forecast Quantities Prints the forecast quantities in the report output as they were entered or preloaded into the Production Schedule Entry programs Forecast Quantity Options Print Only Assemblies with Planned Quantity If this option is not selected the report will print a section for each Assembly Item regardless of planned quantity If this option is selected then only Assembly Items with a planned quantity will be printed Include Sub Assemblies Requirements Selecting this option will include planned quantities on the report that are sub assemblies of other planned Parent Assembly Items FOR EXAMPLE Assembly XYZ has a planned quantity of 20 for the month Assembly XYZ requires two of Sub Assembly ABC Sub Assembly ABC has a planned quantity of 100 for the next month If this box is selected the plan for ABC in the current month will be 140 100 2 20 If the box is left blank the plan for the month is 100 Note If you include sub assemblies in the Production Schedule report and then calculate MRP requirem
20. 4 1 Misma iii 55 A dedsvhst E E EEEE EE 55 Print Destination 2 56 07 56 Report Options viciosa irritar E E E NEE T E EET 57 Print Inventory QUantitles sasos keeru es ee eitean ta 57 Print Additional PleldS 0 e EE 58 Processing 900008 eiii ta 59 Forecast Quantity OPS ita taa 59 Explode Billof Materials TO traia 60 00 6 de ates net aee neste eee tee eee 60 Scheduled MRP 61 Unneeded PO Report 63 VET VIG Weston ii tem ceed 63 BOMP Interface 64 BOMP Interface Overview iecsa 2 cies a E e E EE N E N esas 64 Import Transactions rones a O E A ariel A ES 64 Unselect Alicia taa a G a N E S 65 Select Alicia dia 65 A 66 Import Selected cional cistitis 66 06 66 How Transaction Entry Fields are Populated oooooncnnncnnoconocconnnononononnnonnncnnc cono nono nono nn nora ncnnc nos 66 6 67 LOCA A ON 67 ResponsiDil Veintisiete inline 67 0 67 7 07 TD YPC aise a ee ee ea ee ete a ee ee 67 0 O O 67 0 a 67 CAMA ia 67 Sage PFW PO Interface 69 Sage PFW PO Interface Overview 0 90 69 How Sage PFW s Purchase Order Fields are populated ooococinnccnncccionncooncconnncnnncconnncnanccinnos 69 Purchase Tab 2 a ds it ide delete vet 70 0 a o sa Mts 70 Prepayment Tabu id ps 70 Ares K oO A E on eiii dle vats 71 Credit AD a id 71 Eme Hem DTD ide leida 71 Purge Forecast Plans 73 Purge Forecast Plans Oye Wii ie 73 ED A idO 73 Hen Kei ia
21. 73 1 06 010 a O OS 74 Purge throush 74 Puree PresLoad 11685 ii ea Aid Bs a esteene i ace eee ee 74 Standard Report Information 75 Standard Report 75 Crystal Reports Wind OW dai er ti A ais 75 Stoa PE a e a E a A a a E E i 75 0 Customizing your Software 77 Customizing Screen CaptiOWS oooonoconocnnonconnnonnnononononononnnonn nono EERE E EEEE EEE EER Re 7 Adding Additional fields to the MRP ReportS oooconocnnonnnonconnconncononononononnnonnncnnccnnccnonnncnnncnnnnns 79 Utilities Database 79 Getting Started Getting Started Overview You should have a basic knowledge of the Windows environment and procedures including using Windows Explorer You should also have a complete understanding of your system setup including all hardware network and software configurations The following is a list of items you should know complete and understand before installing our programs v This software is subject to the terms and conditions detailed in the license agreement which is included as part of the software installation Pre sale support for the evaluation software and technical support for users with a support contract is available through 866 275 9028 This software is installed as an evaluation version which will expire 1 month after installation To continue using the programs beyond that time you need to receive an unlock code registered users or purchase it from your Sage PF
22. 9 Compact 80 e Utilities Database Note The Repair Utility should only be run when a corrupted database error message occurs The Repair command should not be run under any other circumstances This Microsoft Access utility will copy each object into a new database If there is a damaged space on the disk compacting will move the files from the damaged space The original database is renamed databasename SAV MDB Step by Step l 2 3 Login as ADMIN using the administrator password Make a backup copy of the database Verify that all users have exited completely out of the MSS from IndustriOS Software system and do not attempt to open the database during the repair process Select Compact from the toolbar Utilities Database 81
23. Find Ctrl F This option allows the user to search through the valid Keys Enter a search value and then select the specific key The selected key will be displayed on the screen First F5 This option displays the beginning record in the maintenance table Previous F6 Moves to the preceding record in the maintenance table Next F7 Moves to the subsequent record in the maintenance table Last F8 Displays the ending record in the maintenance table Exit This button shuts down the current screen and the program returns to the Main Menu 30 Production Schedule Maintenance Production Schedule Maintenance Grid Format Production Schedule Maintenance Grid Format Overview The Production Schedule Maintenance Grid Format screen allows the entry and maintenance of the Production Forecasting Schedule The user may run the Pre load Orders utility and then use this screen to adjust pre loaded quantities add forecasting quantities and or add additional planned items If your Production Schedule is not order driven then this screen should be used to enter the schedule and forecasting This program only allows planning of inventory items with an associated BOM in the Bill of Materials Processor program If you want to use this screen to view and modify pre loaded schedule items you must have the allow modifications to pre load option selected in the Default screen Ea Production Schedule Maintenance
24. Line Items Tab The line items are generated from the components displayed on the Materials Requirement Report A line item is created for each component item and location The order quantity is populated with the MRP item s planned quantity Component Items with the same primary vendor are combined on one Purchase Order Sage PFW PO Interface e 71 Purge Forecast Plans Purge Forecast Plans Overview The Purge Forecast Plans utility allows the user to globally delete items from the Field Definitions Production Schedule Purge Forecast Plans ltem Key Beginning JATLA SSET M STE M LI Ending IDMG 4028 W STE M M ES Purge Through Date 02 15 2001 Location Beginning l Ending Options Y Purge Pre Load Items Purge Clear Exit Item Key ADMIN Demo T The magnifying glass icon located to the left of the Beginning and Ending fields will allow a search of available data Purge Forecast Plans e 73 74 e Purge Forecast Plans Search Value Comment Description FLADA Assembly Item 1 100 000 CALIF 100 003 FLRDA Sub Assembly 3 Level 1 100 003 CALIF Sub Assembly 3 Level 1 300 001 FLRDA Sub Assembly 1 Level 2 CALIF Sub Assembly 1 Level 2 Component level 3 Component level 3 Select Cancel The user may search for a specifi
25. MSS from IndustriOS MRP MPS User Manual Last Updated March 13 2007 1998 2007 IndustriOS Software Inc software Integration Partner Getting Started 7 Getting Started Overview s cbee cccecesscustisecscuenbeuasbadavtadlins rE Eaa AEE OSEKE EARS SENEE escapada 7 System Requirements ss cesc u csensscawvias tonada EEEE EEEE PEENE EE a EE EE EARE RS 7 Basic Functionality 2 8 MRP Process EDE EEE V r E 8 9 MRP Defaults 11 6 0 11 Field Definitions ii its 11 Allow Modifications to Prel0ad ooooonncnnnnnnncnnonnonncnonnonnonncnononncnnnrnn ccoo nn no no nano cnn crias 11 User Specific Plans ie aia 11 Combine Locations iia lili 12 Use Labor Capacity 0 12 Location Key for Combined Locations ooooocnnccnocnnonncononononanonanonn nono cono nnnncnnncnnncnnncnnoos 12 Planner rn n senese pitosas 12 Lead Time from INLOC Field eee eee 13 Elle MGM ity csevsay 2 e a EEE aE O E E ROE eE EE a SE OE AREK TESSE 13 MRP Advanced Features 14 Production Schedule Report 14 Add INMAST Sage PFW Fields 14 Add INLOC Sage PFW Fields 15 Save Temporary Report File as 15 Which Report 15 Material Requirement Planning oococnccnononononanonanonnnonnnonnnonononncnno cnn nono non cnn nonn cnn cnn n ran ncnnncnnncnnnos 16 Add INMAST Sage PFW Fields 16 Add INLOC Sage PFW Fields 16 Save Temporary Report F
26. OMP option selected the Transaction Entry Screen will have an Import Transactions Menu Selection The Import Transactions screen displays the transactions that have been created by the MRP MPS The user may import the data from this screen to Transaction Entry yz Import Transactions lt Selected Comments Assembly Key Location Quantity Type Level Date___ Resp _ Cos p Yes MRPMPS 11 27 98 100 000 FLRDA 100000 lt R_ 10 28 98 ADMIN Ye Yes MRPMPS 11 27798 100 003 CALIF 110000 lt R_ 10 28 98 Ye MRPMPS 11 27 98 100 003 FLRDA 1 100 00 X MRPMPS 11 27 98 300 001 CALIF 2 200 00 X MRPMPS 11 27 98 400 001 CALIF 2 200 00 X Unselect All Changes the Selected Column to NO and the transactions will not be imported into the Transaction Entry Screen However the Import Transactions Menu will remain on the Transaction Screen and the transactions can be selected and imported later Select All Changes the Selected Column to yes and selecting the Import Selected options will import all of the transactions into Transaction Entry BOMP Interface e 65 Import and Edit Moves the highlighted transaction to the Transaction Entry screen The user can modify and save the transaction using all options available in the Transaction Entry screen For more information on the Transaction Entry screen please see the BOMP manual Import Selected This option mov
27. Printer V Requirements Ending Disk V Purchase Needs Print Clear Save Exit test Note normally the sort would be by component key or Date UNLESS you do not have the PO option selected Then you could also sort by Assembly key Component Key Here the user can select a range of Component Keys to run the Action Report with Date Here the user can select a range of Dates to run the Action Report with Assembly Key Here the user can select a range of Assembly Keys to run the Action Report with Print Destination Window If this option is selected then the report output will just show on your screen Printer If this option is selected then the report output will print on the selected printer Disk If this option is selected then the report output will be saved to disk Print Options Open POs If this option is selected then open Purchase Order information will be printed Requirements If this option is selected then BOMP Requirements will print If you had 30 on hand and need 40 this would detail the need for the 40 Purchase Need If this option is selected then purchase requirements will be printed in the report This is the same as the BOMP requirements except if you have 30 and need 40 then only the requirements for the additional 10 would be shown If you have three open jobs with quantities of 15 21 and 4 then the report will show the need for 6
28. Prior to clicking on the Finish button click on Open Advanced Properties button On the task tab of the advanced Properties screen modify the Run field to include the name of the saved parameters i e batch1 batch2 standard etc It is important to enter the computer s user name and password For Windows 98 Similar to XP except you start the task scheduler from the tool bar near the date time On our system we did not have to enter a user name and password as we did on XP 62 e Scheduled MRP Unneeded PO Report Overview This report shows current POs which are not needed based on the MRP report When you open the program you just set the options the same way you have your MRP report set Then run the report you will be able to see all unneeded POs Jo x Print Parameters Assembly Key m Period Parameter 4 Begining Start Date 8 2 2004 EQUIP CLUBS ATLA SSET M STE LI of Periods fi 0 Ending EQUIP CLUBS ATLA SSET M STE ol Days per Period 7 Assembly Location Print Destination Beginning e Window ol C Printer Ending fe LI Print Sequence Assembly Key C Planner Code Assembly Key C Planner Code Yendor Key Plan Name Clear Save Exit ADMIN PREMGL One option that is different from the standard MRP report is the Unneeded PO Summary Report option If this is checked then you will get a summary
29. S from IndustriOS Software resides 3 When changing the text in the INI files for version 4 there is one file for each program The code that is shared by multiple programs is stored in the general ini For instance every lookup uses the same form so in order to alter the prompt for a lookup you would customize the general ini instead of the ini associated with the specific program Use extreme caution when customizing the general ini file as 1t will update prompts throughout the entire program For example to modify the Additional Cost Maintenance form you would open the ADDMNT INI file and change the description to the right of the sign Standard Screen and ADDMNT INI Prompts before changes Customizing your Software e 77 PLANNING COST 11 Account 12 Description 320 Additional Cost File Maintenance 321 Additional Cost Key 322 Description 323 GL Account 324 GL Offset Account 325 Cost 326 Cost Type 327 Labor 328 Sub Contract 329 Setup Type 330 Other Note Actual ADDMNT ini file layout is different then shown however the prompts are the same Customized Screen and ADDMNT INI Text Prompts 11 Account 12 Description 320 Additional Cost File Maintenance 321 Item Key 322 Description 323 GL Control Account 324 GL Offset Account 325 Cost per Hour 326 Additional Cost Type 327 Labor 328 Sub Contract 329 Setup Time 330 Downtime 78 e Customizin
30. Sequence By Here the user can sequence the output of the Net Change Report by either Order Number Order Date Customer Name or Order Status Clear Previous Drop In Selections Checking this checkbox will clear all previously selected Drop In Data If this is not checked then the new data will just be added to the existing data Drop In Step by Step 1 First go into the MRP Advanced Features program Under the Material Requirement Planning tab and check the flag for the Save report file for Net Change report field 2 On Monday or whatever base day you want to use run the MRP as a normal report That means that the Print Net Change Drop In Report flag on the Drop In tab of the Material Requirements Planning report program is NOT checked 3 Go into Drop In Maintenance a Entera range of Order numbers b Decide if you want to clear previous selections or not and hit process After the first time that the base report 2 above is run the Print Net Change Drop In Report flag MUST be checked c A list of orders appear Select the ones that you want to be dropped in and then click the Save button Care must be taken in conjunction with the step above to insure that drop in orders are not duplicated 4 In the Material Requirements Planning report a Go to the Drop In tab b Check the Print flag c Enter the name of the base report MRyymmdd mdb d Optionally check enter data in the remaining fields and run the
31. This will hold the data from one time of running the report The next time the report is run the first file will be deleted and replaced with the new data To select a file location to save the report click on the arrow to the right of the field and fill in the desired file name and directory location The temp files need an mdb extension and those files may require MS Access 2000 or later to be read Save Report File for Net Change Report Checking this checkbox will save MRP reports for future use as the base file to run the Net Change report with The file will be saved in the company directory under the following file name Mryymmdd MDB General Use Custom Report Format If you wish to use a custom report you may select to use it here Use Sub Assembly Location Which Report File to Edit The following is a list of the possible MRP MPS reports Mrp10 Mrp10pa Mrp10pv Mrp20 Mrp20pa Mrp20pv MRP Report 10 columns sorted by assembly key MRP Report sorted by planner code assembly key MRP Report sorted by planner code vendor key MPS Report 20 columns sorted by assembly key MPS Report sorted by planner code assembly key MPS Report sorted by planner code vendor key Format Numeric Output Fields This option allows you to specify the number of decimal places to be printed on the Production Schedule Report and the Material Requirement Planning Report To print two decimal places enter a format of 0 00 To print four decima
32. W reseller You must install the version of our software that is compatible with your Sage PFW Please contact technical support if you are unsure if you have the correct version of our software Before you begin the installation and use of this program you should have in depth knowledge of your Sage PFW Software Pervasive Software Corporation s database engine must be setup and configured properly before our programs will function If you are upgrading from a previous version of the MSS software please follow the upgrade procedure outlined in the System Basics Users Manual It is very important that all users are accessing the same software version and old software does not exist on workstation or network drives This program will not operate independently from our Bill of Material Processor Module All bills of materials must be setup within BOMP before using MRP System Requirements To use MSS from IndustriOS programs you will need the following Y Y Y Hardware Requirements are the same as those for Sage PFW 5 5 Sage PFW 5 5 down to 5 1 MRP requires the following Sage PFW modules Inventory and General Ledger Getting Started e 7 To run the Order Entry Preload program to load live sales orders into the forecast you also need a sales order module BOMP is tightly integrated with the IndustriOS Sales Order Fulfillment Sage PFW SO and Sage PFW Process Manaufacturing Sales Order modules Regardless of the sa
33. acture transaction posted through BOMP Open commit transactions would increase the amount available in the on order row if they are found in the history header table This means that they are in the process of being built and there will soon be more available Commit to Prod Show Detail This will display the transactions in BOMP that created the need being displayed in the MRP Report This list will print immediately following the PO detail if that option is chosen Otherwise it will print immediately following the current data for each component Print Additional Fields Lead Time Prints the Item s lead time as pulled directly from the Sage PFW file set in the MRP MPS Default Maintenance screen Here is a brief explanation of how the lead time calculation works If an item is required on January 26th and there is insufficient quantity and if there is a 14 day lead time then the program will show The requirement on the 26th The need to purchase some of it on January 12th in MRP for components The need to manufacture some of it on January 12th in MPS for assemblies or sub assemblies The amount to be purchased or made is a multiple of the restocking quantity Insufficient quantity means that the on hand quantity will drop below the minimum quantity level Planner Code Prints the Item s planner code as pulled directly from the Sage PFW file set in the MRP MPS Default Maintenance screen Minimum Stock Quantity
34. anual for more information Include Quantities Dated Prior to Start Date Selecting this option will include any planned quantities that are required before the start date These items will be put in the first planning period Include Additional Cost Items Includes the Additional Cost Items from BOMP s Additional Cost Maintenance screen are on the report If you do not select this option then the planned quantity for the Additional Cost Items is not displayed Include Labor Capacity in On Order If this box is checked then the Labor Capacity will be included in the On Order line of the MRP Report Include Lead Time in Calculations Calculates the lead time for each component and schedules the component for the date it should be ordered Page Break after each Item This will add a page break after each item We recommend this option especially if you have selected either of the detail options in MRP Advanced Features as this will make the report much easier to read 48 e Material Requirement Planning Calculate Requirements Using Forecasted Quantities If this option is selected then the required line in the MRP report will be based on the Forecasted line in the Production Schedule Report In other words you want to base your purchases on forecasted sales only If this option is selected then quantities available and committed to sales are not taken into account Production Quantities generated from Production Schedule Report For
35. at require independent demand planning The quantity should be set as a ratio to the planned quantity entered in Production Schedule Maintenance The BOM can be modified before running the Production Schedule and Materials Requirement Report The independent demand will then be included in your calculated report planned quantities Production Schedule Maintenance e 27 Field Definitions a Production Schedule Maintenance O x File Edit Help lt 4 4 gt PI assembly Key al z ADMIN 02715 2001 20 40 Assembly Key GOLF 3009 U WHI M 2 Golf King Golf Cart Location f l Date 02 15 2001 Planned Oty fo a Preleed Ttenn From ade Entry On Hand Minimum Stock Committed to Prod Reorder Quantity Committed to Sales Maximum Order On Order Lead Time ADMIN Demo T Assembly Key This field allows you to zoom on all available Assembly Items The Items shown have an associated BOM in the BOMP module MRP MPS reads the BOMP MDB from the second path entered in the Company Setup screen You may use the Page Down Page Up Ctrl Home and Ctrl End to navigate the search windows The F3 function key will copy information from the Beginning field to the Ending Field Location The user may plan for individual locations or use the combine locations option in the default screen If the combine locations field is selected then the location field will default to the loca
36. ave not been closed out by a manufacture transaction Show Detail If this is checked then the detail will be shown for both Commit to Sales and Commit to Production items in the report Print Additional Fields Lead Time The lead time of the assembly item is the amount of time that normally elapses between the time a work order is issued to production and the receipt of the item into stock or when it is shipped The Assembly Item s lead time as pulled directly from the Sage PFW file set in the MRP MPS Default Maintenance screen Planner Code Prints the Item s planner code as pulled directly from the Sage PFW file set in the MRP MPS Default Maintenance screen Minimum Stock Quantity Prints the Item s minimum stock quantity as pulled directly from Sage PFW s Inventory Location File Maximum Stock Quantity Prints the Item s maximum stock quantity as pulled directly from Sage PFW s Inventory Location File 58 e Production Schedule Report Reorder Quantity Prints the Item s reorder quantity as pulled directly from Sage PFW s Inventory Location File Processing Options Include Lead Time in Calculations Selecting this option will use the lead time field specified in Default Maintenance when calculating when the planned item will be completed on put on hand For example If an item is planned for 10 1 99 and the item has a lead time of 30 days then the report will show the item in the period which includes 10
37. c item or location by pressing the magnifying glass icon entering part or all of the value in the Search Value box and then pressing the lt ENTER gt key Once the desired record is highlighted press lt ENTER gt or the select button The value will be inserted into the entry field Beginning If you want to purge the production schedule for a specific Assembly Item or range of Assembly Items then enter the first item in this field If this field left blank the program will assume that you want to start with the first record Ending Enter the last Assembly Item that the program will purge from the production schedule If this field is left blank the program will assume that you want to end with the last record Location Beginning If you want to purge plans for a specific Location or range of Locations then enter the first location in this field If this field left blank the program will assume that you want to start with the first record Ending Enter the last Location that the program will purge from the production schedule If this field is left blank the program will assume that you want to end with the last record You may use the Page Down Page Up Ctrl Home and Ctrl End to navigate the search windows The F3 function key will copy information from the Beginning field to the Ending Field Purge through Date The utility will purge the planned items for the selected Item Key and Location range through the
38. cord Location BOMP s bills of material are unique to the Assembly Item Key Location therefore this program will only find Assembly Items with the location specified in this field If you specify an Assembly ABC with a Location of CALIF and the Sage PFW Order is for Assembly ABC in Location FLDA the item will not be loaded into the MPS Plan Beginning If you want to search orders for a specific Location or range of Locations then enter the first location in this field If this field left blank the program will assume that you want to start with the first record Ending Enter the last Location that the program will search for in the sales order files If this field is left blank the program will assume that you want to end with the last record You may use the Page Down Page Up Ctrl Home and Ctrl End to navigate the search windows The F3 function key will copy information from the Beginning field to the Ending Field Date The listing will print all planned assembly items that fall in the date range entered in these fields Window Prints the report to a Crystal Reports screen Please see the Standard Reports Crystal Reports section of this manual for more information on using the Crystal Reports screen Printer Prints the report to the default printer specified in Windows Disk Exports the report to a specified file type Microsoft export DLL Files are required to use this options these files can be obtained
39. cord Location BOMP s bills of material are unique to the Assembly Item Key Location therefore this program will only find Assembly Items with the location specified in this field If you specify an Assembly ABC with a Location of CALIF and the Sage PFW Order is for Assembly ABC in Location FLDA the item will not be loaded into the MPS Plan Beginning If you want to search orders for a specific Location or range of Locations then enter the first location in this field If this field left blank the program will assume that you want to start with the first record Ending Enter the last Location to search for in the sales order files If this field is left blank the program will assume that you want to end with the last record You may use the Page Down Page Up Ctrl Home and Ctrl End to navigate the search windows The F3 function key will copy information from the Beginning field to the Ending Field Options Tool Bar Start Date End Date The program will search the sales order Request Date Field using the date range entered into these fields Order Status The order status comes from Sage PFW and relates to the current order status Only orders that have this status will be loaded Available status codes are NN New Order Not Printed NP Work Order Printed v Np Invoice Printed BN Back Order Not Printed BP Back Order Printed Bp Back Order Invoice Printed S Fully Shipped QN New Quote QP Quote Printed
40. d Guide Step 3 BOMP The Bill of Materials Processor needs to be setup and you need to create your bills of materials For more information please refer to the BOMP Manual Step 4 Defaults Set up the MRP MPS Defaults For more information please see on page 11 Step 5 Order Entry Preload Optional Step Run the Order Entry Preload Utility The Order Entry Preload utility allows users to populate the Production Schedule using orders that have been entered into Sage PFW This utility is useful to companies that manufacture items on a make to order basis The program reads the sales order module for orders with the specified order status and fills the assembly s planned quantity with the quantity remaining on the order For more information please see on page 23 Step 6 Production Schedule Entry Enter and or modify the Production Schedule in the Production Schedule Maintenance Screen If your Production Schedule is not order driven then this screen should be used to enter the schedule and forecasting This program only allows planning of inventory items with an associated BOM in the Bill of Materials Processor program For more information please see To Plan for Independent Demand on Component Items create a planning BOM that includes all items that require independent demand planning The quantity should be set as a ratio to the planned quantity entered in Production Schedule Maintenance The BOM can be modified before r
41. e Order Module You will need to assign an Item Type In Sage PFW of F for your sub assemblies or the MPS and MRP reports will not print correct results Please read the BOMP Interface Section of the BOMP Manual and chapters of the MRP MPS Manual to get a further understating of how MRP MPS integrates with BOMP and Sage PFW Proper Procedure for Sample Forecast Types e Ifyou have a long tern forecast and a short term forecast where the only difference is that the long term looks at a longer period of time and is identical to the short term over the short term range of dates then you may enter the long term forecast into the production schedule grid Getting Started gt 9 10 e Getting Started and use the date parameters start date number of periods and days per period to limit the data being reported to the short term view or change the parameters to see the extended view If you have multiple lines which are totally independent in that they do not share any components then you may enter the complete forecast and limit the reporting to the desired line by range of assembly keys in the Production Schedule Report and or the MRP Report and may also limit the components to be printed in the MRP Report If you have several different forecast plans such as best guess optimistic and pessimistic then you would just fill in the plan name by each item in the Production Schedule Maintenance Grid and run the report for the des
42. e user name of the user that was logged into the Main Menu screen when the Production Schedule Report was run Quantity This field is populated with the Production Schedule planned quantity Date This field is populated with the date the Production Schedule Report was run Type The Transaction Type is always defaulted to use the Commit transaction option The user may change the Transaction Type after the transactions are imported into Transaction Entry Please see the BOMP Manual for more information on transaction types Level The Transaction Level is always defaulted to Raw The user may change the Transaction Level after the transactions are imported into Transaction Entry Please see the BOMP Manual for more information on transaction types Complete The transactions are imported with the complete option selected Comment The comment field is populated with the MRP MPS and date BOMP Interface e 67 Sage PFW PO Interface Sage PFW PO Interface Overview If the Create Purchase Orders for Requirements option is selected in the Material Requirements Report Options section then MRP MPS will interface to Sage PFW s Purchase Order Module A Purchase Order is generated for all Component Items displayed on the Material Requirements Report with a planned quantity Also the purchase conversion factor from the Item Master Table is taken into account during interface MRP MPS reads the Primary Vendor Key assigned
43. ecific item or location by pressing the magnifying glass icon entering part or all of the value in the Search Value box and then pressing the lt ENTER gt key Once the desired record is highlighted press lt ENTER gt or the select button The value will be inserted into the entry field Beginning If you want to print the report for a specific Assembly Item or range of Assembly Items then enter the first item in this field If this field left blank the program will assume that you want to start with the first record Material Requirement Planning 41 Ending Enter the last Assembly Item that the program will include in the report If this field is left blank the program will assume that you want to end with the last record Location BOMP s bills of material are unique to the Assembly Item Key Location therefore this program will only find Assembly Items with the location specified in this field If you specify an Assembly ABC with a Location of CALIF and the Sage PFW Order is for Assembly ABC in Location FLDA then the item will not be loaded into the MPS Plan Beginning If you want to search orders for a specific Location or range of Locations then enter the first location in this field If this field left blank the program will assume that you want to start with the first record Ending Enter the last Location that the program will search for in the sales order files If this field is left blank the program wi
44. ents using the production quantities the MRP report will be incorrect as it will add the requirements from both the top assembly and each of the sub assemblies Include Order Entry Preload Items Selecting this option will print all of the Order Entry Preload Assembly Items Production Schedule Report 59 Tool Bar Include Quantities Dated Prior to Start Date Selecting this option will include any planned quantities that are required before the start date These items will be put in the first planning period Explode Bill of Materials To Top level Computes the report quantities by using the top level component items and sub assemblies therefore any components that are used to build the sub assemblies will not be considered in the report Raw level Computes the report quantities by using the lowest level component items therefore the inventory quantities for the sub assemblies will not be considered when processing the report Print Prints the report to the specified print destination Clear This button returns the screen to a blank form New or modified information will be lost if the Save button is not selected before clearing the screen Default Saves the entered report parameters Exit This button shuts down the current screen and the program returns to the Main Menu 60 e Production Schedule Report Scheduled MRP Overview This feature allows the user to run the MRP report as a scheduled task The task
45. es 10 will be interpreted as a 10 increase changing a quantity of 100 to 110 A zero percent 0 means no change 100 stays 100 Increase Days The date from the selected data will be modified by adding this number of days The new date would be used in the forecast table along with the modified quantity If I wanted to use numbers from last Spring add 10 and use them as a forecast for this spring I would put in dates for last Spring 3 23 04 to 5 31 04 check the sales flag check the move flag put 10 in the new modify quantity field and put 365 in the modify date field Therefore a historical transaction date 4 1 04 would be in the forecast with a date of 4 1 05 and a historical transaction with a date of 5 10 04 would be put in the forecast with a date of 5 10 05 Move Sales History to Forecast e 37 Item Type Options Here the user can specify what item types are to be included in the report MRP Action Report Overview Filters 38 MRP Action Report The MRP Action Report calculates Available and on order and if the required quantity in BOMP is greater than Available and on order it will recommend a purchase of the needed quantity 33 MRP Action Report 3 10 x r Component Key y Assembly Key Beginning Beginning ACCES MISCL YAMA 9162 U BLU M 5 Ending Ending a r Date Print Destination Print Options Beginning Window MV Open PO s ER x C
46. es the selected transactions to the open transactions in Transaction Entry Cancel Exits the Import Detail screen and returns to Transaction Entry How Transaction Entry Fields are Populated 66 BOMP Interface File Edit Serial Lot Help Ol lx gt or Jae Transaction Transaction 04 Hl Appply Num 004 ts Assembly 001 0000 Pl BUBASSEMBLY T Location ea 00007 Pl Ealfomia Warehouse 7 Responsibility DMN 7 Pl Quantity fi 30 Comment Date MRPMPS 3 25 2000 Type Level Complete PFW 4 8 PREMGL Transaction Number Apply Num Import and Edit Selecting this option leaves the Transaction Number and Apply Num fields blank The user can enter a 1 10 alpha numeric transaction number or when the transaction is saved it will be automatically assigned by the system Import Selected Selecting this option will populate the Transaction Number and Apply Num will the next transaction number The system uses the Next Transaction Number which is set in the BOMP Defaults Maintenance screen Assembly This field is populated with the Assembly Item displayed on the Production Schedule Report Location This field is populated with the Location displayed on the Production Schedule Report Ifthe Combine Locations option is selected then this field will display the location set in the Defaults screen Responsibility This field is populated with th
47. et with a quantity remaining of 9 and one BOMP commit transactions for the assembly item widget with 5 committed You would show 14 on order on in this field Minimum Stock This field is view only and is pulled directly from Sage PFW s Inventory Location File Reorder Quantity This field is view only and is pulled directly from Sage PFW s Inventory Item Location File Maximum Order This field is view only and is pulled directly from Sage PFW s Inventory Location File Lead Time This field is view only and is pulled directly from the Sage PFW field designated in the MRP MPS defaults screen The lead time is calculated for each item and the item is put in the appropriate planning period Save This button must be selected to store new or modified information to the MRP MDB file New This button returns the screen to a blank form New or modified information will be lost if the Save button is not selected before clearing the screen Production Schedule Maintenance e 29 File Menu Delete This button will permanently remove the displayed record from the live file New Ctrl N This option returns the screen to a blank form New or modified information will be lost if the Save button is not selected before clearing the screen Save Ctrl S This option stores new or modified information to the MRP MDB file Delete This option will permanently remove the displayed record from the maintenance table
48. from the second job and the 4 from the third job MRP Action Report e 39 Material Requirement Planning Material Requirement Planning Overview The Material Requirements Report computes the component quantities that are required to produce the finished good items generated by the Production Schedule Report This report includes the option to create Purchase Orders for all generated raw material items The purchase orders may be viewed modified and posted through the Sage PFW s Purchase Order Module You will need to assign an Item Type In Sage PFW of F for your sub assemblies or the MPS and MRP reports will not print correct results It is strongly recommended for the typical MPS MRP run that the Production Schedule be run with the Include sub assemblies requirements option NOT selected Also the Material Requirements Planning report should be run at the Raw Level and that the Calculate Requirements Using should be set to Production quantities generated from production schedule report The other options are there to give the user increased flexibility For example the Schedule Jobs option allows the user to see ONLY the requirements from currently scheduled jobs in the Shop Floor Control Module Printed Fields Definitions Purchase Quantity The report will include a Purchase field that calculates the amount to be ordered This is the quantity needed to keep inventory from going negative If the Minimu
49. g your Software Adding Additional fields to the MRP Reports See the MRP Advanced Features MRP Report Section of this Manual Utilities Database Utilities Database Overview The utilities that are used to fix corrupted data in the Access database files are found in the Utilities Database Menu It is critical to back up the BOMP MDB and MRP MDB file and make sure all users have exited the MSS from IndustriOS Software before attempting to process any of the utilities It is also very important to follow the instructions related to each utility 3 Maynard Software Solutions Change Password Limit Program Access Register DataBase Repair Compact Update Purge Convert From Platinum Repair The Repair option is a Microsoft Access utility that attempts to repair only the tables queries and indexes in the database The repair does not fix damaged forms reports macros or modules however these objects are copied to the repaired database Step by Step 1 Login as ADMIN using the administrator password 2 Make a backup copy of the database s 3 Verify that all users have exited completely out of the MSS from IndustriOS Software System and do not attempt to open the database during the repair process If all users have not exited from the program or open the program during the Repair process you may lose important data 4 Select Repair from the toolbar Utilities Database e 7
50. he IndustriOS technical support Print Prints the report to the specified print destination Clear This button returns the screen to a blank form New or modified information will be lost if the Save button is not selected before clearing the screen Default Saves the entered report parameters Exit This button shuts down the current screen and the program returns to the Main Menu 56 e Production Schedule Report Report Options Production Schedule Report 3 5 Oj lt Print Parameters m Print Inventory Quantities Processing Options Y On Hand TF Include Lead Time in Calculations On Order TF Create commit transactions in BOMP IF Show Detail Print Forecast quantities BOMP Requirements Page Break after each Item Show Detail M Commit to Sales r Forecast Quantities Options Commit to Production Print only assemblies with required qty J Show Detail JV Include sub assemblies requirements m Print Additional Fields W Include Order Entry preload items Lead Time J Include quantities dated prior to start date Minimum Stock Qty Raw level Maximum Order Qty C Top level JV Reorder Quantity Plan Name Print Clear Save Exit ADMIN test J Planner Code Explode Bill of Materials to Print Inventory Quantities On Hand The On Hand quantity is the balance shown in inventory as bei
51. ile AS 16 Save Report File for Net Change Report 0 16 Use Custom Report Formati siii tae 17 Use Sub Assembly Location 17 Which Report Pile to Edit o iccccists cessascsutsedesecessapatenanionssesnasespivedseeonecaytisedeigesausoayeses 17 A O ieee yess Absentee cea 167 Format Numeric Output Ficldsi cccsssssesstescseseessseniseesinessaseaesoeesedeegensetentnnatincsanseasness 17 Combine Material Requirements Location Maintenance 18 OE Na EE E E E E E E E 18 Combine Production Schedule Location Maintenance 19 10 la iia 19 Drop In Order Maintenance 20 ONE Westin rt platenses detesta E IE EE IT 20 Drop In Order Maintenance Field DefinitiONS oooonnncnnncnnocinonnnancnnnnoncnnnon nono ncnn cnn 21 Order Entry Preload 23 Order Entry Preload Overview oooonoconoccnononononnnonnnonnono nono nono ncnn cnn ono n cnn n cnn n cane nono 0 23 asetibeiateedis o AE E AE EEEE EEE N E ROEDE PE TO EE EEE dested 24 Assembly Keyesa ii eiii 24 A E tee ee E A ee 24 A odeatassebtese seesdeah cabal ues a sea set eoodcases edbeusediogealh se iSent scopodass sctbintdsodeata R N 25 25 Ofder Siats e e aaraa a A E EAA E TR E RES 25 Remove Previous Preload mernans aea e A EERE AIAS 25 TOOLB afruan a A donante E A E aa Ra ETS 25 Production Schedule Maintenance 27 Production Schedule Maintenance Overview 27 7 28 Assembly Key sitiar iia lille dde 28 7 28 air int
52. in Sage PFW s Inventory Item Location File Component Items with the same Primary Vendor and with planned quantities in the same period will be combined on a Purchase Order Important Purchase Orders will be generated each time the MRP Report is run regardless 1f the PO s have been generated previously Do not select the interface option until your MRP Report displays the correct planned quantities Otherwise you will have to delete the duplicate and incorrect Purchase Orders from Sage PFW How Sage PFW s Purchase Order Fields are populated E Purchase Order Entry Ml x File Edit View Help D El 1414 gt 0 Purchase Order Number Eaj ai EA ia ADMIN 10 28 98 06 50 59 PM 1 Purchase 20000 3 Prepayment 4 Addess 5 Ceat C 6 Line tems Vendor Key ATLO1 Atlantic Golf Inc a Ship To Key a Purchase Order Number 00048 Purchase Order Status NN New Order Not Posted a Terms Key 2 2 10 Net 30 la te Order Date 10 28 98 8 Requested Delivery Date 10 28 98 Cancel Date E Ship Via Key T Truck a FOB Key S Shipping point a Comment Key 02 Demo Golf Inc Serving all a Nontaxable Freight Amount Currency US Dollars Required Field F9 Lookup Demo Golf Inc Print Screen from Sage PFW Purchase Order File Sage PFW PO Interface 69 70 e Sage PFW PO Interface Purchase Tab Vendor Key This field defaul
53. ired plan MRP Defaults Default Setup Overview Field Definitions The Default screen allows the user to set optional parameters that are used when running various MRP MPS programs This information is very important and the program will not function properly if the information is entered incorrectly MRP System Defaults loj x File Edit Help Talx od gt o 2 m Planner ID From INLOC Field Allow Modifications to Pre load User Specific Plans I Combine Locations L C Bin Nimes M Use Labor Capacity Table m Lead Time From INLOC Field C None Cary Cost Market Cost test Allow Modifications to Preload This option allows the user to modify the planned quantities of the preloaded orders After running the Order Entry Preload the user can modify the Assembly quantities in the Production Schedule Maintenance screen User Specific Plans When logging in to the MSS from IndustriOS Main Menu screen a 1 8 character user name is required MRP MPS uses the user name to track entries made in the Production Schedule Maintenance Screen If this option is selected the program screens will only display and report on data that is related to entries made by the user that is currently logged into the program If this option is not selected then the program screens will display and report on all items entered into the Production Schedule Maintenance Screen regard
54. l places enter a format of 0 0000 e 17 Combine Material Requirements Location Maintenance Overview 10 x 33 Combine Material Requirement Location Maintenance File Edit Help n 4 gt mn Location 2 Location to Combine CALIF FA Califomia Warehouse PREMGL This allows for a single BOM to be used for multiple finished goods locations when importing via Open Order Commitment This option is to be used for companies that have multiple finished goods warehouses that make product in one location and then move it to others Also the product is shipped from the other locations They want to track what is in the other locations and also want to sell from those locations Normally you would have to maintaining multiple BOMs for each item one for each location This feature avoids this by triggering a translation table to be used by Open Order Commitment and Order Entry Preload When either of those programs reads the sales order files and brings in the records the locations on the records will be changed This same functionality can be found in the BOMP OOC Advanced features section of the BOMP Manual 18 e Combine Material Requirements Location Maintenance Combine Production Schedule Location Maintenance Overview 10 x E Combine Production Schedule Location Maintenance File Edit Help Location to Combine FLADA FA Florida Warehouse ADMIN PREMGL
55. les order module chosen the user interface for this program is the same The program will assume the Sage PFW SO module unless told otherwise To indicate Process Manufacturing turn on the Interface to BatchMaster flag in the BOMP Default program To indicate that you are using the IndustriOS Sales Order Fulfillment module you enter a path in Company Setup see the System Manger manual for the Path to IndustriOS data files v To automatically update purchase orders based on the MRP report you need a purchasing module Either the Sage PFW PO module or the Sage PFW Process Manufacturing PO module may be used Y Bill of Materials Processor Module from MSS by IndustriOS Basic Functionality The MRP MPS module was designed to give Sage PFW users the ability to develop manufacturing forecasting plans and determine material requirements based on the production plan The forecasting plan allows user to take into account such considerations as sales forecasts customer orders minimum stock requirements maximum order and reorder quantities MRP Process Flow 8 e Getting Started Step 1 Install Software Follow the installation instructions outlined in the Getting Started Guide The Getting Started Guide can be downloaded from our web site Step 2 Create and Select a Company The user may setup multiple companies and easily switch between each processing company For more information please refer to the Getting Starte
56. less of the user that entered the data MRP Defaults e 11 12 e MRP Defaults Combine Locations This check box will combine assembly items with multiple locations into the location selected in the Location Key for Combined Locations field This option should be left blank to plan item quantities in individual locations When this check box is checked a new field Location Key for Combined locations will appear See more info on this field below Use Labor Capacity Table Labor capacity is part of our capacity planning tool set The MRP module uses an infinite capacity model and so it does not realistically schedule jobs It does however give you tools to assist you in planning your jobs The purpose of the Labor Capacity file is to allow for different capacities on a day by day basis If the Use Labor Capacity Table box is not checked then the MRP program will use the same daily capacity for all days Including labor items whether additional cost or inventory items in the MRP gives you capacity planning information For example if you specify that the capacity of a labor department is 60 hours and the planned workload calls for 100 hours this would be very obvious You may then reschedule jobs or people to better handle the load If the Use Labor Capacity Table checkbox is checked then the daily capacity will be taken from the Labor Capacity Table If it is not checked then the daily capacity for additional cost ite
57. ll assume that you want to end with the last record Period Parameter The Materials Requirement report is printed using user defined planning periods The report prints the combined component quantities that are required for each of the defined planning periods Start Date Enter the date to be used as the beginning date of the first period Number of Periods Enter a numeric value between 1 20 to be used as the number of planning periods Days Per Period Enter a numeric value to be used as the number of days to be included in each planning period Print Destination Window Prints the report to a Crystal Reports screen Please see the Standard Reports Crystal Reports section of this manual for more information on using the Crystal Reports screen Printer Prints the report to the default printer specified in Windows Disk 42 e Material Requirement Planning Exports the report to a specified file type Microsoft export DLL Files are required to use this options these files can be obtained through the IndustriOS technical support Print Sequence The MRP Report may now be printed in the following sequences e Assembly Key e Planner Code Assembly Key e Planner Code Primary Vendor Key Component Range a Material Requirements Planning AE Print Parameters Component Range Report Options r Component Key Beginning JATLA 4099 M STE M l Ending JIDMG SSET W STE M r Component Location Beginning Ending
58. ly 3 Level 1 300 001 FLADA Sub Assembly 1 Level 2 CALIF Sub Assembly 1 Level 2 FLADA Component level 3 Component level 3 Select Cancel The user may search for a specific item or location by pressing the magnifying glass icon entering part or all of the value in the Search Value box and then pressing the lt ENTER gt key Once the desired record is highlighted press lt ENTER gt or the select button The value will be inserted into the entry field Beginning If you want to print the report for a specific Assembly Item or range of Assembly Items then enter the first item in this field If this field left blank the program will assume that you want to start with the first record Ending Enter the last Assembly Item that the program will include in the report If this field is left blank the program will assume that you want to end with the last record Location BOMP s bills of material are unique to the Assembly Item Key Location therefore this program will only find Assembly Items with the location specified in this field If you specify an Assembly ABC with a Location of CALIF and the Sage PFW Order is for Assembly ABC in Location FLDA then the item will not be loaded into the MPS Plan Beginning If you want to search orders for a specific Location or range of Locations then enter the first location in this field If this field left blank the program will assume that
59. m stock quantity is displayed then purchase will be filled to the quantity that will keep inventory at that level Also if the reorder quantity is displayed the purchase quantity will be limited to quantities divisible by the reorder amount The create purchase orders option will use the purchase quantity when generating Purchase orders You may select the option to only print the items that need to be purchased as associated with above item 40 e Material Requirement Planning Print Parameters Material Requirements Planning Iof x Print Parameters Comp Class Range Report Options Assembly Key Period Parameter Beginning Start Date 027237200 ATLA SSET M STE M LI Ending of Periods fi 0 HELI 4093 M BORM 77 Days per Period 7 Assembly Location r Print Destination Beginning Window Printer Endi E Disk p m Print Sequence gt LI Assembly Key C Planner Code Assembly Key Planner Code Vendor Key Print Clear Default Exit Demo T Assembly Key The magnifying glass icon located to the left of the Beginning and Ending fields will allow a search of available data Search Value f Location CommentDescription A FLADA Assembly Item 1 __ SubAssembly 3 Level Sub Assembly 3 Level 1 Sub Assembly 1 Level 2 Sub Assembly 1 Level 2 Component level 3 Component level 3 The user may search for a sp
60. ms will be taken from additional cost file maintenance in BOMP and for inventory items it will be taken from the minimum quantity in the Item Location file For Additional Cost Items If the Use Labor Capacity Table checkbox in the MRP Report Report Options section is checked then it will put the amount in the table for that item into the appropriate On Order bucket for that item All inventory item keys will be processed this way if it is checked If the Use Labor Capacity Table checkbox is NOT checked then it will multiply the daily capacity times the Days per Period and put that amount in each On Order bucket for that item Location Key for Combined Locations Note this field will only appear if the combine locations option is selected The reports and entry screens will display this location but the inventory quantities will be a combination of all Sage PFW locations MRP MPS will use the combined quantities when calculating net requirements in the MPS and MRP reports All of your Sage PFW Inventory Items must have a valid INLOC record for this location If an Assembly or Component Item does not exist in this location you will receive an error status 4 when planning or running reports Planner ID from INLOC Field Sage PFW does not include a field to enter a Planner ID code as did previous versions MRP MPS has been modified to read one of the following fields to use as a Planner ID code File Menu None If
61. nd those files may require MS Access 2000 or later to be read Which Report File to Edit The following is a list of the possible MRP MPS reports Mrp10 MRP Report 10 columns sorted by assembly key Mrpl0pa MRP Report sorted by planner code assembly key Mrpl0pv MRP Report sorted by planner code vendor key Mrp20 MPS Report 20 columns sorted by assembly key Mrp20pa MPS Report sorted by planner code assembly key Mrp20pv MPS Report sorted by planner code vendor key MRP Advanced Features e 15 Material Requirement Planning 16 e MRP Advanced Features MRP Advanced Features 3 loj x File Edit Help ed lt gt nl Production Schedule Report Material Requirement Planning Add INMAST Platinum Fields to Report r Add INLOC Platinum Fields to Report PurchConvF ctr X Sparel X PhysInProgress X Save Temporary Report File as Use Custom Report Format je Platinum MSS520 MRPtest mdb Ed Use Sub Assembly Location Save report file for Net Change report PREMGL Add INMAST Sage PFW Fields to Report This option is identical to the Add INMAST on the previously documented Production Schedule Report tab Add INLOC Sage PFW Fields to Report This option is identical to the Add INLOC on the previously documented Production Schedule Report tab Save Temporary Report File as This allows the user to select a file name and location where reports will be stored temporarily
62. ng physically present at the stocking location The printed on hand quantity in the first period is pulled directly from Sage PFW s Inventory Location File Each planning period following the first period displays the forecasted On Hand Quantity or the quantity that will be on hand if the planned quantity is manufactured On Order The On Order quantity is derived from the quantity remaining on purchase orders that are open and the Assembly items that are posted using BOMP commit transactions An example would be if you had an open PO with an item key of widget with a quantity remaining of 9 and one BOMP commit transactions for the assembly item widget with 5 committed You would show 14 on order on in this field Show Detail If this is checked then the detail will be shown for both On Hand and On Order Production Schedule Report e 57 BOMP Requirements If this checkbox is checked then all open WIP transactions will be displayed They will print on the report as PLANNED QUANTITY and will be added to the current totals Show Detail If this is checked then the individual WIP transactions will be listed on the report Commit to Sales Prints the Item s committed to sales quantity which is the total of all the open sales orders Note Do not check the Commit to Sales box if you have run a preload or it will cause orders to be counted twice Commit to Production Calculated from Commitments posted through BOMP that h
63. on Type Options 5 J Include Adjustments m Range of Commodity Keys gt Range of ABC Keys r Date Range Beginning Beginning Beginning pl 17172005 Ending Ending Ending 5 5 27172005 r Print Destination Window C Printer Disk Clear Save Exit ADMIN PremGL Demo Data Range of Item Keys Here the user can type or zoom to select the desired range of Item Keys Range of Item Class Keys Here the user can type or zoom to select the desired range of Item Class Keys Range of Commodity Keys Here the user can type or zoom to select the desired range of Commodity Keys Range of Product Keys Here the user can type or zoom to select the desired range of Product Keys Range of Locations Here the user can type or zoom to select the desired range of Locations Range of ABC Keys Here the user can type or zoom to select the desired range of ABC Keys An example is shown below 36 e Move Sales History to Forecast Search Value Description 90 Day Cycle Count 180 Day Cycle Count 365 Day Cycle Count Select Cancel Date Range Here the user can type or zoom to select the desired range of Dates Transaction Type Options Include Adjustments If this option is selected then the report will include negative sales transactions Increase Options Increase Quantity This field allows the user to make a percent change positive or negative It is used to modify the historical quantiti
64. port checkbox The file will be saved in the company directory under the following file name Mryymmdd MDB Print Items With Quantities That Have Changed If this option is selected then only items where the quantity has changed will show up on the report Print if tems Have Changed in the First ___ Columns If this option is selected then only items where the quantity has changed in the selected number of columns will show up on the report Net Change Report Differences The output of the Net Change Report will be similar to the MRP output except that the Purchase row will be replaced with three rows Original Purchase from the BASE temporary report file Revised Purchase as calculated in this run and Net Change Purchase which is the difference of the other two rows Print This button will print the report to the specified print destination Clear This button returns the screen to a blank form New or modified information will be lost if the Save button is not selected before clearing the screen Material Requirement Planning 51 Default Selecting this button will save the current report parameters for future use Exit This button shuts down the current screen and the program returns to the Main Menu 1 of 1 5 8 gt v Totat7o 100 07 27 200 Material Requirements Report Item Key ATLA 4099 M STE M Atlantic Pro Iron Set 3 PW Men steel Primary Vendor Key ATLO1 Right handed std Lead Time
65. rently logged into they system will be printed Unneeded PO report Shows current POs which are not needed based on the MRP report Assembly Key The magnifying glass icon located to the left of the Beginning and Ending fields will allow a search of available data Search Value K Comment Description 100 000 FLADA Assembly Item 1 100 000 CALIF 100 003 FLADA Sub Assembly 3 Level 1 100 003 CALIF Sub Assembly 3 Level 1 300 001 FLRADA Sub Assembly 1 Level 2 300 001 CALIF Sub Assembly 1 Level 400 001 FLADA Component level 3 Component level 3 Select Cancel The user may search for a specific item or location by pressing the magnifying glass icon entering part or all of the value in the Search Value box and then pressing the lt ENTER gt key Once the desired record is highlighted press lt ENTER gt or the select button The value will be inserted into the entry field Forecast Sales Listing 33 Print Destination 34 e Forecast Sales Listing Beginning If you want to print the report for a specific Assembly Item or range of Assembly Items then enter the first item in this field If this field left blank the program will assume that you want to start with the first record Ending Enter the last Assembly Item that the program will include in the report If this field is left blank the program will assume that you want to end with the last re
66. the Production Schedule Entry program An option is included to auto generate transactions within the Bill of Materials Processor for the Assembly Items that need to be manufactured Note sub assemblies should not appear on this report If they do it is because they have been set up with the wrong item type in the Item Master File Sub assemblies should be set to a type of F It is strongly recommended for the typical MPS MRP run that the Production Schedule be run with the Include sub assemblies requirements option NOT selected Also the Material Requirements Planning report should be run at the Raw Level and that the Calculate Requirements Using is set to Production quantities generated from production schedule report The other options are there to give the user increased flexibility For example the Schedule Jobs option allows the user to see ONLY the requirements from currently scheduled jobs in the Shop Floor Control Module e 53 Production Schedule Report EQUIP CLUBS ATLA SSET M STE Print Parameters E Production Schedule Report ATLA SSET M STE M ye HELI 4093 M BOR M EX Assembly Key The magnifying glass icon located to the left of the Beginning and Ending fields will allow a search of available data 54 e Production Schedule Report Search Value LADA Assembly Item 100 000 CALIF 100 003 FLRDA Sub Assembly 3 Level 1 100 003 CALIF Sub Assemb
67. the user to add up to five additional fields from INLOC to the report To make your selection just click on the arrow to the right of the field and the click on the desired INLOC field from the dropdown list You can only print a total of 5 additional fields combined from INLOC or INMAST For example If you had 3 additional fields set up in INLOC you could only have 2 others coming from INMAST Once you have added the desired fields in the MRP Advanced Features program from Windows Explorer double click on the report you will be using to see which report you use see the Which Report to Edit section of this report and click on insert database fields Here you will see a file called Extra Info In that file are 5 fields Add Item 1 to 5 When you specify which fields are to be added in the MRP Advanced Features the program inserts the associated values into those fields You then use the Crystal Design tool to insert these five fields into the rpt file where you want them Save Temporary Report File as This allows the user to select a file name and location where reports will be stored temporarily This will hold the data from one time of running the report The next time the report is run the first file will be deleted and replaced with the new data To select a file location to save the report click on the arrow to the right of the field and fill in the desired file name and directory location The temp files need an mdb extension a
68. this option the required line in the MRP Report will be based on the Start Production line in the Production Schedule Report Or in other words this option should be used if you want to base your purchases on the amount that you need to make which is based on what the Production Schedule Report says you need to make which can be more or less than the forecasted quantity Note If you include sub assemblies in the Production Schedule report and then calculate MRP requirements using the production quantities the MRP report will be incorrect as it will add the requirements from both the top assembly and each of the sub assemblies Schedule Jobs This option allows the added flexibility of running MRP for scheduled jobs only Forecasted quantities are not taken into account if this option is selected This assumes that the scheduled jobs assemblies need to be started on the schedule start date so the components must be in stock on the schedule start date So if this option is selected the required line in the MRP report will be based on scheduled jobs in Shop Floor Control Open Transactions This will only process components that are on the open transaction report in BOMP Print Components All Components If this option is selected all valid components will print on the report With Required Quantity If this option is checked then the component will only print if there is a required quantity With Purchase Quantity If this
69. this option is selected then MRP MPS will not display a Planner ID Code Item Class If this option is selected then the item s Item Class Code from Sage PFW will be displayed as the Planner ID Bin Number If this option is selected then the item s Bin Number as assigned in Sage PFW will be displayed as the Planner ID Lead Time from INLOC Field Sage PFW does not include a field to enter a Lead Time MRP MPS has been modified to use one of the following Sage PFW Inventory Item Location Fields to control lead time None This option will not display the lead time on any reports Carry Cost The Carry Cost field from Sage PFW s Inventory Location file is used to display the lead time of an item The Carry Cost field will need to be populated with the correct lead time for the inventory items Market Cost The Market Cost field from Sage PFW s Inventory Location file is used to display the lead time of an item The Market Cost field will need to be populated with the correct lead time for the item Save Ctrl S This option stores new or modified information to the BOMP MDB file The save button from the tool bar may also used to store new or modified information Exit This button shuts down the current screen and the program returns to the Main Menu MRP Defaults e 13 MRP Advanced Features Production Schedule Report 14 e MRP Advanced Features MRP Advanced Features 1 loj x File Edit Help ole
70. through the IndustriOS technical support Tool Bar Print Prints the report to the specified print destination Clear This button returns the screen to a blank form New or modified information will be lost if the Save button is not selected before clearing the screen Exit This button shuts down the current screen and the program returns to the Main Menu Move Sales History to Forecast Overview This program moves historical sales information into the MRP forecast Once it is moved it is viewable and modifiable in the grid The multitude of ranges is important because companies may want a 10 increase in one product line a 5 decrease in another and so on We recommend that you save the different settings so that if one product line is done incorrectly you can purge the forecast and start over without having to re enter all of the parameter sets Move Sales History to Forecast 35 Range Options E Move Sales History to Forecast x Range of Item Keys Range of Product Keys m ltem Types to Include Beginning Beginning IV F Finished Goods 10 YR EMB RING pD p J L Labor z 2l z 5 O Overhead Ending Ending N Nor Stockina ABRASIVE 7 R Raw Material m Range of Item Class Keys Range of Locations Increase Options Beginning Beginning Increase Quantity El 5 Increase Days fo Ending Ending A m Transacti
71. tion selected in the default screen and will be grayed out If you are planning for specific locations then enter or zoom to select the Assembly Location BOMP s bills of material are unique to the Assembly Item Key Location therefore a BOM must exist for the planned Assembly Key and specified Location The MPS and MRP report data will not be correct if plans are entered for an Assembly Location combination that does not have a valid BOM in BOMP Date This is the schedule date for the manufacture of the Assembly The Order Pre load utility populates the date field with the sales order s request date 28 e Production Schedule Maintenance Planned Quantity This is the quantity to be manufactured If you ran the Order Preload then this field displays the sales order s order quantity View Only Field Definitions Tool Bar On Hand This field is view only and is pulled directly from Sage PFW s Inventory Location File Committed to Production Calculated from open Commit transactions that haven t been completed through a Manufactured transaction posted through BOMP Committed to Sales This field is view only and is pulled directly from Sage PFW s Inventory Location File On Order The On Order quantity is derived from the quantity remaining on purchase orders that are open and the Assembly items that are posted using BOMP commit transactions An example would be if you had an open PO with an item key of widg
72. ts to the Primary Vendor Key assigned to the inventory item in Sage PFW s Item Location File Ship to Key This field is not populated Purchase Order Number MRP MPS assigns the Purchase Order Number from Sage PFW Next Event Id file Purchase Order Status Defaults to NN new order not posted Terms Key This field is defaulted from Sage PFW s AP Vendor File Discount This field is not populated Order Date Defaults to the date the MPS report was run Requested Delivery Date Defaults to the date the MPS report was run Cancel Date This field is not populated This is a required field in Sage PFW s Purchase Order File The user must open the Purchase Orders and assign this value before the PO can be posted through Sage PFW Ship via Key This field is defaulted from Sage PFW s AP Vendor File FOB Key This field is defaulted from Sage PFW s AP Vendor File Comment Key This field is defaulted from Sage PFW s AP Vendor File Nontaxable Freight Amount This field is not populated Currency Sage PFW Currency is displayed Misc Tab Information in this screen defaults to the Vendor information entered into the AP Vendor File Prepayment Tab The fields in this screen are not populated Address Tab Information in this screen defaults to the Vendor information entered into the AP Vendor File Credit Tab Information in this screen defaults to the Vendor information entered into the AP Vendor File
73. unning the Production Schedule and Materials Requirement Report The independent demand will then be included in your calculated report planned quantities Step 7 Planned Forecast Listing Run the Planned Forecast Listing Report This report will list the Production Schedule plans that have been entered and or pre loaded between a specified range of dates items and locations The listing will also show who entered the plan and when it was entered For more information please see on page 33 Step 8 Production Schedule Report Run the Production Schedule Report The Production Schedule Report is generated for all finished good items that need to be manufactured in order to fulfill the production plans formulated in the Production Schedule Entry program For more information please see on page 53 BOMP Interface An option is included to auto generate transactions within the Bill of Materials Processor for the Assembly Items that need to be manufactured Step 9 Materials Requirement Report Run the Materials Requirement Report The Material Requirements Report computes the component quantities that are required to produce the finished good items generated by the Production Schedule Report For more information please see on page 40 Sage PFW Interface This report includes the option to create Purchase Orders for all generated raw material items The purchase orders may be viewed modified and posted through the Sage PFW s Purchas
74. upon the export DLL files the specific workstation has installed in the Windows System directory Set the directory box to the Drive and Folder where the report will be saved The Drive can be selected from the dropdown menu box Double clicking on the drive will display all available Folders Double clicking on the Standard Report Information e 75 Folders will display all sub folders and the files will be displayed in the Files box 3 Select OK and the report will be saved in the directory specified 76 e Standard Report Information Customizing your Software Customizing Screen Captions This feature was added to our software to allow foreign companies to adjust our software to their language however all users may find it useful to customize the software to fit your company s individual manufacturing needs All of the captions field descriptions prompts and screen descriptions are modifiable Follow this procedure to update the captions 1 Download the prompt file from our version 4 0 download web page You must contact us for the web address and have a current support contract to receive this upgrade You should download the prompt exe file into the directory and folder that you installed the MSS from IndustriOS Software 2 Double click on the prompt exe file This file will be unzipped into the directory in which it resides All of the ini files must be unzipped into the MSSSOFT directory or the directory where the MS
75. version of the report This option will print two lines per item with the first showing the assembly key description and location The second would be the Changes to POs line If the summary option is not checked then the report will be like the current MRP report in format Unneeded PO Report gt 63 BOMP Interface BOMP Interface Overview MRP MPS will interface to the Bill of Materials Processor if the Create Commit Transactions in BOMP option is selected in the Production Schedule Report Options section A BOMP transaction is generated for all Assembly Items displayed on the Production Schedule Report with a planned quantity If the Include Requirements option is selected then the Production Schedule Report will display the planned quantity for any required Sub Assembly Items therefore a BOMP transaction will be generated for these items along with the Parent Assemblies This chapter explains how to import the transactions into the Bill of Material Processor Important BOMP Transactions will be generated each time the PS Report is run regardless 1f the transactions have been generated previously Do not select the interface option until your PS Report displays the correct planned quantities Otherwise you will have to Import and Delete the duplicate and incorrect BOMP transactions Import Transactions 64 e BOMP Interface After running the Production Schedule Report with the create commit transactions in B
76. x 4 gt r Production Schedule Report Material Requirement Planning Add INMAST Platinum Fields to Report r Add INLOC Platinum Fields to Report PurchConvF ctr X Spare1 v Phys nitD ate Save Temporary Report File as Use Custom Report Format C Platinum MSS520 MPStemp mdb PREMGL Add INMAST Sage PFW Fields to Report This option allows the user to add up to five additional fields from INMAST to the report To make your selection just click on the arrow to the right of the field and the click on the desired INMAST field from the dropdown list You can only print a total of 5 additional fields combined from INLOC or INMAST For example If you had 3 additional fields set up in INLOC you could only have 2 others coming from INMAST Once you have added the desired fields in the MRP Advanced Features program from Windows Explorer double click on the report you will be using to see which report you use see the Which Report to Edit section of this report and click on insert database fields Here you will see a file called Extra Info In that file are 5 fields Add Item 1 to 5 When you specify which fields are to be added in the MRP Advanced Features the program inserts the associated values into those fields You then use the Crystal Design tool to insert these five fields into the rpt file where you want them Add INLOC Sage PFW Fields to Report This option allows
77. you want to start with the first record Ending Enter the last Location that the program will search for in the sales order files If this field is left blank the program will assume that you want to end with the last record You may use the Page Down Page Up Ctrl Home and Ctrl End keys to navigate the search windows The F3 function key will copy information from the Beginning field to the Ending Field Period Parameter The Production Schedule report is printed using user defined planning periods The report reads the date entered for the Assembly in the Production Schedule Production Schedule Report e 55 Tool Bar Maintenance screen and combines all planned quantities into the defined planning periods Start Date Enter the date to be used as the beginning date of the first period Number of Periods Enter a numeric value between 1 20 to be used as the number of planning periods Days Per Period Enter a numeric value to be used as the number of days to be included in each planning period Print Destination Window Prints the report to a Crystal Reports screen Please see the Standard Reports Crystal Reports section of this manual for more information on using the Crystal Reports screen Printer Prints the report to the default printer specified in Windows Disk Exports the report to a specified file type Microsoft export DLL Files are required to use this options these files can be obtained through t

MRP/MPS User Manual - Maynard Software Solutions

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