CP-81 The best waze to get to destination MRP! Paul Whiteman Lexell Blue Susan Pucciano Lexell Blue

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1 CP-81 The best waze to get to destination MRP! Paul Whiteman Lexell Blue Susan Pucciano Lexell Blue

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 2

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 3

4 Manufacturing Maturity and the MRP Roadmap 4

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) 5

6 Manufacturing Maturity Where are you in Manufacturing Maturity? Procurement Inventory BOM Production Control Sales Orders Routings Infinite Capacity Schedule ECN MRP MPS Finite Capacity Schedule Dynafact Tool Sophistication 6

7 Manufacturing Maturity MRP Prerequisites Product Definition Inventory Procurement BOM Production Control Sales Orders Routings Infinite Capacity Schedule ECN MRP MPS Finite Capacity Schedule Dynafact Tool Sophistication 7

8 Costpoint Production Costpoint Test Roadmap to MRP Requirements Configuration Master Data Setup Testing MRP MRP Training MRP Go-Live Implement prerequisite Costpoint modules Data cleanup: Parts, BOM, Projects, Supply, Demand, Inventory Configuration Update MRP schedule runs 8

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 9

10 System Setup and Configuration 10

11 System Configuration MRP Settings Production Control Settings Shop Floor Calendar Purchase Requisition Settings XX 11

12 Parts Basic Part Data Multiple v Latest Part Revision Part Type Part Status Make / Buy Active Flag UoM Conversion 12

Min/Mult Lot Size Period TIP: Use Period to reduce number

13 Parts Planning Details Planning Types MRP MPS Reorder None 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 % 13

Parts - Lead Times TIP: Start out basic using just Manufacturing and Purchasing Vendor as a minimum Make Parts Stocking Manufacturing + Insp Pick Planning Need Date Due Date

14 Parts - Lead Times TIP: Start out basic using just Manufacturing and Purchasing Vendor as a minimum Make Parts Stocking Manufacturing + Insp Pick Planning Need Date Due Date Planned In-Shop Date Planned Release Date Planned Order Date Buy Parts Receiving & Inspection Vendor Planning & Buyer Need Date Due Date Planned Open Date Planned Order Date 14

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:

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 15

16 Bills of Material xx XX 16

17 Inventory Project Setup 17

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 18

19 Inventory Abbrev Peggings 19

20 Demand, Supply & Inventory 20

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 21

22 Supply Purchase Requisitions Purchase Orders Inventory Transfer Reservation supply for destination project Manufacturing Order TIP: No supply should be created independently from MRP 22

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) 23

24 How to use MRP 24

Firm MRP Planned Orders Purchase Requisitions Manufacturing

25 MRP Processing Steps Update MRP Manage MRP Action Messages Detailed Part Schedule Order Updates (Cancel, Qty, Schedule) Firm MRP Planned Orders Purchase Requisitions Manufacturing Orders Transfer Reservations MRP Reports Substitute Part Replacements 25

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

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 26

27 Manage MRP Action Messages xx 27

28 Manage Detailed Part Schedule xx 28

29 MRP Reports Costpoint MRP Reports Recommend Cognos MRP Reports: Gross Requirements, Scheduled Receipts, Action Messages 29

30 Firm MRP Planned Orders xx 30

31 New MRP Features 31

32 New in Costpoint

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 33

34 Substitute Part Action Message 34

35 Substitute Part Requirements Update 35

36 How will we cleanup this data? 36

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 37

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 38

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 39

Questions? Paul Whiteman PaulWhiteman@LexellBlue.

40 Questions? Paul Whiteman Phone: Susan Pucciano Phone:

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AVANTUS TRAINING PTE LTD Manufacturing II in Microsoft Dynamics NAV 2009 Course 80261A: 3 Days; Instructor-Led About this Course This three-day course explores the advanced manufacturing functionality of Microsoft Dynamics NAV