VPi Advanced Topics. Rick Pollman

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1 VPi Advanced Topics Rick Pollman VPi Support Team, October 3, 2011

2 AGENDA Maximize planning using VPi features Managing forecasts Quick review of last year s enhancements Waterfall Material Shortages Managing multiple resources within a work center Individual Operation Overlap Shipping Buffer by Item Planned Order Time Fence Operation Delay Time Group Mode 2

3 Forecast Consumption Overview Consumes Forecast within a Calendar Month This period, Backwards in the same month & then Forward Forecast is generated and consumed in 4 ways Individual Item Component Item Planning Bill Product Family Forecast split Split monthly number into weekly numbers Forecast demand time fence Global setting Individual Item 3

4 FORECAST SPLITTING Host ERP forecast managed in monthly buckets and VPi will split the monthly number into daily or weekly buckets 4

5 VPi Engine Process Flow Host ERP System Extract Data Files Format Files Upload Plan Transfer Data VPi VPi DbUtility Map Data and split forecast Configuration Settings VPi Planning Engine Write Schedule Pass Cancel Load data and perform forecast consumption VPi Database Microsoft Access / SQL Server database 5

6 VPi Engine Process Flow ERP Monthly forecast Host ERP System Extract Data Files Format Files Upload Plan Transfer Data VPi VPi DbUtility Map Data and split forecast Configuration Settings VPi Planning Engine Write Schedule Pass Cancel Load data and perform forecast consumption VPi Database Microsoft Access / SQL Server database 6

7 VPi Engine Process Flow ERP Monthly forecast Host ERP System Extract Data Files Transfer Data VPi Format Files Forecast Splitting and Upload Time Plan Fence parameters VPi DbUtility Map Data and split forecast Configuration Settings VPi Planning Engine Write Schedule Pass Cancel Load data and perform forecast consumption VPi Database Microsoft Access / SQL Server database 7

8 Forecast Demand Fence by Item

9 Forecast Demand Fence by Item Monthly Forecast split into Weekly Buckets Forecast is not dropped but pushed out beyond Demand Fence

10 MANAGING FORECAST DEMAND Component Level

11 CMPOC10 BOM Where Used CMPOC10RED CMPOC10RBLUE CMPOC10GREEN Customer Order will be for end items CMPOC10 Forecast will be for component 11

12 Component forecast setup in PPITEM Component Forecast setup details in the ERP file PPITEM Warehouse Item number Family Forecast Plan ID Family ID Bill IPFMID IPPRTF Item 1 COMPOC10 FULL 0 =============================================================== Forecast the component 12

13 MANAGING FORECAST DEMAND Planning Bill

14 PBCOLOR Planning Bill Forecast will be for the Planning Item in the host ERP using standard planning bill structure PBCOLOR DBUTIL will create individual end item forecasts based on the planning bill CMPOC10RED 50 % CMPOC10RBLUE 30% CMPOC10GREEN 20% 14

15 Planning Bill Forecast setup in PPITEM Planning Bill Forecast setup details in the ERP file PPITEM Warehouse Item number Family Forecast Plan ID Family ID Bill IPFMID IPPRTF Item 1 PBCOLOR PBCOLOR 1 1 COMPOC10RED PBCOLOR 0 1 COMPOC10BLUE PBCOLOR 0 1 COMPOC10GREEN PBCOLOR 0 =============================================================== Forecast the Planning Bill 15

16 MANAGING FORECAST DEMAND Product Family

17 PFCOLOR Product Family Forecast will be for the Product Family Item in the host ERP using a BOM and Routing common to the end items PFCOLOR Forecast remains as the Product Family Item and its BOM and Routing initially drives the load in VPi CMPOC10RED CMPOC10RBLUE CMPOC10GREEN 17

18 Product Family Forecast setup in PPITEM Product Family Forecast setup details in the ERP file PPITEM Warehouse Item number Family Forecast Plan ID Family ID Bill IPFMID IPPRTF Item 1 PFCOLOR PFCOLOR PFCOLOR 0 1 COMPOC10RED PFCOLOR 0 1 COMPOC10BLUE PFCOLOR 0 1 COMPOC10GREEN PFCOLOR 0 =============================================================== Forecast the Product Family 18

19 Splitting the Item forecast 400 per month Customer order Qty 375 for week 3 Action Week 1 Week 2 Week 3 Week 4 Forecast FC consumption

20 Forecast Summary viewed from the Engine 20

21 Features introduced in 2010

22 Vendor Multi-sourcing Multiple vendor planning Split Rotate Mirrors current XA MRP functionality 22

23 Which Customer Orders to Push Out Quickly identify customer orders in trouble work with Production to expedite work with Sales to notify customer Option to print Option to export to Excel spreadsheet 23

24 WriteSchedule Pass Waterfall Chart

25 Waterfall Feeding Supplies

26 Waterfall Material Shortages

27 Managing Capacity Multiple Resource Units per Work Center

28 Multiple Resource Units per Work Center What is a Resource Unit? One or more people One or more like machines 28

29 Managing Multiple Resource Units per Work Center WKCTR WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID LTH1NC _HOUR Eighteen hour calendar MACHINE WORKCENTER_ID START_DATE END_DATE UNITS LTH1NC 5/10/2010 5/10/ LTH1NC 5/12/2010 5/13/ LTH1NC 5/14/2010 5/17/ Override WKCTR fixed Units utilizing the MACHINE table 29

30 Managing Multiple Resource Units per Work Center WKCTR WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID LTH1NC _HOUR MACHINE WORKCENTER_ID START_DATE END_DATE UNITS LTH1NC 5/10/2010 5/10/ LTH1NC 5/12/2010 5/13/ LTH1NC 5/14/2010 5/17/ Standard Capacity 3(units) * 18(hours) = 54 hours 30

31 Managing Multiple Resource Units per Work Center WKCTR WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID LTH1NC _HOUR MACHINE WORKCENTER_ID START_DATE END_DATE UNITS LTH1NC 5/10/2010 5/10/ LTH1NC 5/12/2010 5/13/ LTH1NC 5/14/2010 5/17/ Manage the capacity by changing the number of units available for specific time frames. 31

32 Managing Multiple Resource Units per Work Center WKCTR WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID LTH1NC _HOUR MACHINE WORKCENTER_ID START_DATE END_DATE UNITS LTH1NC 5/10/2010 5/10/ LTH1NC 5/12/2010 5/13/ LTH1NC 5/14/2010 5/17/ (unit) * 18(hours) = 18 Hours 32

33 Managing Multiple Resource Units per Work Center WKCTR WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID LTH1NC _HOUR MACHINE WORKCENTER_ID START_DATE END_DATE UNITS LTH1NC 5/10/2010 5/10/ LTH1NC 5/12/2010 5/13/ LTH1NC 5/14/2010 5/17/ (units) * 18(hours) = 108 Hours 33

34 Managing Multiple Resource Units per Work Center WKCTR WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID LTH1NC _HOUR MACHINE WORKCENTER_ID START_DATE END_DATE UNITS LTH1NC 5/10/2010 5/10/ LTH1NC 5/12/2010 5/13/ LTH1NC 5/14/2010 5/17/ (unit) ** 18(hours) = 18 Hours 34

35 Split Order Qty across multiple Units Traditional Global Setting (SplitQtyAcrossUnitsForNonDrums) has been to split the order quantity for all work centers or none New Config setting: SplitQtyAcrossUnitsForNonDrums= -1 drops the global setting and becomes work center dependent using values (0, 1 or 2) in WKCTR field ATTRIBUTE5

36 Individual Operation Overlap Traditional Global Setting (TransferEntireBatch=) has been: - all operations set to overlap or - all operations are sequential TransferEntireBatch=0 combined with the value in the field Transfer_Size in ROUTE and WOROUTE provides the ability to plan sequential and overlapped operations

37 Shipping Buffer by Item

38 Planned Order Time Fence Horizon Start Date + PART table MinMRPLeadTime establishes a Planned Order Time Fence the logic pushes the planned order to the Order Time Fence or the released Order s Due Date if later than the fence

39 Operation Delay Time Original Design Required you to know the work center capacity (i.e.: 8, 16, 24 hrs) and multiply by 3,600 seconds times the number of days

40 Operation Delay Time cont. Group Mode combined with Operation Delay Time select multiple operations enter the desired Operation Scheduled Start Date and VPi handles the calculations!

41 Fixed Yield Fixed Yield is stored in the field YIELD in the PART table values.01 to 1.00 are reserved for Part Yield (XA defines it as Shrinkage) any whole value greater than 1.00 represents Fixed Yield Examples of how different part yields would be interpreted fixed quantity and 95 percentage yield fixed quantity and 100 percentage yield fixed quantity and 85 percentage yield fixed quantity and 100 percentage yield

42 Replenishment Item Replenished Manufactured and Purchased Items (Lean Manufacturing - Red, Yellow, Green tag) Replenishment logic: three tier reorder point system decoupling customer orders or forecast demand. This can be used to maintain an inventory level without requiring independent demand to drive the planning.

43 Review the Budget Timephased Resource Load Summary

44 Timephased Resource Load Summary By Work Center Weekly or Monthly buckets 44

45 The VPi value Replaces and Extends functionality of MRP, CRP and PCC

46 VPi extended functionality Real time graphical plan management Maintains the manufacturing order start and due date Component requirement dates are re-synced when the order start date is changed VPi calculated dates are updated in MOROUT Unique calendars for each work center Create/Manage multiple units within a work center Spread a manufacturing order across multiple units within a work center ability to plan concurrent or overlapped operations 46

47 The VPi value for the experienced MRP customers considering a move to VPi

48 Routings based on MRP Lead Time For customers who are confident in their MRP Lead Times but lack precision with routing run times VPi will generate an internal routing using MRP Lead Time when the standard routing is not downloaded for an item works only with planned and firm planned orders manufacturing orders use the live routing 48

49 VPi Training Chicago November 29, 30 and December 1st

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