Advanced Planning from Standard MPS/MRP
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The document outlines a customized advanced planning solution for Orrcon, a division of Hills Industries Limited, which incorporates the JDE ERP system. It details a workaround using MPS/MRP cycles to manage production effectively by linking item numbers to specific cycles and creating branch plants and calendars for streamlined operations. This approach aims to reduce setup times and achieve weekly production goals for each product family.
Advanced Planning from Standard MPS/MRP
- 1. Advanced Planning from Standard MPS/MRP Darren Swindells Hills Industries Limited 16 August 2010 The most comprehensive Oracle applications & technology content under one roof
- 2. The Situation JDE (rel. 8.10)being implemented as ERP solution across Hills Group Orrcon had unique requirement and was next! Product manufactured in Cycles at Orrcon Budget and time-frame would not allow an off-the-shelf ‘APS’ solution
- 3. About Orrcon – Racing Team .. Oh, and on the side we make steel pipe & tube as well …
- 4. About Orrcon – Tube Mills Manufacturers of steel Pipe & Tube Large division of Hills Industries Limited Local manufacturing in Brisbane, Adelaide & Wollongong
- 5. About Orrcon – Make in Cycles Set-up time is significant Each change of profile incurs set-up To reduce downtime – roll groups of products once every 4 weeks
- 6. About Orrcon – Changeovers Full-Changeover 1/4-Changeover 1/2-Changeover
- 7. Problem with Standard MPS/MRP R3483 (Master Planning Schedule-Multi-Plant) Plans Work Orders for Date of Need (& Demand is dated daily) Orrcon groups Planned WOs into pre-published Rolling Cycles for each Product Family Only make each product once per Cycle
- 8. The Solution – Create MPS/MRP Cycles – Step 1 (Buyer Number) Link each Item Number to a Cycle using the ‘Buyer Number’ Buyer 201 = Cycle 1 Buyer 202 = Cycle 2 Buyer 203 = Cycle 3 Buyer 204 = Cycle 4
- 9. The Solution – Create MPS/MRP Cycles – Step 2 (Cycle B/Ps) Create ‘Branch Plants’ for each Cycle B/P 241=Cycle 1 B/P 242=Cycle 2 B/P 243=Cycle 3 B/P 244=Cycle 4
- 10. The Solution – Create MPS/MRP Cycles – Step 3 (Cycle Calendars) Create ‘Shop Floor Calendars’ for each Cycle B/P 241=Cycle 1 B/P 242=Cycle 2 B/P 243=Cycle 3 B/P 244=Cycle 4 ‘ W’ Working Day - only in one week from Cycle
- 11. The Solution – Create MPS/MRP Cycles – Step 4 (Create MPS Versions) Create versions of MPS that are linked with ‘Branch Plant’ Shop-floor Calendars for each Cycle One version for each Cycle Continued …
- 12. The Solution – Create MPS/MRP Cycles – Step 4 (Create MPS Versions) Data Selections (only select items that belong to the Cycle) MCU = Cycle SFC (to get records) BUYR = Cycle group from Item Branch Continued …
- 13. The Solution – Create MPS/MRP Cycles – Step 4 (Create MPS Versions) Processing Options (call Shop-Floor Calendar for Cycle) Multi-Facility Tab 1. Date Branch = Cycle Branch Plant MPS then uses the Shop Floor Calendar from this Branch Plant This is what makes the Cycles possible! Continued … Date Branch This was actually designed to reduce processing time when Multi-Facility MPS/MRP was generated – however it also achieves Cycle Planning when used for this Work-Around
- 14. The Solution – Create MPS/MRP Cycles – Step 5 (Generate MPS) Generate MPS (R3483) Note: ALL Cycles are generated each week – to create correct projected requirements for components
- 15. The Solution – Create MPS/MRP Cycles – Step 6 (Detailed Message Review) Planned Order Messages now group so each product is only made once per week in Detailed Message Review Note: Request Date Changes from 30/08/10 to 29/09/10 – jump of 4 weeks
- 16. Summary Work-around: using R3483 ‘Date Branch’ feature designed to save Processing Time to achieve some ‘APS’ functionality of grouping Item production into correct weekly buckets Requires set-up of Branch Plants, Shop-Floor Calendars and one MPS/MRP version for each Cycle Can also be used for Manufacturing AND Purchasing ACHIEVES OBJECTIVE = one setup for each product family every 4 weeks
- 17. Questions?
- 18. Tell us what you think… http://feedback.insync10.com.au
Editor's Notes
- #4: Mark Winterbottom (Frosty) & Steven Richards
- #5: LARGE PIPE & TUBE *(OIL, GAS, WATER) Eurabedella (NSW ) – water pipe-lines | STRUCTURAL | PRECISION tube
- #7: Explain Cycles: purpose to do setups once per family in monthly grouping. Minimise setup time (downtime).
- #8: Rolling cycles are published to customers - | rolling cycle allows planned WO’s into future to project demand for Paint, Steel etc in Cycles (so not delivered and sitting around for 3 weeks until used – paint goes off – etc)
- #9: APOLOGISE for not showing as a live demo – but watching an MRP generation run is only exciting to narrow group of people NOTE: Buyer field is used as it is available on MPS data selection and not used for Manufactured item. Reverse for Purchased item (I.e. use Planner Number for Cycle)
- #12: Note – MPS is called from menu by Planning Staff – they follow steps on menu (Step 1 Cycle 1 tasks etc) – they follow one set for each of 4 weeks then start again
- #15: Explain: per normal outcome of MPS generating when there are Non-Working days in the SFC, MPS will delay any past due requirements until the next W day, and bring forward requirements between then and the next W day
- #16: Processing from this point on is same as usual after normal MPS generation … RECAP – this same process works for MPS and MRP level for Manufactured AND Purchased Items