PowerPoint Presentation Best Waze to MRP.pdf · CP-81 The best ‘waze’ to get to destination...
Transcript of PowerPoint Presentation Best Waze to MRP.pdf · CP-81 The best ‘waze’ to get to destination...
CP-81
The best ‘waze’ to get
to destination ‘MRP’!
Paul Whiteman – Lexell Blue
Susan Pucciano – Lexell Blue
©2016 Deltek, Inc. All Rights Reserved 2
Agenda
Introductions
Manufacturing Maturity and MRP Roadmap
System Configuration and Master Data Setup
Demand – Supply – Inventory
How to use MRP
New MRP features
How will we cleanup all this data?
Q&A
©2016 Deltek, Inc. All Rights Reserved 3
Lexell Blue
Lexell Blue, LLC headquartered in Northern Virginia
Comprised of four partners and a team of consultants with extensive experience with the Deltek
GovCon suite of products
Costpoint consulting services:
– Costpoint Implementations and re-implementations
– Manufacturing / Materials / Procurement
– Labor / Leave / Payroll / HR / T&E
– M&A Integration and Divestitures
– Data Migration and Restructures
– GCS Premier to Costpoint Conversions
– Project Management
– BI Reporting
– Extensibility & Interfaces
©2016 Deltek, Inc. All Rights Reserved 5
MRP Benefits
Project based materials requirements planning tool with complex project planning algorithms help
planner buy and make decisions
Minimizes risk of material shortages
Improve on-time delivery
Minimize risk of excess inventory
Efficiency improvements: Automated generation of supply (Purchase Requisitions, Manufacturing
Orders and Transfer Reservations)
©2016 Deltek, Inc. All Rights Reserved 6
Where are you in Manufacturing Maturity?
Inventory
MRP Dynafact
Finite
Capacity
Schedule
Infinite
Capacity
Schedule
Tool Sophistication
Manufa
ctu
ring M
atu
rity
Procurement
BOM
Production
Control
ECN MPS
Routings
Sales
Orders
©2016 Deltek, Inc. All Rights Reserved 7
MRP Prerequisites
Inventory
MRP Dynafact
Finite
Capacity
Schedule
Infinite
Capacity
Schedule
Tool Sophistication
Manufa
ctu
ring M
atu
rity
Procurement
BOM
Production
Control
ECN MPS
Routings
Sales
Orders
Product
Definition
©2016 Deltek, Inc. All Rights Reserved 8
Roadmap to MRP
Data cleanup: Parts, BOM, Projects, Supply, Demand, Inventory
Implement prerequisite Costpoint modules
Testing MRP
MRP Training
Requirements
Configuration
Master Data Setup
Co
stp
oin
t
Pro
du
ctio
n
Co
stp
oin
t
Te
st
ConfigurationUpdate MRP
schedule runs
MRP
Go-Live
©2016 Deltek, Inc. All Rights Reserved 9
Tips for the MRP roadmap
Accurate MRP Input = Accurate MRP Output. It is all in the master data and setup accuracy
Keep it simple. MRP is a complex algorithm, especially with new features. The more features that are utilized, the harder to maintain and debug issues
Don’t be afraid of running MRP to view the recommendations.
Ensure all of your demand is represented in Costpoint
©2016 Deltek, Inc. All Rights Reserved 11
System Configuration
MRP Settings
Production Control Settings
Shop Floor Calendar
Purchase Requisition Settings
XX
©2016 Deltek, Inc. All Rights Reserved 12
Parts – Basic Part Data
Multiple v Latest
Part Revision
Part Type
Part Status
Make / Buy
Active Flag
UoM Conversion
©2016 Deltek, Inc. All Rights Reserved 13
Parts – Planning Details
MRP Planning Type Ordering Policies
– Discrete Lot Size
– Min/Mult Lot Size
– Period
TIP: Use Period to reduce number of orders
Maximum Lot Qty
Floor Stock
Common Stock
Scrap %
Yield %
Planning Types
– MRP
– MPS
– Reorder
– None
©2016 Deltek, Inc. All Rights Reserved 14
Parts - Lead Times
Stocking
Need
Date
Due
Date
Manufacturing + Insp
Planned
In-Shop
Date
Planned
Release
Date
Pick Planning
Planned
Order
Date
Receiving & Inspection
Need
Date
Due
Date
Vendor
Planned
Open
Date
Planning & Buyer
Planned
Order
Date
Make Parts
Buy Parts
TIP: Start out basic using just ‘Manufacturing’ and
‘Purchasing Vendor’ as a minimum
©2016 Deltek, Inc. All Rights Reserved 15
Parts – User Security Access
TIP: Use Result Set Security to restrict access to various part master attributes by user role
Engineering/CM: Basic Part Data
Planning: Planning Details, Lead Times, UoM Conversions, Project Requirements, Substitutes
Quality: Assign Standard Text, Basic Part Data
Procurement: Alternate Parts, Item Vendor
©2016 Deltek, Inc. All Rights Reserved 18
Inventory Abbrev Setup
Setting up default End Item / Subassembly / Buy Parts Inventory Abbrev relationship
Setup to support various business models
– Buy and build to project
– Buy to common, build to project
– Buy and build to common
©2016 Deltek, Inc. All Rights Reserved 21
Demand
Sales Orders
MPS Forecasts
Inventory Reservations
– Issue to Project
– Issue to PO
– Transfer Reservation - demand for originating project
Safety Stock – setup in Manage Parts > Project Requirements
Manufacturing Order
TIP: All material demand should be represented in Costpoint
©2016 Deltek, Inc. All Rights Reserved 22
Supply
Purchase Requisitions
Purchase Orders
Inventory Transfer Reservation – supply for destination project
Manufacturing Order
TIP: No supply should be created independently from MRP
©2016 Deltek, Inc. All Rights Reserved 23
Inventory
Inventory Accuracy
– Cycle Counting / Physical Inventory
– Reconcile Inventory Transactions Utility
MRP Netting Location Types
– On-Hand
– Incoming Inspection
– Shipping
– MRB (Optional Configuration)
MRP Non-Netting Location Types
– On-Hold
– MRB (Optional Configuration)
©2016 Deltek, Inc. All Rights Reserved 25
MRP Processing Steps
Update
MRP
Manage MRP
Action
Messages
Detailed Part
Schedule
Firm MRP
Planned
Orders
Purchase
Requisitions
Manufacturing
Orders
Transfer
Reservations
Substitute Part
Replacements
Order
Updates
(Cancel, Qty,
Schedule)
MRP Reports
©2016 Deltek, Inc. All Rights Reserved 26
Update MRP
Warehouse range selection
Full Regeneration v Net Change
Updating MRP
– Update Low Level Codes
– Deletes existing MRP Action Messages, Gross Requirements, Scheduled Receipts
– Creates new MRP Action Messages, Gross Requirements, Scheduled Receipts
TIP: Automating the processes on Costpoint Job Management
– Schedule Update Low Level Codes to run weekly (recommended)
– Schedule Update MRP to run nightly (typical)
– Provide notification for batch process success/failure
©2016 Deltek, Inc. All Rights Reserved 29
MRP Reports
Costpoint MRP Reports
Recommend Cognos MRP Reports: Gross Requirements, Scheduled Receipts, Action Messages
©2016 Deltek, Inc. All Rights Reserved 33
New in Costpoint 7.1
Transfer Reservation Action Messages – option to create Transfer Reservations if there is available
inventory in another project within the planning project group
Use Common Inventory – the system will use all parts in the common stock inventory, regardless
of whether or not the parts are flagged as Common Stock.
Default MRP Action Message Types – select which action messages will default as checked when
entering the Manage MRP Action Message screen - no more unchecking boxes!
Inventory Allocations - MRP process takes into account inventory allocations when calculating
available supply
Expired Shelf Life Inventory not available for planning
©2016 Deltek, Inc. All Rights Reserved 37
Data Cleanup
Parts (Status, Planning flags, Lead Times, Safety Stock, Substitute Parts)
Manufacturing BOM (Make/Buy, Part Type, LT offset, Effective Dates)
Demand
– Closing obsolete orders: Manufacturing Orders, Sales Orders
– Closing obsolete Reservations (Issue to Proj/Transfer/Issue to PO)
– Look for orphan Reservations from SO/MO (RES_HDR, RES_LN)
– Updating to correct Part Revision on SO line, MO requirements (Multi-Revision environment)
Supply
– Closing obsolete orders: Requisitions, Purchase Orders, Manufacturing Orders
– Updating to correct Part Revision (Multi-Revision environment)
Inventory
– Accuracy
– Common Inventory designation
©2016 Deltek, Inc. All Rights Reserved 38
Data Cleanup Methods
Manual updates
– Find/Replace function on queried datasets
– Expedite PO and MO screens
– Tip: Run MRP after all demand is clean, and review Cancel Order and Decrease Qty
messages
Preprocessors/Imports:
– Item: Most part data can be updated for Oracle db, but limited for sql db
– BOM, Purchase Order, Sales Order
Database update scripts
– Perform high volume data updates
– Able to update status on closed/inactive projects
©2016 Deltek, Inc. All Rights Reserved 39
Summary
Manufacturing maturity and the MRP roadmap
Key system configuration and master data setup
Demand – Supply – Inventory
MRP processing steps
New MRP features
Data cleanup
©2016 Deltek, Inc. All Rights Reserved 40
Questions?
Paul Whiteman
– Phone: 571-214-9613
Susan Pucciano
– Phone: 703-608-9483