MRP "A" vs. "O" messages

[zkanan]

MRP \"A\" vs. \"O\" messages

I have spent 2 days searching past posts and have not found an answer to this. I apologise if I missed it. Here is my question: We are part of a chemical company so we deal with job order type (batches). On many occasions the planner releases WO's greater than actual demand. The planner expects MRP to request buyers to order components and raw materials. Instead, MRP generates warning messages requesting the planner to reduce the Qty of the WO and it (MRP) expects the planner to take it's suggestion and therefore not bother generate an "O" message to order the components (WHY IS THAT?). Is there a way to have MRP generate "O" message along with the "A" message without having to freeze each WO since we like to keep our schedule flexible till the last minute.

Thanks
Zak

 

[Krofire.com]

Re: MRP \"A\" vs. \"O\" messages

There are several ways of getting an approximation to your requirements all of which are documented and should have been covered in your training. You are aware of the Freeze Functionality that can be applied to each WO. That would be a good start but you have already rejected this. There is also an MPS option within the R3482 that does effectively Freeze all Work Orders.

You can also try using Minimum Order Quantities in combination with Batch Bills and Routes if you always make a minimum batch size. This is what it was designed for. However, your question about why MRP doesn't want to buy Components for WO's that have no demand suggests a deeper misunderstanding. MRP is attempting to drive all stocks to zero. That is what it does. If you wish to hold stock balances then you can use Safety Stock.

You could try to extend your Freeze Fence out to the point at which you enter WO's. However, I suggest that you enter an MPS to give you demand. This would be the Frozen WO's that you have already suggested. If you don't like that then use Forecast with an appropriate Planning Rule and Planning Fence (there are several to choose from) such that you can plan against your expected requirements rather than actual Customer Orders.

In UDC 34/MT you can also delete F, L, A and G Messages if you don't want them to appear. However, this is global for all users of this UDC and I have rarely seen Users use this option.

Finally, there is the "Firm Planned" Status Processing Option in R3482. This is the Status the WO can be at beyond which the MRP will no longer explode Planning Messages down through the Bill of Material. This assumes that this status represents the point after which you have issued stock and the WO is now WIP. If you set this Status early enough you may be able to suppress the undesirable messages. However, this would just kill your MRP and negate most of its purpose.

Good luck with this. If in doubt seek professional help.

 

[zkanan]

Re: MRP \"A\" vs. \"O\" messages

Thanks Mark. I guess I was looking for an easy solution. We do have min orders setup but sometimes we have to exceed that. I guess on those occasions planner should freeze the WO. I will also look into the MPS R3482 setup. It's true that the concept of MRP is to drive stock to zero, unfortunately the means through warning messages become too cumbersome that users rarely go through the warning messages (an average of 800/day warning messages for us). Where can I go to read about minimizing these warning messages/system's nervousness so that it does not react to the slightest change in plan?
Thanks again and I'm so glad I found JDElist.

 

[Krofire.com]

Re: MRP \"A\" vs. \"O\" messages

Your concerns are actually very normal in this respect. When it comes the system nervousness then I guess you will be aware of the Damper Days in R3482 for Expedite/Defer?

I find that most clients get quite drowned by Warning Messages. If, like many, you don't want to get rid of "A" from UDC 34/MT then I have spec'd mods to P3411 in order to allow the filtering out of the "A" Messages by default. This is possible but requires a mod.

Alternatively there is always the R3411 which many forget about. You can tailor this program to do almost anything so it may be worth checking to see if you can make it 'process' Warning Message automatically, in batch, as soon as R3482 finishes and before the Planners get to see the result. I think I may have tried this a few years ago but don't recall the result. It would allow you to filter by the "View" option in P3411 against the Processed versus Unprocessed messages. If it works.

Cheers.

 

[mns_cfpim]

Re: MRP \"A\" vs. \"O\" messages

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I've followed your post and Mark's responses. Here is something else to
consider.

Is your "order policy code" on the item branch Mfg values screen set to 1
(lot for lot)? If so, try resetting it to 4 (periods of supply) and set
the next data field (value order policy) to the number of additional days
of supply you want the system to plan after it encounters demand. I've
found that the OPC=4 effectively shuts off the "reduce' messages.



Michael N. Shapiro, CFPIM, CIRM
cell- 303-619-2276


On Mon, 26 Jul 2004 15:00:10 -0500 zkanan <[email protected]> writes:
I have spent 2 days searching past posts and have not found an answer to
this. I apologise if I missed it. Here is my question: We are part of a
chemical company so we deal with job order type (batches). On many
occasions the planner releases WO's greater than actual demand. The
planner expects MRP to request buyers to order components and raw
materials. Instead, MRP generates warning messages requesting the planner
to reduce the Qty of the WO and it (MRP) expects the planner to take it's
suggestion and therefore not bother generate an "O" message to order the
components (WHY IS THAT?). Is there a way to have MRP generate "O"
message along with the "A" message without having to freeze each WO since
we like to keep our schedule flexible till the last minute.

Thanks
Zak



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Thanks
Zak</DIV>



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[zkanan]

Re: MRP \"A\" vs. \"O\" messages

Michael, thank you much for the suggestion. I have a feeling our "lot for lot" policy has a lot to do with it. Trying that right now.

Thanks
Zak