Warning: There is stuff going on in MRP that can be difficult for some
people to figure out ... for example, some items are on MRP order because
of minimum safety stock, which is effectively invisible on MRP300 pegging
...another example is effectivity dates vs. when orders originally into the
system ... if past due on arrival, MRP might not plan it. BPCS sometimes
does a poor job with visibility of dead orders that are affecting
MRP. BPCS supports negative allocations, but does a poor job managing the
consequences.
We are on 405 CD ... the report has both been used intermittently, and
heavily modified. I am not familiar with all the special cases it
supports, and it has been many months since I studied the logic.
We never bought AS/Set, so I am faced with trying to modify the RPG that it
generated. This is practical in some applications, impractical in others.
We use phantoms exclusively as textual aids.
If you were to look at our BOM for end customer parts, you would see
* a bunch of EC item #s ... these are Engineering Changes which contain
information or a repository of textual explanation of what happened, and
how advanced this part is in the revision change numbering system
* an occasional MM item # ... these are molds and other factory tooling
that needs to be inserted in molding or other machines at a stage of
production. An MM item # does not get "used up"
** both EC and MM are non-inventory phantom item classes ... as children in
BOM of parent parts, they have no grandchildren, they are at the very
bottom of the BOM hierarchy
Currently it has been many months since MRP250 was used, because of
management pressure to reduce dependency on reports that have excessive
pages of green bar paper consumption. In my opinion, the result can be
excessive additional time for production control personnel to do their
job. This is a pendulum ... later complaints about manual time taken to do
things, that the computer theoretically can do for us will bring some
reports back into popular use. The pendulum swings each way every few
years. This is also compounded by some people wanting stuff on reports
that is not in our system to provide.
In general our modifications seek
* To reduce the number of different places our employees have to go look
... in vanilla BPCS you get info from one report, go look up inquiry bunch
of other places ... we try to update original report with as much as is
practical that our people will need, so not have to dig elsewhere, or do
additional steps.
* To improve clarity and organization of data on report to improve
readability, navigation, reduce ambiguity
* To provide access to alternate theories of what the relevant facts are
* To avoid wasting paper
Our modifications included
* The report is now MRP252 SQLRPG
* Items shown on the report as RELEASABLE new orders ... we also show
on-hand currently for those items
* We show the status of existing shop orders out there on the same items
now needed ... this is because sometimes it makes more sense to increase
existing order quantitites than release new orders. There's additional
number crunching to show expected addition to on-hand if the current
existing orders are completed, vs. what additional quantity is really
needed by the higher MRP demands. (exclude closed shop orders from the
equation)
* We attempt to identify for what customers the work is being done ... this
is because we make to customer order, final factory assembly areas
organized by types of customer end products. However we have lacked
consistency in how parts are identified as to what customers they are made for.
* The arrangement of data on the report has been altered to enhance
user-friendliness & at the same time avoid any appearance of wasting paper.
* Some values are bold printed to aid report navigation and highligh fields
most heavily used
* In a merger with another company, we got a batch of items with no
routings ... so when those items show up on this report, we print a warning
that they cannot be manufactured the normal way, due to the missing routings.
Hello,
We are curently on BPCS 8.2.01.
Does anyone use report "MRP250D - Releasable Orders Report"
We can not explain some of the results on the report.
Questions :
- Is there anyone in the field using this report and able to explain the
exact functionality or how it is build up ?
- Can the report be used with multiple level BOM with phantoms?
Regards,
Peter Heeren
Thetford BV
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