Advanced Planning from Standard MPS/MRP
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Transcript of Advanced Planning from Standard MPS/MRP
Advanced Planning from Standard MPS/MRP
Darren SwindellsHills Industries Limited
16 August 2010
The most comprehensive Oracle applications & technology content under one roof
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
About Orrcon – Racing Team
• .. Oh, and on the side we make steel pipe & tube as well …
About Orrcon – Tube Mills
• Manufacturers of steel Pipe & Tube Large division of Hills Industries Limited Local manufacturing in Brisbane, Adelaide & Wollongong
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
About Orrcon – Changeovers
Full-Changeover
1/4-Changeover
1/2-Changeover
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
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
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
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
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 …
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 …
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 …
1. 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
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
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
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
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