User Manual Mrp

Material Requirements Planning
USER REFERANCE MANUAL

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USER REFERENCE MANUAL

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© Nalco Saudi Co. Ltd. 2010

Page 1 of 21 Revision: Baseline


Document History Log
This page is for informational purposes and does not have to be retained with the document
Status Document Effective Page Description of Change
Change Revision Date
Baseline 20.01.10



Table of Contents
Content Page
Document History Log
Table of Contents
Purpose of Document
Scope
Definitions

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

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

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

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

Chapter 4: FULL CYCLE CHART 21


Chapter 1: FORECAST
Functionality

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

Scenario 1: Create New Forecast
In case you are going to create a new forecast, you have to do the following:

 Open the forecast entry/adjust form:

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

 Update the following fields:
 Forecasted Item General Data:

Field Name Field Description Values
Forecast Number identifying a given 0 to 9999
forecast.
Segment The factory/plant for which the 1001: For Dammam Plant,
forecast belongs 2001: For Yanbu Plant
Stock Code The YSLD code for which Any of NALCO SAUDI codes, press
forecast to be entered. F4 to see the full list.

 Forecasted Item Details:

Row A sequential line number Provided automatically by the system
Date The date at which the The monthly format Myymm will be
forecasted quantity in the followed,
specified row is required to be Example: use M1012 for Dec 2010
delivered.
Quantity The forecasted quantity to be As provided by sales forecast.
delivered at the specified date

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


Scenario 2: Amend/Adjust Forecast

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


Menu Path  Forecasting  Enter/Adjust Forecast  Forecast
 Stock Control
 Select the forecast you are going to amend by either:
 Pressing F4, and selecting the specific item immediately, or by
 Selecting the forecast parameters one by one, started from selecting the forecast number, followed
by selecting the segment, then selecting the specific item

 Do the required amendment either by adding new row, adjusting or deleting an existing one
 The screen will automatically assume you are going to “ADD” a new row, and provided an auto row
number and date, you can adjust the date, and enter the quantity you need.
 If you are going to adjust an existing row, then press “ESC” once to go to the row field, enter the
row number to be adjusted in the row field, followed by pressing TAB, the existing parameters of
this row (date and quantity) will appear so that you can adjust whatever you want.
 If you are going to delete the forecast row, then select the row as in . then just enter a “ZERO”
quantity in the quantity field, followed by pressing “Enter” or “TAB”

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



Scenario 3: Print Forecast

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

 Open the forecast print form:

Menu Path  Forecasting  Print Forecast/Budget  Forecast
 Stock Control

 Enter the parameters of the forecast to be printed:

Forecast Number of the forecast to be 0 to 9999
printed.
Stock Code The YSLD code(s) for which Stock items range to be included in
forecast to be printed. the print out.
- If full set of all items required in
the forecast is required then
leave both fields empty,
- If forecast of specific item only is
required, then enter the item
code in both fields.
Date The period for which the Period range in format of ddmmyy.
forecast to be printed. - If all period included in the
forecast required to be printed,
then leave default values (which
are: 000000 as start from date
and 999999 as end date),
Type of Date Type of date required All
Distributed Distribution required Select “Total”, as NALCO will not use
forecast distribution.

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


Scenario 4: Insert Forecast into Plan

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

 Open the move forecast to item plan form:

Menu Path  Forecasting
 Move Forecast to Item Plan
 Enter the parameters of the forecast to be inserted into (moved in) the master plan:

Forecast Number of the forecast to be 0 to 9999
moved in plan.
Forecast Date The period for which the Period range in format of ddmmyy.
forecast to be moved in plan. - If all period included in the
forecast required to be moved in
plan, then adjust start date to be:
000000 and leave end date as
default: 999999.
Note: By default the starting date is
today’s date, which can be obtained
also by pressing F6.
Stock Code The YSLD code(s) for which Stock items range to be “appeared
forecast to be moved in plan. as forecasted items” in the plan.
Warehouse Warehouse identification Use mainly:
number, the warehouse number
“to which plan” the forecast will 01: For Dammam main warehouse,
be moved in. 02: For Yanbu main warehouse

Notes:
 Moving Forecast into a plan is helping in understanding and analysing the
results of the master plan, it has nothing to do with the processing of the master
plan calculations which is based on the parameters entered in the “create plan
form” which are explained into chapter 2, scenario 1.


Scenario 5: Remove Forecast from Plan

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

 Open the move forecast to item plan form:

Menu Path  Forecasting
 Delete Forecast in Item Plan
 Enter the warehouse for which forecast(s) are going to be deleted from (moved out) its master plan:

number, the warehouse number
“from which plan” the forecast 01: For Dammam main warehouse,
will be moved out. 02: For Yanbu main warehouse

OK to Delete A confirmation question for Yes.
completing the deletion process (Default is “NO” in case if last minute
decision was not to move it out the
plan)

Notes:
 This is not a deletion of the forecast or any part of it, it is jus a “move-out”
function, which disable forecast parameters from appearing into the master plan
report, this is a useful tool to clean forecast from the plan in case of having multi
plans, in order to avoid analysis confusion.
 Deleting forecast or part of it, is explained in chapter 1, scenario 6, you can click
here to check it.


Scenario 6: Delete Forecast

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

 Open the forecast delete form:

Menu Path
 Forecasting  Delete Forecast/Budget  Forecast

 Enter the parameters of the forecast to be deleted:

Forecast Forecast(s) range to be deleted If one forecast only to be deleted,
from the database. then enter forecast number twice (as
from and as to), other wise enter the
range of forecasts to be deleted.
If you need to delete several
forecasts that cannot be selected as
one range, you have to run this
function more than once, to get the
un-wanted forecasts deleted.
Date The period range to be deleted Period range in format of ddmmyy.
from the forecast. - If all period included in the
forecast required to be deleted,
then leave default values (which
are: 000000 as start from date
and 999999 as end date),
Stock Code The YSLD code(s) to be deleted Stock items range to be deleted from
from the forecast. forecast(s) can be selected by
pressing F4.
Section The factory/plant for which the 1001: For Dammam Plant,

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


Chapter 2 MASTER PRODUCTION SCHEDULE [MPS]
Functionality

This function gives a supply/demand statement (on the parents level), which includes the
following inputs:
Demand inputs:
Forecast,
Undelivered Sales orders,
Work orders demand
Supply inputs:
Stock on Hand,
Undelivered Purchase orders,
Existing in-complete work orders supply

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

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

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

Scenario 1: Create MPS

You want to create a master plan.

Prerequisites

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

Procedures
 Open the Create MPS form:

Menu Path  Master Planning Schedule
 Create MPS
 Enter the parameters of required to run the MPS:

Scenario 2: Print MPS

You want to enter a master plan.

Procedures



Reservation Date Period of reservations (sales If you are in a steady state situation,
orders and opened work orders) period should start by today’s date,
to be considered. press F6 to get it, otherwise you can
start by date 000000 or any proper
date.
Forecast Forecast number for which MPS 0001 – 99999, the forecast number
is to be run. under concern
Segment Plant for which MPS to be run You can select a specific plant or
both, based on your requirements
1001: Dammam Plant
2001: Yanbu Plant
Forecast Date Forecast Span/Period of If you are in a steady state situation,
forecasted items to be period should start by today’s date,
considered. press F6 to get it, otherwise you can
date.
Safety Stock Level Confirmation request if safety Yes.
stock to be considered from
MPS calculations.
Stock Code The YSLD code(s) to be deleted Stock items range to be deleted from
from the forecast. forecast(s) can be selected by
pressing F4.
number, the warehouse number 01: For Dammam main warehouse,
“from which plan” the forecast 02: For Yanbu main warehouse
will be moved out.

Scenario 6: Delete MPS

You want to delete/clean master plan.
 Open the Create MPS form (same one used for creating MPS, click here to review it):

 Create MPS


 Enter the following parameters:

Field Name Values Field Name Values
Reservation Date From 000000 to 999999 Safety Stock Level Leave as default
Forecast Select forecast number relate Stock Code Enter from “Dummy”
Segment From 1001 to 2001 To “Dummy”
Forecast Date From 000000 to 999999 Warehouse Leave as default

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

Scenario 2: Print MPS
 Open the Print MPS form:

 Print MPS
 Enter the parameters of required to print the MPS:

 Item select:

Which Selection Term The system allow to enter a Recommended to press “Enter” any
selective fields by entering the continue without any narrow
field number here, you can selections.
enter its parameters, for
example, if you entered “1” then
“Enter” you will be able to enter
“stock code” range, and so on.

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


 Enter final MPS-report parameters

Gross Requirements Period of MPS report demand If you are in a steady state situation,
from presentation. period should start by today’s date,
press F6 to get it, otherwise you can
date.
Type of Period Type of period for supply You can select the most suitable
presentation: period for supply presentation,
T: Transactions, recommended inputs are: T or M
D: Days,
W: Weeks,
M: Months,
Y: Years.
number, the warehouse number 01: For Dammam main warehouse,
“from which plan” the forecast 02: For Yanbu main warehouse
will be moved out.

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

Sample output could be like:


Scenario 3: Print Action List

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

 Print Action List

Which Selection Term Select a number from 1 to 11 to Press Enter to go for next screen, do
select which parameter/field to not select any field.
be entered. - Select 1 only if you are interested in
checking MPS for specific item or
range of items.
Stock Code The items code which appeared Stock items range to be considered
in MPS for MPS calculations.

Stock Code Range of stock items for which Leave it as default
action
Warehouse Warehouse number, for which Use mainly:
MPS proposals to be checked. 01: For Dammam main warehouse,
02: For Yanbu main warehouse
Planner Planners name, for whom MPS Leave it as default
proposals to be checked.
Status Code Items status code, 0 to 7 Leave it as default
Start Date Period for which MPS proposals If you are in a steady state situation,
to be checked. period should start by today’s date,
press F6 to get it, otherwise you can
date.
Expedite Confirmation request if MPS Select Yes/No based on your
proposals for “expediting” order requirement, recommended to select
completion/delivery is required YES always.
Release Confirmation request if MPS Select Yes/No based on your
proposals for releasing new requirement, recommended to select
orders. YES always.
Delete Confirmation request if MPS Select Yes/No based on your
proposals for deleting existing requirement, recommended to select
orders. YES always.
Forward Confirmation request if MPS Select Yes/No based on your
proposals for “forwarding” order requirement, recommended to select
completion/delivery is required YES always.
Backward Confirmation request if MPS Select Yes/No based on your
proposals for “back wording” requirement, recommended to select
order completion/delivery is YES always.
required


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



Scenario 4: Validate MPS

You want to enter a master plan.

Prerequisites

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

Procedures
 Open the Planning List per Transaction:

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

Which Selection Term The system allow to enter a Recommended to press “Enter” any
selective fields by entering the continue without any narrow
field number here, you can selections.
enter its parameters, for
example, if you entered “1” then
“Enter” you will be able to enter
“stock code” range, and so on.

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


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

Warehouse Warehouse number/range, for Use mainly:
which MPS required to be 01: For Dammam main warehouse,
verified. 02: For Yanbu main warehouse
From Del. Date The period required for MPS Enter the period suitable to you to
validation confirm the MPS output.
With Forecast A confirmation request if Select “YES”, this is the important
forecast to be printed with the field to be able to validate the MPS.
master plan.

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



Scenario 5: Amend/Adjust MPS

You want to amen/adjust/add/delete MPS proposal.
 Open the Enter/Adjust MPS form:

 Enter/Adjust MPS
 Enter the parameters of the MPS to be amended:


Procedures

Stock Code Range of Stock items to be Enter item code (range of codes) to
checked be amended),
If you want to add a new item to the
plan, leave the range as default.
Warehouse Warehouse number/range, for Use mainly:
which MPS required to be 01: For Dammam main warehouse,
verified. 02: For Yanbu main warehouse
Stock Items with MPS Confirmation request from the Preferred to select “NO”
only? system regarding if the items to
be shown are those with
recommended work orders to
be released only, or to show all
items in the plan
Show Forecast A confirmation request if Select “YES”
forecast to be printed with the
master plan.
Forecast Date Enter forecast range to be Leave it as default.
presented.
Type of Display Type of transactions to be Leave it as default. “T”
display


Chapter 3 MATERIAL REQUIREMENTS PLANNING [MRP]
Functionality


Scenario 1

You want to enter a new forecast.

Procedures


Chapter 4 FULL CYCLE CHART
Functionality


Scenario 1

You want to enter a new forecast.

Procedures


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