1. MRP Module. 2. Record. 2.1 Material Requirement Planning

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1 Mrp

2 1. MRP Module In the MRP module you can insert and/or automatically create your production plans, calculate and list in different ways your material and semi products requirements needed to realise the production plan separately according to quantity and date and follow-up automatic orders and manufacture orders for the related periods. In this module you can furthermore identify your existing sources as well as your required sources and plan your capacity according to this information. 2. Record 2.1 Material Requirement Planning This section helps production companies to calculate their material orders and manufacture orders for products and semi products with an economical and

3 timely manner in order to flawlessly implement the production plan, and prepare the related reports that will facilitate the work of their planning and purchasing departments. The Material Requirement Planning module comprises three sections: 1. Requirement Planning Entry, 2. Material Requirement Planning Operation, 3. Requirement Planning Reports Requirement Planning Entry This is the section where you can enter according to dates the codes and quantities for the product that you plan to manufacture. Companies that operate on customer orders and produce in relation to order quantities should first run the Extra Operations/Production Plan Preparation section before they enter the quantity information and insert the remaining orders planning records according to the delivery dates. It is possible to later modify this information in this section. Date There are no restrictions for the date entry. You can specify a plan, as you desire, daily or with specific intervals. You can, for example, enter plans for specific periods, i.e., every Monday (weekly), for the first day of every month (monthly), or for the 1 st, 10 th, 20 th days of every month (10-daily). Product Code You can enter the product codes for which you have already defined the inventory card and BOM. You can also enter product codes or semi product codes if needed. Order No For companies that produce by orders and wish to trace their raw material and semi product requirements according to these orders, this is the section where they should enter/retrieve the product s customer order number, which they previously inserted in the Invoice Module. In the case that you manually enter the product requirement on the requirement planning page, you can select the orders from the order number lookup. If you inserted the product requirements with the Production Plan Preparation operation, which will be discussed later in this document, the programme inserts the related order numbers. Order Sequence No This field indicates the row of the order that will be included in the MRP. To be able to use this field you should select the above-explained Man. Order and Planning Based on Order Rows parameter. You can use the Order Sequence Number field to separately plan for the inventory items that repeat several times in the order. Quantity In this field you should enter the desired production quantity related to the product code.

4 Customer Order Balance These fields are for information purposes, to assist you in forecasting the manufacture quantities of products. You can get these values that will constitute a base for your plan in the Operations/ Production Plan Preparation section Date Inquiry You can modify the MRP date with the help of the Date Inquiry section. If, for example, you notice that you entered 12/07/2006 for your MRP records, whereas this date should be 10/07/2006, you can correct the MRP date information in this section. When you press the Date Inquiry button, the programme displays the below-shown window. When you enter the new date and press the OK button, the dates on the related records will be updated as 10/07/ Batch Delete This function enables you to quickly delete the MRP records. You should indicate the date interval for the records you want to delete and press the OK button Min.Inventory Control You can run this operation to include the inventories, which have balances below the minimum limits specified in the inventory planning records, in your material requirement plans. The below-shown warning window opens when you press the button.

5 When you press the Yes button, the programme includes in the plan the inventories that have dropped below the given minimum limits Run / Report MRP The below-shown queries will be displayed when you press this button. Start Date

6 The programme displays the system date by default. In general, you should not modify this date, and regardless of the date on which you made the plan entries, you should run the operation as of the current date. This is because, when evaluating the inventory-order-manufacture order onhands you should consider the status on the current date. This date is not related to the date of the plan entry. End Date This is the date of the last day on which you will run the plan. You should leave this field blank to allow operation until the last day. Order Qnty. / Requirements / All When calculating material requirement, if you wish to consider only the recorded customer orders, then you should select the Order Quantity option. If, however, you want to consider the recorded manufacture orders regardless of the customer orders, then you should select the Requirements option. If you wish to calculate the material requirement that involves both the order quantities and the requirements, then you should select the All option. Only Products This option enables you to list only the products on the MRP Results page of the MRP Report. List Details When you do not select this parameter, on the MRP Results page of the MRP Report you will see the product, semi product and raw material requirement quantities for the planned period in their totals according to date. When you select this parameter, the product, semi product and raw material requirement quantities are listed individually for every requirement record for the same date. In other words, you will be able to see which from requirement records of which product/s and dates the total requirement amount that you calculate for a semi product originates. List Details Separate While serving the same function as the List Details parameter, when you select this parameter you can list the requirement information on a separate page titled DETAIL in the MRP Report. Check Min. Stock You should select this parameter if you wish to consider the minimum inventory quantities recorded in the inventory cards when calculating the requirement. If you do not select this parameter the programme does not consider the minimum inventory quantities. Check Onhand You should select this parameter if you wish to consider the current inventory onhands when you are calculating the raw material and semi product requirement quantities by running the plan. You should not select this parameter if you wish to consider for the products on the plan only the quantities in the BOM, i.e., disregard the inventory onhands of the semi product and raw material requirements. Check Product Onhand

7 You should select this parameter, if you want the programme to calculate the onhand quantity related to the products and semi products on the plan and deduct these quantities from the plan, You should not select this parameter if you want the programme to consider the quantities on the plan as is. The programme does not query, thus does not calculate the product onhands if you do not select the Check Product Onhand. Check MO For the products and semi products, which you recorded in the Plan entry section, if you want to verify the open manufacture orders that are not produced or partly produced, and calculate these in the net requirement quantities, then you should select this parameter. You should not select this parameter if you do not want these open orders to affect the recorded quantities. Check Supp. Order You should select this parameter when you run the Plan if you want to consider your undelivered orders, i.e., your raw material orders and semi product orders that you have partially outsourced and placed orders for the quantity you outsourced; otherwise you should not select this parameter. MO Range You should use this section when you have selected the Check MO parameter. You should indicate a manufacture order range if you wish to include in the plan some of the existing manufacture orders. MO Excl. Range: If you want to exclude some of the manufacture orders that fall in the MO range that you indicated in the above-explained field, you can specify an exclusion range in this field. For example, if you enter and in the MO Range field and then enter and in the exclude range, then the programme does not include the product or semi product quantities recorded in manufacture orders and in the requirement calculation. Support General Structuring Code In companies that use flexible structuring, at the time you process the Material Requirement Planning, you may not yet know the specifications of the products you are plan. You may want to plan for general purposes, without having the exact specifications. We can assume that the general structuring code support is used for a structurable product family. The planning is made not according to structured products but for a product family. When you start running the application, the general structuring code (or the product family structuring code) is the automatically generated structuring coded You cannot modify the definitions of this structuring code. You should define the BOM related to the general structuring code (structuring code = ) on product basis. If any of the materials or semi products that are used in the product can be structured,

8 then in the BOM you should enter for the structuring code of these components. In the production plan, you can enter the products that you will manufacture on the same plan both as product family (structuring code = ) and according to their own structuring code, while you can also plan individually according to family and structuring detail. The benefit of this function is: The user who prepares this plan writes the manufacture quantities for the long-term planning according to the product families. Later, as the period approaches, the quantities that are planned on family group basis will be specified according to the structuring details. For a healthier planning, when writing the manufacture quantities according to the structuring details the planner should have reduced the family-based manufacture quantity that he/she previously entered. With the new application, the planner is able to separately plan for the manufacture that he/she entered according to the product families and the manufacture that he/she entered according to the structuring details. Thus, in the same MRP you can record and run two separate production plans, i.e., according to product families and structuring codes When you select the Support General Structuring Code option, the programme plans the products on the production plan without considering the structuring codes, according to the general (product family) structuring code BOM, and when processing with inventory onhands calculates all of the current onhand for the related inventory, disregarding the structuring code. Do not Check Structuring Codes When you select the above-explained option, the programme considers the products as a product family, regardless of their structuring code recorded in the production plan, and plans accordingly. Whereas in this option, the programme plans only those that you entered as product families, i.e. the products for which you entered the structuring code = We can describe the purposes of these two options with the following examples. Support General Structuring Code : Do not Check Structuring Codes : The planner wants to prepare the production plan for the long term and the short term separately, using the product family codes for the long term and the structuring code details for the short term. In cases where both options are selected, the programme runs only the MRP only for the product family plan (structuring code = ).

9 Support General Structuring Code : X Do not Check Structuring Codes : X The plan is prepared for those products that are entered in the production plan according to their structuring code details. The programme considers the BOMs and inventory onhands related to the structuring code. It is an operation based on full structuring code detail. Support General Structuring Code : Do not Check Structuring Codes : X The planner enters the production plan according to the estimated structuring code detail. While the planner wants to prepare the short-term plan in structuring detail (neither of the options selected), he/she wants MRP to calculate the product family for the long-term plan. In other words, there is one production plan and this plan is based on structuring detail. However, when running the MRP, regardless of the product structuring code, the MRP processes a global operation (according to product family) for inventory, manufacture orders and product BOMs within the given time interval (for the long-term). When you do not select the General Structuring Code parameter, it is not possible to select the Do not Check Structuring Codes parameter. The programme automatically runs after the initial query and calculates the raw material and semi product requirements for the production plan you entered. It generates a report at the end of this operation. This MRP report consists of three pages: MRP Result Order Detail MRP Report

10 This page includes the following information calculated in the MRP: your raw material and semi product requirement quantities, if applicable the minimum order quantities, the quantities integrated from orders and manufacture orders, net requirement and remaining balance Order On the Orders page you can view the information about which raw material and semi products you should order from which suppliers and in which quantities, notify, loading and delivery dates. The programme calculates both the order quantities and the dates according to the Order Policies that will be discussed later in this document Detail To be able to see the MRP report in further detail, you should select the List Details Separate parameter on the window that opens when you press the Material Requirement Planning/Run - Report MRP button. In this window you can see the information about which product or semi products the raw materials and semi products are use in. Example: If, P1 (product) BOM is, RM1 (raw material 1)- 5 units, RM2 (raw material 2)- 3 units: inventory onhands are, P1-3 units, RM1-12 units, H2-25 units:

11 Production plan is, P1-10 units; then: Parameter Inventory Code Requirement Inventory onhand control - P1 7 units Yes Product Onhand Control RM =23 unit Yes RM =0 (zero) Inventory onhand control - P1 10 units Yes Product Onhand Control RM =38 unit No RM =5 units Inventory onhand control - P1 10 units No RM1 50 units RM2 30 units Number of Levels: This is the number of levels found in product trees. To calculate this number you should base your calculation on the product tree that has the most number of levels and calculate 1 for every product and again 1 for every semi product. The lowest raw material level should not be counted. The programme runs the following operations in the plan: Starting with the first product of the first day as of today, calculates when (date) and in which quantities the semi products and raw materials that are recorded in the product BOMs will be required; and in order to meet these requirements, when (date) and in which quantities you ought to generate raw material orders and semi product manufacture orders. The programme writes this information in a file for future reporting Important Points in Calculating Material Requirement When calculating the material requirement in the MRP module, there are several sections where you enter information such as the supply time, minimum limits, order policies that affect the information about the requirement quantities, supplier order quantities and dates. Customer/Supplier Inventory Records in the Inventory Module Current Account Planning Records in the Current Accounts Module Inventory Planning Records in the Inventory Module In the Customer/Supplier Inventory Records section you can define planning information according to both supplier and inventory. Thus, you can enter different transport times, minimum order quantities for the same material that you buy from different suppliers.

12 In the Current Account Planning Records section you can define information such as order policies, transport time and notify period only on customer basis. And in the Inventory Planning Records you can enter planning information only on inventory basis. For example, if you enter the transport time for an inventory in the Inventory Planning Records and the programme cannot identify any information about that inventory in the Customer/Supplier Inventory Records section, then it assumes that this transport time is the same for all suppliers in the planning. The programme considers this information according to the above-given sequence. This is to say, it first verifies the Customer/Supplier Inventory Records section for the inventory. If it cannot identify any related information in this section then in the Inventory Master Records Current Account/S code section it checks the Current Account Planning Records related to that supplier. If the programme cannot identify any information also in this section, then it plans according to the definitions recorded in the Inventory Planning Records Production /Notify Period In some applications, you have to notify the side industrialist a specific time before the loading of the order. Similarly, to enable timely delivery of the semi products that you manufacture, you may have to give the manufacture order a specific time before the delivery date. You can enter the production/notify Period in the Inventory Planning Records on inventory basis only in days. You can define this information by selecting one of the day/month/year periods according to supplier in the Current Accounts Planning Information section and according to supplier-inventory in the Customer/Supplier Inventory Information section. In the MRP operation, the programme perceives this period as the production period of the semi products to be manufactured. In the supplier orders, the programme counts backwards by the notify period starting with the loading date calculated in the MRP and verifies whether or not there is a delay in notification. You can get a separate report for the requirements that display late notification or loading. For example, let us assume that the loading period for the raw material which the supplier should deliver on is 3 days and the notify period is 2 days. If the loading and the notify periods are daily, then the report generated in the MRP looks as below.

13 Transport Times The transport time of a raw material is the time spent between the material s exit from the supplier and delivery to you. In the MRP application you can plan with different transport times according to either the supplier or the raw material. You can define the transport times either in the Inventory Module/Customer- Supplier Inventory Information field as detailed according to inventory or in the Current Accounts Planning Information field without inventory details only according to the supplier. In the MRP application, the programme considers the transport times when calculating the supplier s loading and delivery dates. If you have entered the transport times for any raw material in the Customer/Supplier Inventory Records, then it first considers this information. If you have not entered any information in this section, then the programme considers the definition recorded in the Current Account Planning Record of the supplier. If again there is no definition recorded in this section, then the programme considers the transport time defined on inventory basis in the Inventory Planning Records. Example: Basing on the product tree given above in Example-1, if the Production/Notify periods for P1 is 2 days, RM1 is 5 days and RM2 is 3 days, Transport times for RM1 is 1 day, RM2 is 2 days, Production plan is 01/08/2003 P1 10 units, then In order to have P1 ready on 01/08/2003, you should give the manufacture order on 30/07/2003. To be able to start the operation for P1, you have to have received RM1 and RM2 on the same date, i.e., on 30/07/2003. Therefore you should place the order of RM1 on 24/07/2003'de, (5 days notification + 1 day transport time), and RM2 on 25/07/2003'de (3 days notification + 2 day transport time).

14 Date Inventory Code Requirement Notify Order Delivery MO 01/08/2003 P1 X 30/07/2003 P1 X 30/07/2003 RM1 X X 30/07/2003 RM2 X X 25/07/2003 RM2 X 24/07/2003 RM1 X Loading Period and Date In cases where suppliers load only on specific days of the week or month, you can use the Loading Period and date fields to calculate the loading days in your planning. You can define the transport times either in the Customer-Supplier Inventory Records field according to supplier-inventory or in the Current Accounts Records according to the supplier. If you select weekly for the period type you should specify on which day of the week the loading will take place and if you select monthly for the period type you should specify on which day of the month the loading will take place. If loading is possible every day then you should select daily for the period type. In the MRP application, the loading time of the supplier is calculated by counting backwards from the transport time starting with the delivery date. If, however, this date does not match with the given definitions, the programme specifies and records the first loading date that precedes this date according to the given definitions. This is the date that you should inform the supplier. Warning: The date calculated here is the date the supplier loads the order. For any raw material, if you have defined the loading period/day in the Customer/Supplier Inventory Records, the programme first considers the information in this definition. Otherwise, it considers the definition in the Current Accounts Planning Information field. If, again, there is no information recorded in the Current Accounts Planning Information field, the programme considers the period type and day that you defined according to inventory in the Inventory Planning Records. For example, let us assume that the transport time for the raw material, which the supplier should deliver on , is 3 days. If the supplier loads its deliveries only on Fridays, MRP calculates this loading day as Friday In this case, since the transport time is 3 days, you will receive the material on , i.e. two days before your requirement date. If the loading were made every day, the supplier s loading date would have been Confirm Period and Time

15 If you have agreed with your suppliers over a periodic order system and you want to generate the supplier orders, which are created from the MRP results, according to this system, then you can use the Confirm Time field. For example, let us assume that you place orders with your suppliers every week. The order you place this week includes the order quantities planned for the following n months and are confirmed for n weeks as of the following Monday. In the week following this week, you again place new orders that involve the same times. Besides these main weekly orders, you may also have to place extra orders. In this case, you should use the Order Revision System that is explained in the Invoice Module course book, in order to store the backdated records of the weekly orders and record these in the order system. The orders that are confirmed in the MRP results are initiated after the start date according to the production/notify period. The orders that fall in the time interval of the confirmation period after this date will be recorded as confirmed. If the programme identifies an order that you should have placed within the time interval of the production/notify period, the system assumes this order is delayed and should have been placed earlier, because now the supplier lacks the time for production Planned Weeks When supplier orders are created from the MRP results after the confirm time, you can use this section to place these orders with the supplier as the Planned Orders. You can cumulate the orders that generate for the period after the confirm period, according to the number of weeks as you desire and create weekly planned orders Planned Months You can use this section to place monthly planned orders with the supplier on the dates after the planned weeks, for those generated in the MRP. Example: if Production/Notify Time: 1 week Confirm Time: 1 week Planned Weeks: 1 Planned Months: 1 Mrp Start Date: 01/04/2003, then You should count backwards from the MRP start date until you reach the first date according to the notify period and mark the notify date after this day. For example, is a Tuesday. Since your notify period is weekly, the notify time will start on the first day of the following week, i.e. on The period between 07/04/2003 and 13/04/2003 is the notify time. In the MRP results, the programme records the orders that display their loading dates between 14/04/2003 and 20/04/2003 as daily and confirmed orders according to their specific dates.

16 The MRP accumulates the orders that display loading dates that fall between 21/04/2003 and 27/04/2003 in one week and generates weekly planned orders on a single row with a loading date of 21/04/2003 and delivery date of 27/04/2003. The MRP accumulates the orders that display loading dates that fall between 28/04/2003 and 30/04/2003 and generates monthly planned orders on a single row with a loading date of 28/04/2003 and delivery date of 30/04/2003. The MRP accumulates the orders that display loading dates that fall between 01/05/2003 and 31/05/2003 in a month and generates monthly planned orders on a single row with a loading date of 01/05/2003 and delivery date of 31/05/ Order Policy (Lot Size) The order policy means for raw materials, the number by which the order amount should be multiplied, and for semi products the number by which the production quantity should be multiplied. If there is a given coefficient required by the supplier or one that you accepted as company policy, you should indicate this value and select Fixed Lot Size for your order policy. If you can place orders in the required quantities, then you should leave this value as 0 (zero) and select Lot for Lot for your order policy. Since it will be possible to manufacture in the desired quantities particularly for products and semi products, you should specify the Lot for Lot quantity. You can define the order policy according to supplier and inventory in the Customer/Supplier Inventory Information section, according to inventory in the Inventory Planning Records section and according to supplier in the Current Accounts Planning Information section. If you have previously defined an order policy for a raw material/semi product in the Customer/Supplier Inventory Information section, then the programme first considers this information. If you have not entered a definition in this section, then it considers the definition recorded in the Current Accounts Planning Records of the related supplier. If again you have not entered a definition in the previous section, then the programme considers the order policy that you defined in the Inventory Planning Records section on inventory basis. Example: For the product BOM given in Example-1, the lot sizes are calculated as below. Inventory Code P1 RM1 RM2 Lot Size 0 (zero) 10 units 5 units

17 Parameter Inv. Onhand Control - Yes Product Onhand Control Yes Inv. Onhand Control Yes Product Onhand Control No Inv. Onhand Control - No Inventory Code Requirement MO Qnty. P1 7 7 RM =23 30 RM =0 - P RM =38 40 RM =5 5 P RM RM Order Qnty. If there is a semi product in your BOM and lot size is defined, the production quantity of this semi product would not be equal to the required amount but calculated according to the lot size. In that case, the raw material requirement would be calculated according to this production quantity Order Ratio You can use the Order Ratio section to calculate the distribution ratio of the supplier orders, which are generated in the MRP, among multiple suppliers. The records, which will be transformed into supplier orders in the MRP, will be distributed among the different suppliers according to the value you entered in the order ratio field in the Inventory Module/Records/Customer-Supplier Inventory Records section. Companies that partially supply their semi products from third parties and partially manufacture in-house can use this application to calculate ratios. If you have not entered an order ratio or the total according to suppliers is less than 100%, the programme assigns the remaining rate to the supplier whose Supplier Code is recorded on the Inventory Card. If the inventory in question is a semi product, then the programme creates a manufacture order for the remaining ratio. If the order ratios total is greater than 100%, then this means that you are generating excess orders in the ratio of the value that exceeds 100. This needs attention. For example, if the order ratios total is 120, in MRP the programme will calculate 12 units instead of 10 for the order. If you have entered order ratio for a semi product in the Customer/Supplier Inventory Records section, the programme assumes that you will purchase this semi product and does not plan for the raw materials in the related lower levels in the MRP. The programme calculates the ratio that adds to 100% after the ratio you

18 indicated as the quantity to be manufactured and plans for this quantity in the lower levels. You must enter the order ratio in the related fields of the Customer/Supplier Inventory Records in order to enable the programme to consider the order policy, transport time, notify period, loading days, confirm and planning period in MRP. Example: In the above-given example we discussed the calculation of requirement quantities and dates, order/manufacture order quantities and dates. If we assume that the inventory onhand and product onhand control parameters are (Y)es, we can complete the example in the below-given table. Date Inv. Code Req. MO Qnty. Ord. Qnty. 01/08/2003 P1 7-30/07/2003 P1-7 30/07/2003 RM /07/2003 RM2 0 (zero) - 25/07/2003 RM Inventory and Order Balances When calculating the (raw material, semi product, product) requirements of the inventory items, if Inventory Onhand Control = (Y)es, the behaviour is as given below. On the first day when the material is required, gross material requirement (quantity generated by the product BOM) - inventory onhand - expected supplier - expected manufacture order quantity On later dates, gross material requirement (quantity generated by the product BOM) - closing inventory onhand - deliveries up to date since the last date Example: if 1. for the production of raw material RM1 on 30/07/2003, the required quantity is 35 and the onhand quantity is 10, the expected delivery from supplier orders on 25/07/2003 is 2. Then the net requirement of RM1 on 30/07/2003 is =23 units. Date Inv. Prod. Onhand Order Net Req.

19 Code Qnty. In 30/07/2003 RM We have discussed in the previous examples that in order to have the 23 units of RM1 on 30/07/2003, this order has to be placed on 25/07/2003 and in 30 units due to the lot size. Date Inv. Code Prod. Qnty. Onhand Order In Net Req. Ord. Qnty. 25/07/2003 RM /07/2003 RM Due to this planning you will have 30 units more of RM1 on 30/07/2003. The 10 units of onhand and the 2 units of delivery are the actually existing quantities. The 30 units of new entry are the entries from planning. Date Inv. Code Prod. Qnty. Onhand Ord. In Net Req. Ord.Qnty. Plan.In 25/07/2003 RM /07/2003 RM Together with the 30 units, which are expected to be received on 30/07/2003, you will have 42 units of RM1 onhand; you will consume 35 units and have 7 units of RM1 remain onhand. Date Inv. Code Prod. Qnty. Onhand Ord. In Net Req. Ord.Qnty. Plan.In Closing 25/07/2003 RM /07/2003 RM Let us assume that at the later stages of your planning, you again need RM1 on 15/08/2003. Let us assume that the required production quantity (gross requirement) is again 35 units. In the previous step, you had planned a closing onhand of 7 units on 30/07/2003. In this case your table will be as given below. Date Inv. Code Prod. Qnty. Onhand Ord. In Net Req. Ord.Qnty. 25/07/2003 RM /07/2003 RM /08/2003 RM /08/2003 RM Plan.In Closing Let us assume that your planning ends here and the above-given planning records are generated. You can get two separate lists for this plan.

20 * The consumption quantity and consumption date of RM1 according to this plan. Date Inv. Code Prod. Qnty. 30/07/2003 RM /08/2003 RM1 35 When and how many units of RM1 should you order according to this plan. Date Inv. Ord.Qnty. Code 25/07/2003 RM /08/2003 RM Timing Mistakes If you enter plans in short notice, some requirement or order records may bear dates earlier than the current date because of the supply times. In this case the programme marks these records that display overdue delivery or notify dates with an *. When you see this mark, you should understand that the related planning is physically impossible to implement. Example: The plan in the above-explained example considers the production of 10 units of P1 on 01/08/2003. If this plan were prepared on 01/08/2003, in other words you were processing the plan on 01/08/2003, then the requirement and order records for RM1 generated in the plan would be as below. Date Inv. Prod. Ord.Qnty. Code Qnty. 25/07/03 * RM /07/03 * RM /08/03 RM /08/03 RM Planned Engineering Changes Another application that can modify the material requirements in the MRP is the revisions you make in the BOMs for future operations. You should reflect these changes, which you insert in the Planned Engineering Changes section in the Production Module, on to the plan and calculate the requirement quantities accordingly. To do this, you should use the Planned key in the Planned Engineering Changes section. When you use the Planned key, the engineering changes you define in the revision will not be realised in the BOM but used only for planning purposes. In this section the programme opens a window that queries the revision numbers. On this window, you should select the revision

21 number that will be displayed in the planning and then press the PLANNED key. After this process, the programme runs the planning with the new components or the modified quantities of the old components. For example, on the BOM of product P1, you wish to replace the raw material coded 001 with raw material coded 002 on In the requirement plan you prepare on you should calculate the requirement quantity for raw material 002 instead of Alternative Material Usage Yet another application that can modify the material requirements is the alternative material usage for the components in the BOMs. The MRP supports only the Ratio among the alternative material policies. In this policy, the required material quantity is calculated according to the ratios specified in the BOM or the alternative definition. For example, let us assume that in the BOM you indicated a ratio of 80% for raw material RM1 and 20% for raw material RM2 that is the alternative of RM1. If, in this case, you need 100 units of RM1 for the manufacture of the product, the system uses 80 units of RM1 and 20 units of RM Manual Scheduling This section simultaneously runs the Material Requirement Planning (MRP1) and the Capacity Planning (MRP2) according to the filters defined on the parameters page and calculates the current production plan and the

22 occupancy rate of the workstations according to dates. In cases that you exceed the capacity or work below the capacity level, you can modify the production plan in order to maintain the balance Parameters In the Parameters section you can specify the data, which you want to consider in calculating the requirements and capacity. You can read the details about the Parameters in the Material requirement Planning and Capacity Planning sections explained later in this document Production Plan The production plan window comprises two sections. The upper section involves MRP1 information about the product requirements on the basis of customer orders according to the date and structure of the plan, which either you manually enter in the material Requirement Planning section or is generated by the programme with the Production Plan Preparation operation. The lower section displays the capacity usage ratios of the workstations according to the dates given in the current production plan that is based on the definitions, which you entered in MRP2. Add Product You can use this function to add new products in the plan according to the capacity situation. If desired, you can also enter order numbers to follow-up the requirements according to the related orders. Add Date You can use this function to add new date with the purpose of spreading the requirement quantities in the plan to different dates according to the capacity situation. When you press the Add Date button, the programme opens a window where you can view the product and order numbers. You cannot

23 modify these fields. After you add the new date, you should manually enter the product requirement quantity in the column displayed for the new date. Refresh You can use this button to delete the date and product columns, which do not include requirement quantities and resort the products on the plan according to their inventory codes. You can also process the Add Product, Add Date and Refresh operations by right-clicking anywhere on the requirement quantities in the upper window, then using the insert row, insert column and refresh options in the dropdown menu. The Insert row option can be used for adding a product, the Insert Column for adding date. Calculate This is the button that calculates both the requirement quantities and the capacity at the same time according to the constraints specified on the Parameters page. If you get a report before you press the Calculate button after you enter modifications in the Parameters, the report you retrieve displays the last situation before you entered the modifications. Capacity Details You should use the Capacity Details section after you run the Capacity Planning section in order to view the information related to the capacity situation according to the stations. The section becomes active when you click anywhere on the lower section of the window in which the capacity information is displayed. You can also access the same window while you are in the cells that display the occupancy percentage by double-clicking the left button of your mouse.

24 The window that opens displays the detail information about your capacity usage according to date and workstations. By using the Occupancy Detail button you can access the current capacity and requirement capacity information for the related workstation that is valid for the date you are positioned on. You can also view the products and operations from which the requirement capacity originates. This window is for information purposes and cannot be modified. Occupancy percentage is calculated with the following formula: Requirement Capacity / Current Capacity x M.R.P. Report This button serves for the same function as the Run M.R.P./ M.R.P. Report button explained in the Material Requirement Planning section below and runs the requirement for the products in the production plan according to the constraints in the Parameters section. The report includes information about the semi product and raw material requirement quantities and the time information for the supplier orders and manufacture orders. You can read further in the Material Requirement Planning section below. 2.3 Work Center Definition

25 The Work Center is the production unit where one or more operations of the same kind run simultaneously and one worker/machine or a group of workers/machines work at the same time. You can think of the Work Center as a cost centre. You can run one or more operations in the Work Centers. The sequence and number of operations may vary according to the products, however the operations run on the workstations in that work centre should be similar and the station should be located in the same area. If you wish to plan for both labour capacity and machine capacity of the same workstation, then you should define separate workstations for these two. For example, the dyeing, washing and drying operations sections in a carpet factory are separate workstations. The operation in every workstation is the same within itself. Workst. Code This is the field where you can give a code for the defined workstation. The Workstation Code can be maximum 5 characters long. A code number has to be assigned to every workstation. Workst. Descr. In this field you should enter the name of the workstation. Department If you are using cost accounting you can record the product main group code in this field. You can also enter any desired codes for the purposes of reporting. Labor Costs This is the field where you can enter, if available, the standard unit labour cost amounts for the workstation. When you enter a value in this field, the programme calculates the standard labour cost that corresponds to the requirement labour capacity in Capacity Planning. Overhead Costs This is the field where you can enter, if available, the standard overhead costs for the workstation. When you enter a value in this field, the programme calculates the standard overhead cost that corresponds to the requirement capacity in Capacity Planning. Setup Time If you require a preparation period to start the operation in the defined workstation, you can indicate the required time in this field. This information is default for all operations in that workstation. In Capacity Planning the programme considers the setup time that is defined on operation basis. Production Time This is the time spent for the production of 1 unit of product/semi product in the defined workstation. This information is default for all operations in that workstation. In Capacity Planning the programme considers the production time that is defined on operation basis. Target Queue Time This is the targeted time, which a product should spend in the queue. Currently this field is for information purposes only. Avg. Queue Time

26 The programme will later calculate the Average Queue Time. Currently this field is for information purposes only. Max. Queue Time This is the maximum targeted time, which a product should spend in the queue. Currently this field is for information purposes only. Max. Queue Allow This is the number of products that can line up in the queue. Currently this field is for information purposes only. Std. Simultaneous Operations/Shift 1.,2.,3. This is the number of workers/machines that can simultaneously work in shifts. The programme considers this information in calculating the workstation s current capacity. 2.4 Operations Catalog This is each of the operations you run in sequence when you manufacture the product. An Operations Catalog is given in the programme. You can record any kind of operation that you run in your plant. When you define the operations for a product (routing) in your BOMs, you can select operations from this catalogue. Each operation has to be run on the workstations in the plant. You should define the workstation, the simultaneous operation unit that can be used (number of counters), production time, setup time, lot size for transit to the next operation and time information for the workstations related to the operation.

27 Operation Code In this field you should enter the code number by which you want to follow-up the defined operation. The programme uses this code number in the BOMs of the related operation. Operation Descr. This is the field where you should record the operation s name. Workst. Code In this field you should specify the workstation in which run the defined operation. You cannot leave this field blank. You can use the lookup key in the related field to view the lookup that lists the previously defined workstations. Simult. Operation This is the number of counters that can be simultaneously used in the operation. You may run the same operation on multiple machines. If the existing machines can run the same work at the same time for the same product, then you should enter the total number of machines. If, due to apparatus availability, you can run only one machine at a time, then you should enter 1 in this field. Operation Explanation This section enables you to enter any detailed explanation related to the operation. Transport Qnty. This is the quantity that is transferred to the next operation. Setup Time In this field you should indicate the time you require to prepare to start the defined operation. For example, you may need to wait 30 minutes for the machine to warm up. This time occurs once before the production of one lot. In other words, you should not need to warm up the machine at every production. Production Time In this field you should enter the time spent between the start of the production in the defined operation and the complete production of 1 unit. Transport Time In this field you should enter the time spent after the end of one operation to move to the start of the next. 2.5 Machine Definitions

28 This is the section where you can define the information about which machines are used in which operations, their costs per hour, production and setup times, priority codes, group codes and status either in connection with Netsis Fixed Assets programme or by free coding. In order to link to the Netsis Fixed Assets package you should make the required arrangements in the Link to Other Packages option of the Auxiliary Module. After you make the necessary arrangements you should select the Lookup option in the Lookup Package field and write in the Workplace section the description of the company for which you previously created in the Fixed Asset package and of which you want to retrieve the information. 2.6 Employee Definitions

29 This is the section where you can define the information about the workstations in which the employees work, their positions, costs per hour, group codes and status either in connection with Netsis Personnel programme or by free coding. In order to link to the Netsis Personnel package you should make the required arrangements in the Link to Other Packages option of the Auxiliary Module. After you make the necessary arrangements you should select the Lookup option in the Lookup Package field and write in the Workplace section the description of the company for which you previously created in the Personnel package and of which you want to retrieve the information. 2.7 Calendar Definitions Plant Work Calendar

30 This is the section where you should create your plant s work calendar. After you enter the programme by months and years, when you press the CREATE CALENDAR key, the programme automatically generates monthly calendars. The programme distributes the daily shifts in the calendar according to days. When calculating the number of shifts, the programme considers the shifts, which you defined in the Parameters section. For example, if you have entered in the Parameters section the time for 2 shifts then the calendar includes 2 shifts per day. Users can modify the deviations in this calendar. For example, if you do not work on Sundays, then the shifts displayed on Sundays should be modified as zero, if there are holidays these should be modified. In the same way, if in a certain period you plan to work shifts more than the routine, then you should increase the number of shifts for these dates Work Center Calendar

31 If the general plant work calendar differs from the calendars of individual workstations, then in this section the general plan calendar is reflected on that of the workstation. When you press the Create Calendar key in this section, the programme retrieves the Plant Work Calendar to this section. You can make the necessary related modifications if you need to change the information about the shifts Machine Repair Calendar

32 If there is a specific repair or maintenance schedule for the machines you use in your production, you can enter this information in this section. In this way you can track which machines will be out of order on which dates and hours for maintenance. 2.8 Definition Operations In this section you can make sales forecasts by various methods basing on your previous sales data, manually modify the forecast data and create budget tables with the forecast. The section s works in the following way: 1- Specifying the companies (past years databases) to be used in the forecast and creating preliminary data from this data, 2- Testing the forecast which are derived from preliminary data via different models and recording the forecast data generated with the approved model, 3- Manually modifying the data if necessary, 4- Generating budget data from the forecast data Run Forecasting Preparation This is the section where you can select the databases (companies), which you want to retrospectively review in detail for the forecast and specify filters for the inventories that you want to include in the forecast. Companies that will be Used for Forecast To the left of the window you can see the list of all the companies that are stored on the database. You can select the companies, which you want to take as base for your forecast by clicking on the checkbox to the left of every entry. Forecasting by Filter

33 In the Filter section to the right of the window, you can, if desired, select specific inventories and define filters for those that you want to include in your forecast. To get information about using the Filter window please see NNR / Netsis Nested Report Wizard / Filter / Filter Section Usage, Creating Filters. Run and Cancel Buttons After you specify the companies and the inventories, which you wish to include in your forecast, you can create the data by using the Run key. In the preparation work that you make in this section, you only organise the data related to the previous year and do not yet start the forecast process. Thus, in this section, you cannot move on to the forecast process before you make the database selection and process the preparation by using the Run button. In the preparation operation, the programme considers the years for every company and transfers to the preparation table the inventory sales values of only the related years Forecasting Operation This is the section where you can test the forecast derived from past sales data via various methods, store the data generated with the best method and create the base for the forecast budget. Before you start the forecast operation in this section you must first run the past data preparation section (See, Run Forecasting Preparation). Codes that will be Forecasted

34 In the section to the left of the window you can find the inventories or the inventory groups according to the cumulate field that is described in the Forecasting Parameters (See, Definition Operations). You use your mouse to select the codes for which you want to run forecast. To select more than one entry, you should press the CTRL key and simultaneously click on the code with your mouse. You can run the forecast operation only for the code(s) you select. You can view the forecast in the graphics on the right-hand side separately for every code and only for the selected code at a time (See, Forecasting Graphics). Select Methods that will be Forecasted The forecast methods used in this application support internationally acknowledged statistics methods. Different forecast results will generate with every method. To view the forecasts that generate via the different methods, you can select the method by checking the box to the left of each entry Supported Methods Constant Model with first order smoothing This is the most relevant method to use if the Time Series does not have seasonal and trend components and deviates around a constant average by random fluctuation. It forecasts the following period by putting weight on the nearest previous value. This method is meaningful for short term forecasts. Trend Model with first order smoothing This is the most relevant method if the time series has the trend component. It calculates the trend by smoothing the previous values. Trend + Seasonal Model with first order smoothing This method is relevant if the time series has both the trend and seasonal components. Seasonal Model This method is relevant if the time series has only the seasonal component. Trend Model with second order smoothing

35 This method is relevant if the time series has only the trend component. The model and forecast are calculated over first order smoothed data. Constant Model Moving Average This is the relevant method to use if the time series shows random fluctuation around a constant average. For every new forecast, the old data is dropped and the calculated average is used. (Moving Average). Constant Model Weighted Moving Average Computes moving averages by putting more weight on the nearest data. Constant Model and Trend Model This is the relevant method to use if the time series has a linear trend component. Formulates the data model with y = a+bx. Second Order Trend Model This is the relevant method to use if the time series has a second order (curved) trend. It adds the x square variable to the formula to be used in forecasting Run Forecasting With the help of this button on the toolbar, you can run forecasting and get the graphic drawings on the right-hand of the window. The forecasting will be made for the inventories, which you selected on the codes that will be forecasted window, or for the inventory groups according to the cumulate field that is described in the Forecasting Parameters (See, Definition Operations) and according to the data that are calculated as the result of the used method(s) (see, Supported Methods). Forecasting results will be displayed in the graphics section (see, Forecasting Graphics). The programme will first display on your screen the graphics chart generated for the last of the selected inventories or inventory groups. You should select the inventory or inventory group, of which you wish to view the graphic, as a single entry on the codes that will be forecasted window. Forecasting Graphics

36 This is the section where you can view the graphic charts, which display the factual data (past data), the preparation data (processed past data) and the forecasted data (forecast based on past data), and which are prepared according to the selected forecasting methods, individually for every inventory or inventory group that you selected Method Tabs When you press the Run Forecasting button, the programme runs the forecast for the inventories or inventory groups according to the method(s) that you selected. If you have selected more than one method, then the programme displays the graphics that are generated for every method, separately on different tabs on the same window. The programme further selects the graphics that is the most relevant for the data among the prepared graphics and displays the related tab. You can view the other graphics by moving to the related tab Reviewing the Graphic The X-axis on the graph shows the time intervals. These are given in the period intervals as you defined in the parameters (see, Forecasting Parameters Definition Operations). In the example the period type specified in the Forecasting Parameters is Monthly. Last two years data was scanned and the forecast for the following one year was queried (see, Forecasting Options/ Forecasting Period Number). In this case, the X-axis is divided into 36-month intervals but due to the lack of space the gridlines are drawn by two-month intervals.

37 The Y-axis shows the sales quantities. The range between the minimum and maximum sales quantities of the related product or product group is sectioned on the Y-axis. The red graph line shows the actual past data positioned on the time (Z) / quantity (Y) axes. The green graph line shows the corrected graphic after the selected method algorithm is applied to the past data. The blue graph line shows the forecast that is generated when the same method is sustained. Warning: The forecast data starts as of the last date of the past data ends. For example, if the forecast is made in November 2005 and the past data covers 2004 and 2005, because the past data includes data until November 2005, the forecast starts as of December If the forecast is queried for 12 months (see, Forecasting Options/ Forecasting Period Number), then the graphic shows a forecast until December Select as Forecasting Method After reviewing the graphic charts generated according to each of the methods, you should select the graphics that is best suited to generate quantities per your budgeting needs. When you select the Select as Forecasting Method option on the tab that displays the graphic chart that you want to select, the programme saves the quantities that are calculated with this method (See, Save Forecasting). Warning: You should mark the Select as Forecasting Method option separately for every inventory or inventory group. In this way you will be able to use different methods that best suit different inventories or inventory groups Statistics MSE This is the average of the squared values of the differences of the forecasted values and the actual data. The more accurate the forecasts, the smaller are the differences. Thus MSE should be expected to be closer to zero. The method that displays the smallest MSE value is the method with the best forecast. AIC This comparison method also includes the number of parameters that are calculated in MSE and used in the model. It is more accurate and reliable comparison model than MSE. The AIC s of suitable models are expected to be close to zero Save Forecasting After you select on the Codes that will be Forecasted window (see, Select Codes that will be Forecasted) the inventories or inventory groups, for which you want to run a forecast, (see, Run Forecasting) then select the best suited

38 method among the displayed graphics, (see, Forecasting Graphics/ Select as Forecasting Method) you can use this button on the toolbar to save the quantities forecasted according to the period intervals (e.g., monthly, quarterly, etc. see, Forecasting Parameters Definition Operations) between the forecast start date (see, Forecasting Options / Forecasting Start Date) and the latest forecast date. The programme allows manual modifications of saved forecast values before the data is transferred to the budget (see, Forecast Modified Display). Warning: The start date of the forecast is the first period that commence after the end date of the actual data (e.g., the following month). But the start date of the records is the date that you specify in the Forecasting Options / Forecasting Start Date. The end date of the forecast is the last date counting the number of periods which you specified in the Forecasting Options / Forecasting Period Number. The end date of the records is the same as the end date of the forecast. Example: Let us assume that Forecasting period type is selected as Monthly. The forecast is run in October The actual data preparation operation involves the years 2004 and The actual data en date is October If the forecasting start date is specified as 01/01/2006 and the Forecasting Period Number as 12, then the forecast will be run for 12 months between 11/2005 and 11/2006. The records will be generated for the period between 1/2006 and 11/ Forecasting Options Forecasting Start Date This is the start date, which the programme considers when sending the forecast to the forecast records. Warning: The forecast starts as of the date on which the actual data ends. But you can specify a later date and start your records after the forecast start date (See, Save Forecasting). Forecasting Period Number This is the time defined in periods for the term, which you want your forecast to cover starting as of the date on which the actual data ends (see, Forecasting Parameters Definition Operations / Forecast Value Period Type). Trend Inclination Factor In methods that involve trends, this is the % factor you can use to soften abrupt inclinations (rising or declining). The trend inclination is reduced at the ration you indicate (see, Supported Methods). Reset Negative Values If, according to the selected method, the forecasted values drop below zero, then you can use this function to reset these values (see, Supported Methods). Exclude Deviating Values You should select this option in order to run the forecasting without considering the values that fall below or above the standard deviation value

39 when using forecasting methods. This is the value in periods that is counted backwards to calculate the average in the Moving Average Method, Forecast Modified Display This window is the window where you can view the forecast data that is prepared in the Run Forecasting section and modifying the data if necessary (see, Run Forecasting). Cumulative Code This is the option you can select with the purpose of modifying the any forecasted value in the inventory cumulative information field in the parameters (see, Forecasting Parameters Definition / Cumulative Info). You can use the lookup to select the cumulative codes for which forecast data are generated. Grid Usage The grid will display the forecasts for the selected code in terms of years, periods within the year (e.g., months if selected monthly, Q1, Q2, Q3 and Q4 if selected quarterly, etc. see, Forecasting Parameters Definition / Forecast Value Period Type) and the forecasted sales quantity information. When you drag your mouse on the forecast quantity cell and press the Enter key, you can switch to the modification mode and modify the value in the cell. Save and Cancel Buttons You can use these buttons to save and cancel the modifications you made. If you close the window without saving, the modifications you made will be lost Forecast Inventory Distribution

40 This operation transfers the forecasted data that is created in the Run Forecasting section (see, Run Forecasting) to the budget table after the viewing and modification operations are completed (see, Forecast Modified Display). If, in the cumulative code section, you have defined a cumulative code besides the inventory code (see, Forecasting Parameters Definition / Cumulative Info), then the operation will generate the budget values by distributing the forecasted quantities among the inventory codes related to this cumulative code. The forecasted quantities will be distributed among the inventory codes according to the ratio between the actual sales values of the inventories related to the cumulative code and the total actual sales. Group Code Range This is the option by which you can define an interval in order to filter the budget transfer operation according to the cumulative code interval. You can use the lookups to get the cumulative codes for which forecasts are calculated. OK and Cancel Buttons The OK button creates the budget values from the forecast data and the Cancel button quits the operation. 2.9 MPS Planning Operation Converting Forecast Quantities to MPS Periods Forecast quantities that are calculated with forecasting operations are created according to the period basis that you define in the Forecasting Parameters. This period may be different than the period of the Main Planning Scheme. For example, the forecast quantities can be created monthly while the main planning scheme is weekly. With this operation, the programme converts the forecast quantities calculated for the related forecast periods into Main Planning Scheme periods and generates the forecast quantities, which will be used in MPS. Even if the forecast period is the same as the MPS period, you have to run this operation in order to reflect the forecast quantities, which are created in the forecasting operations, to the MPS. When you run this section, the programme deletes the MPS records that were previously generated for the related period and recreates the records with the new data. At the end of the operation, the forecast quantities that are determined for the forecast periods are converted into MBP periods.

41 When calculating the forecast quantities for MPS, the programme considers the Plant Work Calendar (see, MRP/ Calendar Definitions / Plant Work Calendar). The MPS forecast quantities cannot be generated unless you have specified the definitions in the Plant Work Calendar. To be able to include the days on the calendar in the working days of the related period, the number of shifts has to be different than 0 (zero). When calculating the working days, the programme adds 1 additional day to the working days, if the number of shifts is greater than 1. For example, if the forecasted quantities in the forecasting operations are monthly and the MPS period is weekly, during the conversion the system will first divide the forecasted quantities into the total working days in the related months and calculate the daily forecast quantities. As explained, the working days calculation is based on the Plant Work Calendar. For example, if the forecast quantity for January is 1000 and the total working days in the same month are 20, the forecasted daily sales quantity will be calculated as 50 (1000/20). The programme then calculates the working days in the first week. If, for example, there are 4 working days in the first week, then the forecast quantity for the 1 st MPS period is calculated as 200 (50*4). Starting Date This is the field where you specify the start date of the period for which the MPS forecast quantities will be calculated. Active Starting Date The conversion will be calculated as of the next day of the starting date. When the operation is initiated, the programme displays the actual (active) starting date in this field. For example, if the Starting Date is , then the Active Starting Date will be Generating MPS Charts of Inventories This operation is used for calculating the MPS and ATP (Available to Promise) quantities by using the forecast quantities that are calculated in the Converting Forecast Quantities to MPS Periods operation. The following information is considered in this calculation: the total order quantities, minimum inventory level, parametrically maximum inventory level, (see, MRP / Parameters / Main Production Scheduling), lot size (inventory planning records, lot size), previous period s inventory onhand quantities and capacity information.

42 The forecast quantities must be converted into MPS periods before the operation is started (see, Converting Forecast Quantities to MPS Periods). You can view the values, which are created with this operation, in the Monitoring/Updating MPS Information section Monitoring/Updating Forecast Quantities This is the menu that you can use for viewing and modifying the forecast quantities calculated by running the Converting Forecast Quantities to MPS Periods operation. The MPS forecast quantities calculated for the selected inventory will be listed by periods. If you modify the forecast quantities in this section, the programme calculates the MPS and ATP quantities in the Monitoring/Updating MPS Information section according to the quantities you modified in this section Monitoring/Updating MPS Information This is the menu you can use for viewing and, if necessary, modifying the values which are calculated by running the Generating MPS Charts of Inventories operation Inventory Filter and Ordering Definitions

43 This tab is used for defining filters for the inventories of which the MPS information will be monitored/modified. Start Date This is the field where you can specify the date as of which the MPS information will be monitored. Filter is the section where you should define the filters that you wish to apply to the inventories that will be listed on the Inventory MPS Information page by using the inventory fields. In the aboveshown example, only the inventories with group code SAMPUAN can be viewed in the Inventory MPS Information Inventory MPS Info. This tab is used for monitoring or modifying the values, which are calculated by running the Generating MPS Charts of Inventories operation. In this section, the MPS information is displayed according to the periods that are defined in the selected inventory and the MPS parameters. All of the inventories that match the filter criteria defined in the Inventory Filter and Ordering Definitions tab will be listed on the left hand side of the window. You can also use the lookup in the Inventory Code field to get the list of these inventories. The period number applicable for the MPS information is displayed in the column title of the related information. To view the dates that are covered by the related period, you can also drag your mouse on any one of the information cells in the related column. The Date Interval information will be displayed at the bottom of the window.

44 Save Values Some of the information displayed on this page can be modified by users (e.g., Forecast Quantity). In this case, you can either have the programme recalculate the MPS quantities according to these updates (see, Reflect Changes to Window) or you can keep the previous values without considering the modifications (see, Recreate MPS Values). This button is used for storing either the values that are recalculated according to the modifications or the MPS values calculated before the modifications are entered. When you press this button, the programme saves the values that are displayed on the screen. When you later open this window, you will view the last saved values. Reflect Changes to Window If you modify the values related to the inventories when you are in the Inventory MPS Information tab (e.g., Forecast Quantity), you can use this button to reflect the changes to the window and recalculate the MPS Quantity, Inventory Balance Quantity and ATP Quantity values. This button recalculates the modified values only for viewing purposes. To save the recalculated values, you should use the Save Values button. Recreate MPS Values When you modify the MPS information of inventories on this page and press the Reflect Changes to Window button, you can view the information related to the modified MPS. If, however, you want to view the previous unmodified values, you can use this button. Inventory Code You can select the inventories for which you want to view the MPS information in the Inventory Code field on the upper left side of the window. You can also use the inventory code list to select the same inventory codes. Only the

45 inventories that match the filter criteria defined on the Inventory Filter and Ordering Definitions page will be displayed in the Inventory Code List. Forecast Qnty. This is the section that you can use for monitoring/ordering the forecast quantities that are calculated by the Converting Forecast Quantities to MPS Periods operation or are created by using the Monitoring/Updating Forecast Quantities menu. This value gives the forecasted sales quantity for the related period. The Quantity Information field will be active when you double-click on the entry and allow you to write in any quantity as necessary. In order to recalculate the MPS values according to the updated quantities, you should successively first press the Save Values button, then the Recreate MPS Values button. Forecast Modified Qnty. This is the field where the programme brings the information of the quantity, which should be added to the forecast quantities. The Modified Quantity is calculated in two cases. The first is when the order quantity that is recorded in the related period is greater than the forecast quantity. The second is when the inventory balance quantity calculated for the related period is greater than the maximum inventory quantity. In these cases, the modified quantity is calculated as exemplified below. This field cannot be modified. New Forecast Quantity This is the field where the programme automatically inserts the values that are recorded in the Forecast Quantity and the Forecast Modified Quantity rows. The information in this field cannot be modified. Total Order Quantity This is the field where you can view the quantity information in the recorded orders while the MPS calculation is processed. The Total Order Quantity will not be updated during the order records; this information will be equal to the actual order quantity only when the main production scheduling is processed. For example, let us assume that on 05/07/2006 the customer order balance for a certain product is 100 units. When you calculate the MPS quantity on this date the programme will assume that the Total Order quantity is 100 units and calculate according to this value. Then, on 06/07/2006 you enter an order for 50 units of the same product. If you view the value in this field before you calculate the MPS quantity (see, Generating MPS Charts of Inventories and Recreate MPS Values), you will not see the actual order quantity (100+50=150), but the order quantity that was considered in the previous calculation. However, when you process the MSP calculation, the programme will update the total order quantity and display 150. Current Order Quantity This is the section where the order quantity, which is calculated in the system for the related period, by also considering the orders that were recorded after the MPS calculation is made. If the quantity information in this field is different from the Total Order Quantity, the Current Order Quantity will be displayed in red colour. For example, when the customer order balance for a product is 100 units on 05/07/2006 and you calculate the MPS quantity on the same date, the programme will consider the total order quantity as 100 units,

46 and calculate over this value. When you enter an order for 50 units of the same product on 06/07/2006 and view the MPS information, you will see that the Current Order Quantity is displayed as 150 in red. New Order Quantity While in the Customer Order records operation, you can retrieve this window with a shortcut key and enter order quantities on period basis. You should use the New Order Quantity field the record your new order quantities. Minimum Onhand In this row, the programme automatically inserts the minimum quantity, which you enter on the Inventory Planning Records/ Planning-2 page. Users are not allowed to modify the minimum inventory quantities on this page. Maximum Onhand In this row, the programme automatically inserts the maximum quantity, which you enter on the Inventory Planning Records/ Planning-2 page. In order to enable the programme to consider this quantity information in the MPS calculation you must first select the Consider Maximum Inventory Onhand While Calculating MPS Quantity parameter on the MRP/Parameters /Main Production Scheduling page. Selecting this parameter will prevent the Inventory Onhand Quantity, which is calculated according to the MPS quantity, to exceed the maximum inventory balance. Users are not allowed to modify the maximum inventory quantities on this page. Lot Size In this row, the programme automatically inserts the lot size, which you recorded in the Inventory Planning Records, for the related inventory. Lot size quantity defines how many units each production group can consist of at the minimum. In the case that the lot size information is available, the MPS quantity will be calculated as multiples of the lot size value. MPS Quantity This is the main production scheduling quantity that is calculated with the Generating MPS Charts of Inventories operation. The MPS calculation varies according to different conditions. The calculations according to these different conditions are described in the below-given examples. Inventory Balance Quantity This quantity is calculated by subtracting the related period s new forecast quantity from the total of the MPS quantity and the previous period s inventory onhand quantity. ATP Quantity This quantity is the sellable inventory quantity that is calculated by subtracting the related period s order total from the total of the Modified Forecast quantity and the previous period s inventory onhand quantity. The calculation methods for MPS Quantity, Inventory Onhand Quantity and ATP Quantity according to this information are explained in the Extras / Calculating MPS Values section (See, Extras / Calculating MPS Values) Graphical Display

47 This section displays in graphic format the values that are recorded in the Inventory MPS Information Transferring MPS Info to MRP MPS involves only the production planning for products. The components that are required in the production of these products are not planned in MPS. In order to be able to manufacture the products in the quantities calculated in MPS, you need to plan also for the required materials. Thus, this operation sends MPS quantities to MRP and calculates the material requirement by running the MRP.

48 In this operation the programme sends to MRP only the planned quantity information related to the defined date interval. It is also possible to define filters for the products that you want to send to MRP by defining filters for the inventory fields in the Filter section Capacity Calculating When you select the Consider Factory Capacity While Calculating MPS Quantity parameter on the MRP/Parameters /Main Production Scheduling page, the programme considers the capacities of the stations that are recorded in the bill of materials while calculating in MPS, and creates the production plan accordingly. The capacity information is stored cumulatively on stations bases. In case there is mismatch with the capacity information used in MPS, this operation is used in order to recalculate the cumulative capacity values. This operation can be processed only by the user who is authorised as the Administrator Parameters MRP I Create purchase requisition instead of Purchase Orders for MRP

49 Supplier orders can be generated by using the MRP / Generate Orders operation with the purpose of meeting the raw material requirements specified in MRP. If, however, companies trace their purchasing processes beginning with the request/proposal stage, they should first receive the request before they generate the order. If you select this parameter you will be able to generate purchase demands instead of orders by using the MRP / Generate Orders operation. Revision follow-up for MRP at Purchase Order? If you have agreed over a periodic order system with your suppliers, then you can use this parameter to organise the supplier orders that are generated in the MRP results according to this system. In order to do this you should use the revision application for the supplier orders in the Invoice Module. When you select this parameter, the programme revises the orders that are stored in the system according to the order revision logic. Man. Order and Planning Based on Order/Product After calculating the material requirement in the MRP Module, it is possible to create manufacture orders according to products and orders. To be able to do this, you should select the Manufacture Order and Planning Based on Order/Product parameter in the MRP / Parameters section. In this case, in the manufacture orders of the semi products you will be able to monitor the order and product for which the semi product will be manufactured. You can view the orders that relate to the manufacture of semi products and products in the Order No field on the manufacture order record. And in the Ref. Man. Ord. No. field you can view the information about the products for which these semi products will be manufactured. When this parameter is selected, the programme inserts the product s manufacture order number in the Ref. Man. Ord. No. field. Man. Order and Planning Based on Order Rows If, in a customer order, the same inventory is entered on more than one row, then the system adds these quantities and considers the total for these entries in preparing the material requirement plan, and opens a single manufacture order for the related order. If, however, the Manufacture Order and Planning Based on Order Rows parameter is selected, the system counts all of the rows in the customer order individually, hence plan separately for every row and create separate manufacture orders for these quantities. For example, if the same inventory is recorded twice in the same order with different delivery dates, then it is possible to create two separate manufacture orders according to their delivery dates. To activate the Manufacture Order and Planning Based on Order Rows parameter, you should first select the Manufacture Order and Planning Based on Order/Product parameter. In order to enable order row-based follow-up, the system queries the Ord. Cont. Field on the Material Requirement Planning and Manufacture Order windows. This field shows the inventory s row sequence on the order that is indicated in the Order No field. This feature enables you to create separate manufacture

50 orders for the inventory items that are repeated in the same order and further separately plan for each of these entries. If this parameter is not selected, the programme does not insert a sequence number in this field. Modification While Generating Man. Ord. from MRP If you have created a manufacture order according to the results that are generated in MRP operation for a specific time interval, then when you run the MRP again for the same time interval, the programme can process the necessary updates on the manufacture orders. This function saves users from having to delete or modify one-by-one the manufacture orders that are previously created by the programme in the Production Module. In order to enable the programme to run in the above-explained way, you should first select the Modification While Generating Man. Ord. from MRP parameter in the MRP / Parameters section. If this parameter is not selected, then you will be required to individually delete or modify the manufacture orders that are previously created according to the former plan. When this parameter is selected and you press the Initialize Manufacture Orders button while in the Generate Manufacture Orders operation, then the system resets the quantities of manufacture orders related to the previously processed MRP. Supplier Determination Method at MRP Generation At the stage of placing supplier orders for the components that are generated by the Material Requirement Planning, there are two different ways that you can specify the suppliers with which you place the orders. These are the Distribution Rates and Priority/Capacity options. If, in the Parameters section of the MRP Module, you select the Distribution Rates option in the Supplier Determination Method at MRP Generation parameter, then the programme understands that it should consider the values that are recorded in the Order Ratio field of the Customer/Supplier Inventory Records section to determine the supplier with which the order will be placed. In this case, if we assume that you purchase a certain raw material (e.g., RWM1) from three different suppliers (e.g., supplier accounts 001, 002 and 003), then the programme verifies the Customer/Supplier Inventory Records to determine the appropriate supplier. Let us assume that the records for RRWM1 display the following information. Supplier Code Order Rate If, in the MRP, the required order quantity for this raw material is specified as 1200 units, then the MRP results will be as follows. Inventory Code Supplier Code Order Qnty. RWM *0,4 RWM *0,35 RWM *0,25

51 If, however, you have selected the Priority/Capacity option in the Supplier Determination Method at MRP Generation, the programme considers the Priority information recorded in the Customer/Supplier Inventory Records and the information in the Capacity fields that are recorded in the window which will be displayed if the parameter is selected, and then determine the supplier/s with which the order should be placed. If the inventory should be supplied for more than one supplier, when you create the supplier order in MRP, you should specify in the Priority field the supplier with highest priority. In order to be able to place the order with the priority supplier, the related supplier should have the adequate capacity for the related period. You should enter the supplier s capacity in quantity in the Capacity field. You should also select in the Capacity Period Type, the period for which this capacity is applicable. You can select any one of the Daily, Weekly, Monthly, Quarterly or Yearly options as the Capacity Period Type. Let us assume that the below-given priority and capacity information is recorded according to suppliers in the Customer/Supplier Inventory Records for raw material RWM1. Supplier Code Priority Capacity Period Capacity Type Monthly Weekly Daily 30 Let us further assume that the MRP result for the given inventory is as below. Inv. Code Req. Qnty. Notify/Prod. Date Req. Date RWM If no orders were previously placed for this inventory, then the programme generates the orders to the following suppliers according to the priority and capacity sequences: first 90 units to supplier code 003, then 70 units to supplier code 001, and then 100 units to supplier code 002. Since supplier code 002 s daily capacity is 30 units and you place the order 4 days before the delivery date, supplier 002 s actual capacity in the related period will be 120 units. If later, you need to place another order for RWM1 for the related period, since suppliers with the 1 st and 2 nd priorities do not have sufficient capacity, you can place an order of 20 units ( ) with the 3 rd priority supplier. Factory Order for MO at MRP Generation The programme is designed to verify the plant work calendar when determining the requirement dates of semi products and products when processing the material requirement planning operation. Accordingly, the programme assumes that there will be no production operations on the days that display 0 (zero) shifts and does not include these days in the planning. Thus, the application runs in the below-described way if this parameter is selected: The Bill of Materials is,

52 P1 SMP1 RWM1 RWM2 The manufacture times given for P1 and SMP1 in the Inventory Planning Records are 5 and 3 days successively. A customer order is recorded for P1 for the date If the plant work calendar is not taken into consideration, then the result for the above-given manufacture will be as follow. Inventory Code Notify/Prod. Date Req. Date P SMP If, however, the plant does not work on weekends, public holidays or holidays special to the company, this result can be quite misleading. Hence, to be able to plan more accurately, in the MRP/Calendar Definitions/Plant Work Calendar section you should indicate the shifts on non-working days as 0 (zero). In this case, when determining the manufacture start date (notify date), the programme will not count the non-working days. If the notify date coincides with a non-working day, then the programme shifts the production to an earlier date. In the above example, in order to be able to deliver P1 on , the production should start on (production time: 5 days). But since and are weekend days, production should start on When the number of shifts for the non-working days is indicated as zero, the MRP operation gives the following result. Inventory Code Notify/Prod. Date Req. Date P SMP Factory Order for Supplier Orders at MRP Generation The programme is designed to verify the company s general calendar or the calendars that are defined according to suppliers when determining the order dates of the raw materials when processing the material requirement planning operation. Accordingly, the programme assumes that there will be no activity on the days that are defined as non-working days in the calendar and does not plan any order transactions for these days. If the notify date coincides with a day, which is defined as a non-working day on the related supplier s calendar, the programme plans the order for the previous working day.

53 When this parameter is selected, the application runs in the below-described way: The Bill of Materials is, P1 SMP1 RWM1 The production times for P1 and SMP1 are as given in the above example. There is a customer order due on for the product (P1). The raw material RWM1 is purchased from supplier code 001. The notify/production time of the supplier is 3 days, and the supplier s calendar is as shown below. September 2006 Mon Tue Wed Thu Fri Sat Sun The weekends are shown in yellow on the calendar. The days highlighted in grey are the days, on which the supplier runs its annual maintenance, are thus defined as special non-working days. Case 1: Factory Order for MO at MRP Generation = Selected Factory Order for Supplier Orders at MRP Generation = Not Selected Inventory Code Notify/Production Date Requirement Date P SMP RWM If the programme does not verify the supplier s calendar, then it does not consider the non-working days of the supplier when determining the notify date, and assumes that the supplier will produce on these dates. In the above-given example, the programme will create the supplier order for although this is a Saturday. Case 2: Factory Order for MO at MRP Generation = Selected Factory Order for Supplier Orders at MRP Generation = Selected

54 Inventory Code Notify/Production Date Requirement Date P SMP RWM In this example, the programme verifies the supplier s calendar and calculates the notify time by going three days back from the requirement date MRP II Advanced Production Planning You will be able to use this section when the Advanced Production Planning parameter is selected in the MRP II tab of the MRP Module/Parameters section. The Advanced Production Planning tab will be created when you select this parameter. Shift-1, 2, 3 Start This is the field where you should enter the starting times and the durations according to the shifts. The total work times for every shift are used in calculating the standard capacity. The standard capacity will be calculated as zero if you do not enter the times in this section. Shift-1, 2, 3 Employee Count In this field you should enter the number of employees that will work on maximum three shifts. Time Unit The units for the values that you enter in fields that involve timings, such as production time, setup time, transit time in the Work Center Definition, Operations Catalog and the Machine Definitions operations, are determined according to the parameter you select in this section. If entering hours for the times shall raise problems due to the existence of smaller values, you can also specify the units in minutes. The results may be reported in both hours and minutes. If you select Minutes as the Time Unit, then the system assumes that the value of 5 that you enter in the production

55 time field means 5 minutes and includes this value in capacity planning. The shift times and employee counts are default values for entities. These should be redefined in the related sections according to workstations and days Main Production Scheduling Parameters for forecasting operations can be defined in the MRP Module/ Records/ Parameters menu option, Main Production Scheduling tab, Forecasting Parameters section. Forecast Value Period Type This information is related to the time period of the forecast. You can run daily, weekly, monthly, quarterly or yearly forecasts. For example, if you select the Monthly option, the programme considers the monthly cumulative sales quantities and calculates monthly sales forecasts. In the same way, when you select the quarterly option, the programme considers the four quarters, every 3 months of the year and calculate sales forecasts by quarters. Cumulative Info This field queries the inventory information, according to which you want to cumulate the past inventory sales quantities. Hence, the sales forecasts will also base on this information. If, for example, you indicate the group code field in this parameter, the programme will cumulate the past sales quantities data for the above-given intervals according to group codes. Thus, the forecast will also be calculated according to group codes. This cumulative operation option was designed since forecasting and budgeting according to inventory codes may be too detailed for some organisations. In the transition from forecasting operation to main production scheduling, however, the system will breakdown the grouped forecasts according to inventory codes.

56 You can select any of the inventory code, group code, code1 code5, inventory code+structuring code options. 3. Operations 3.1 Generate Requisition 3.2 Generate Orders

57 This is the section that enables the automatic transfer of the supplier order records that are created for raw materials to the Supplier Orders after you run the Material Requirement Planning operation. You should run this section after you list the planning records and confirm the placement of supplier orders. The start and end dates will be inserted in these fields as the date intervals of those records that you wish to transfer from the list that is created in the MRP section. If you press the Confirm One-by-One key, the programme displays the materials list for which orders will be created, and allow you to confirm those that you wish to transfer to the supplier orders. If you do not press this key, then the programme transfers all of the material records as a whole without asking for confirmation. If the notify or loading date is overdue for any one of the orders, then the programme selects the Delayed Notification or Delayed Loading parameters for this order and does not create a supplier order. If, in the material requirement planning records, the programme does not identify any records, for which orders should be created, or any records, which were inserted for the specified time interval, then the system displays a warning window and does not run the operation to generate orders. Note: To be able to monitor and follow-up the supplier orders that are generated in this section, you should have selected the Order Follow-up parameter in the Invoice/Records/Purchasing Parameters section and be using the supplier orders function. You should enter the supplier codes and the order ratios related to the inventories in the Customer/Supplier Inventory records section, as explained in the Material Requirement Planning section. In the case that

58 you are purchasing the material from more than one supplier, you should distribute the order quantities among suppliers by using the order ratios in the Customer/Supplier Inventory Records section. If, however, you are working with a single supplier, then you can either indicate the order ratio as 100 in the Customer/Supplier Inventory records section or you can use the Current Account/Supplier Code field in the inventory card. 3.3 Generate Manufacture Orders This is the section that enables the automatic transfer of the manufacture orders that are generated for products and semi products to the Manufacture Orders section after the Material Requirement Planning operation. You should run this section after you list the planning records and confirm the placement of manufacture orders. The start and end dates will be inserted in these fields as the date intervals of those requirement records that you wish to transfer from the list that is created in the MRP section. If you press the Confirm Oneby-One key, the programme displays the materials list for which manufacture orders will be created, and allow you to confirm those that you wish to transfer to the manufacture orders. If you do not press this key, then the programme transfers all of the manufacture order records as a whole without asking for confirmation. If, in the material requirement planning records, the programme does not identify any records, for which manufacture orders should be created, or any records, which were inserted for the specified time interval, then the system displays a warning window and does not run the operation to generate manufacture orders.

59 When the Modification While Generating Man. Ord. from MRP parameter is selected in the MRP parameters, and you press the Initialize Manufacture Orders button in the Generate Manufacture Orders section, the programme resets the manufacture order quantities of the previously processed MRP operation. The programme displays the below-shown warning window when you press the Initialize Manufacture Orders button. If you press the Yes button on this window, the programme considers the below given aspects and process accordingly. If the manufacture order is already partially produced, it will not initialize the manufacture order. It will modify the manufacture order according to the produced quantity. If the new quantity required according to the new MRP is less than the quantity consumed from the manufacture order, then it will record the manufacture order quantity as the used quantity. For example, a manufacture order for 10 units is generated at the end of the first MRP, and 6 units are produced in connection to this manufacture order. Even if the requirement is 5 units according to the new MRP, the programme will modify the manufacture order quantity as 6 units because 6 units were previously produced with this manufacture order. If some of the inventories are omitted from the MRP, then the programme modifies the manufacture order quantity for these inventories as 0 (zero). If production was made for the inventory, which is omitted from the MRP, in connection to the manufacture order generated by the previous MRP, the programme will update the manufacture order quantity according to the quantity produced. For example, the requirement for a certain product is 30 units at the end of the first MRP and 10 units were produced in connection to the manufacture order. Even if this inventory is omitted from the second MRP, when updating the manufacture orders, the programme will modify the quantity field for this inventory as 10 units.

60 If the total quantity for the manufacture order was produced, then the programme will not process any modifications for that manufacture order. 3.4 Production Plan Preparation This option is for generating the product requirements, which can constitute the basis of material requirement planning. To do this, deliveries for customer orders have to be identified according to their dates. Date Interval This is the time interval of the plan records that will be generated. The programme deletes the plan records that are recorded for this time interval and generates new records. Daily / Base Date This information specifies whether you want to plan the customer orders for their individual delivery dates or plan all deliveries within a certain period for a single delivery date. Base Date If plans are prepared in specific periods, this is the date to be recorded for the related plan records. Example: Let us assume that you get the below-listed customer orders. Delivery Product Quantity Date 01/08/2003 P1 10 units 03/08/2003 P1 12 units 06/08/2003 P1 8 units

61 11/08/2003 P1 14 units If you process your plan Daily, then the above-given records will be generated in Planning as is. With the Base Date you can prepare your plan in several ways. If you are preparing the plan for 10-day periods, you should run the Production Plan Generation section twice for the above-given records and enter the following parameters. 1. Date Interval: 01/08/ /08/2003 Base Date: 01/08/ Date Interval: 10/08/ /08/2003 Base Date: 10/08/2003 In this case the planning records will be as follows. Date Product Quantity 01/08/2003 P1 30 units 10/08/2003 P1 14 units If you are preparing the plan for 1-month periods, then you should enter these parameters when running the Production Plan Preparation operation for the above-given records. Date Interval: 01/08/ /08/2003 Base Date: 01/08/2003 In this case the planning records will be as follows. Date Product Quantity 01/08/2003 P1 44 units All Products / Order Balance If desired, you can record all of the products for a single base date in the planning entry. This option may be preferred by organisations that deal with a big variety of products in order to avoid the task of manually entering every product. Order No. Range If you want to include in the plan only a certain part of the customer orders, then you can use this section to specify an order number range. In this case, in the plan entry section, the programme generates only the product requirements for the orders that fall in the given interval. Order Based Refraction You should select this parameter if you want the programme to prepare the requirement plan for every product separately according to customer orders. Otherwise the programme generates the product s requirement quantities in total, without considering the order details for every product. The aboveexplained daily/base date query is a determinant in this option.

62 Example: Product Code Ord. Deliv. Date Ord. No Ord. Qnty. PP PP PP PP PP If you select the Order Based Refraction option and chose Daily: Product requirements will be generated with the details shown in the abovegiven table. If you DO NOT select the Order Based Refraction option and chose Daily: The requirement quantities will be generated as below. 10 units of PP units of PP1 25 units of PP2 22 units of PP2 If you select the Order Based Refraction option and chose Base Date: The requirement quantities will be generated as below. Base Date: units of PP units of PP units of PP units of PP units of PP2 If you DO NOT select the Order Based Refraction option and chose Base Date: The requirement quantities will be generated as below. Base Date: units of PP units of PP2 3.5 Generate W.House Transfer from MRP Results

63 After you generate the material requirement report, if some part of the product will be supplied from the inventory onhand quantities, then you can use this section to transfer these product, semi product and raw material inventory onhand quantities to another warehouse. This is not a standard operation for the MRP application. To be able to use this application you should first select the Local Warehouse Application parameter in the Inventory Module. When you press the OK button in this section, the programme generates the Warehouse Transfers vouchers in the Invoice Module. Number This is the Number of the Warehouse Transfer Voucher, which will be generated. The programme inserts the number that is subsequent to the last voucher number recorded in the Warehouse Transfers section. In W.Hs. Code This is the code of the warehouse to which the portion of the requirement quantities (that will be supplied from the inventory onhand) will be transferred. The warehouse code, which you enter in this field, must be previously recorded in the Inventory Module/Local Warehouse Definitions section. Out W.Hs. Code For product, semi products and raw materials, this is the code of the warehouse from which the portion of the requirement quantities (that will be supplied from the inventory onhand) will be transferred to another warehouse. The warehouse code, which you enter in this field, must be previously recorded in the Inventory Module/Local Warehouse Definitions section. Date This is the date of the transfer voucher, which is generated for the warehouse transfer. Cumulate Inventory

64 If in the plan, some of the products, semi products or raw materials are entered several times, then you should select this is the parameter to transfer these in their total quantities from the warehouse. Project Code This field is active when the Project Application parameter in the Auxiliary Module/Company Branch Parameter Definitions section is selected. When you enter the project code in this field, the programme inserts this code on the warehouse transfer voucher. You must first define the project codes in the General Ledger Module/Project Code section. 3.6 Store/Load Production Plan You can use this operation for storing the production plans, which you previously generated in the Material Requirement Planning section according to dates or by running the Production Plan Preparation operation under their revision numbers, and later retrieving/reloading them when necessary. Every time you run the Production Plan Preparation operation, the system clears the information recorded on the existing plan and replaces this information with the new entries. Companies that wish to keep the information in these plans should select the Save option to store their plans. The programme numbers the revisions starting with 1. You can also record the plans by dates or in alphabetical order. When you want to retrieve the plan you should select the Load parameter and specify the related revision number in the lookup and press the OK button. At the end of this operation, the programme transfers the product requirement recorded in the revision to the plan record. 3.7 Minimum Inventory Value Calculation According to MRP Results 3.8 Capacity Planning

65 This operation makes the calculations that are necessary for identifying the requirement capacity and prepares the Capacity Table. You can process the calculation according to either the product/semi product requirements generated by the Material Requirement Planning or the existing manufacture orders or the total capacity requirement that includes both of these options. The Capacity Table includes the capacity requirement information for the required production quantities according to the date, product code and operations. You can get the data that is generated in this operation in the MRP/Reports/Capacity Report section Definitions Required for Generating Capacity Planning The operations that need to be processed in the Capacity Planning operation and the results this report generates are described in the examples below. Let us assume that you produce a product with three operations. In this case, you should define the following: Workstations Workstations are your plant s production centres, each of which consists of production units (machine/worker) that are responsible of their own operations and process the similar operations. Example: STA1 : Washing Station. 1 machine. STA2 : Drying Station. 1 machine. STA3 : Fixing Station. 1 worker.

66 Operations These are the operations that are conducted during the product s manufacture. To simplify the issue, let us assume one operation for every workstation. Example: OP1 : Washing. OP2 : Drying. OP3 : Fixing Bill of Materials (Routing) To be able to plan the capacity, you should first define the routing. The routing is the operational bill of material for a product or semi product. The product s operation sequence (routing) is defined in the Production/Bill of Materials section. Let us define our product tree as below: Example: --- P SP1 1 unit RM1 1 unit RM2 1 unit OP OP OP Production Time This is the time required for the production of one unit in every workstation. It is defined according to every operation. If desired, you can also modify the routing definition on product basis for the same operation. Example: OP1 is 2 HOURS, OP2 is 1 HOUR, OP3 is 0.5 HOUR Requirement Capacity This is the capacity required for the production of the product in the defined quantity. Example: For the every unit of product P1, for which the routing is given above, SP1 RM1 1 unit

67 RM2 1 unit OP3 0.5 hr Total 0.5 hr P1 SP1 1 unit OP1 OP2 Total 0.5 hr 2 hrs 1 hr 3.5 hrs capacity required. If 100 units of P1 shall be produced, then Requirement Capacity is calculated as = 100 * 3.5 =350 hrs Current Capacity This is the plant s capacity according to the workstations within a given time unit. (Time Unit: may be daily or weekly, Capacity: May be in terms of workstations or the plant in general. These will later be discussed in detail.) Example: Let us assume that the above-described plant works 1 shift per day and every shift works 8 hours. In this case, within a time period of 1 week, Station STA1 STA2 STA3 Current Capacity 56 hrs 56 hrs 56 hrs In order to realise the above-defined production, Station Req. Capacity Curr. Capacity Diff. Capacity STA1 2 * 100 = STA2 1 * 100 = STA3 0.5 * 100 = In the example, we see that there is capacity deficiency in the washing and drying stations while surplus in the fixing station Simultaneous Operation Unit In the example, we can see that there are bottlenecks in the production processes of the machines in STA1 and STA2. Let us assume that you add one more machine to each of these stations in order to increase their capacities. Example:

68 To produce 100 units of P1 in one week, Station Sim. Oper. Prod. Time Req. Cap. Curr. Cap. STA1 : Washing 2 machines 2 hrs (OP1) * 8 * 7 = 112 STA2 : 2 machines 1 hr (OP2) * 8 * 7 = Drying 112 STA3 : Fixing 1 worker 0.5 hr (OP3) 50 1 * 8 * 7 = 56 Dif f. Ca p In this case, there is again capacity deficit in STA1, but the capacity of STA2 is now adequate Working Calendar In the example above, if you run STA2 on 2 shifts per day instead of 1 shift, then you will achieve an operational capacity of 2 machines * 16 hrs/day * 7 days = 224 hrs in order to match the current capacity with the requirement capacity. The working calendars of the plant and the workstations can be easily defined in the Calendar section. In the Calendar section you should define the number of shifts per day. On non-working days such as Sundays and holidays, you should enter zero for the number of shifts. The Capacity Planning operation calculates the capacities of the workstations according to the calendar that you define Setup Time This is the time spent for the one-time operations that performed for every production before initiating the actual production process on the machines. Every machine (simultaneous process) requires this time for once. The process should be defined for every operation (routing). During the requirement planning calculation of operations that require setup times, the extra capacity requirement is calculated as = simultaneous process * setup time. Example: Let us assume that the two drying machines in STA2 in the above-given example each require 2 hours of setup times. In this case the requirement capacity would be modified as below. Station Sim. Prod. Time Req. Cap. Curr. Diff. Op. Cap. STA1:Washg 2 2 hrs (OPR1) 200 2*8*7=1-88

69 mach 12 STA2:Drying 2 mach 1 hr(opr2) 100+(2*2)= 104 2*8*7=1 12 STA3:Fixing hr (OPR3) 50 1*8*7=5 worker Transport Time, Transport Quantity These are the section in which you should define the time and quantity constraints in transiting from one operation to the next one. Constraints may arise due to transport problems. For example, the semi products, which are produced in a certain operation, may need to be first placed in containers before being transported and the containers can contain items up to a certain quantity. When one container is filled it is transported to another section by any vehicle. The container s capacity used here is the transport quantity and the time the vehicle requires to move the container to the other section is the transport time. This information is defined for every operation (routing). The transport time affects the requirement capacity. Example: In the above-given example, if OP2 s Transport Quantity is 20 and Transport Time is 1 hour, then 100 units of product would be transported in 5 trips and would require 1 hr * 5 trips = 5 hours of extra capacity. Then the requirement capacity for OP2 would be: Station Curr. Op. STA1:Wash 2 mach STA2:Dry 2 mach STA3:Fix 1 worker Prod. Time Req. Cap. Curr. Cap. 2 hrs (OPR1) 200 2*8*7= hr(opr2) 100+(2*2)+5= 2*8*7= hr(opr3) 50 1*8*7= 56 Diff If the transport quantity is 1, in other words, if every unit that is produced should be transported to the next operation immediately, the requirement capacity for the transport time would be Transport Time * Production Quantity. If the transport quantity is 0 (zero), this means that all the units can be produced before moving to the next operation. In this case the requirement capacity is equal to the transport time (because the product is transported once) Not using the total Simultaneous Capacity

70 As indicated above, workstations comprise machines/employees that function in the same or similar way and by same or similar capacities. Sometimes, even though there are multiple machines that can perform the same work, the nature of the work requires the operation to be run on limited number of machines. This is a condition that is generally experienced with plastic/metal injection machines. The cause is the requirement to produce with a certain moulding apparatus (on any apparatus) installed on the machine. This is to say that if the apparatus is used on one of the machines, it cannot be used on the other machines due to lack of the special apparatus, which in turn means that the capacity only one machine can be used in the production of that product and the other machines will remain idle even though they have the capacity to operate. In this case, when defining the stations, you should define the number of simultaneous operations equal to the number of machines, but the number of simultaneous operations equal to the number of moulds (apparatuses). Example: Let us assume that in the above-given example you require special apparatus on the drying machines and you have one apparatus for one product. In this case, Station Sim. Oper. Req. Cap. Curr. Cap. Diff. Cap. STA1:Washing 2 machine STA2:Drying 2 machine 109 2*8*7=112 3 (OP2 Drying 1 machine 109 1*8*7=56-53 Opr) STA3:Fixing 1 worker Here, even though the capacity in terms of workstations seems to be adequate, there will in fact be a bottleneck due to the limited number of apparatuses Cost Information If desired, you can define unit labour cost and other unit costs on operations bases. The cost of requirement capacity can be reported as current capacity cost and difference capacity cost. 4. Reports 4.1 Capacity Planning Report

71 This is the reporting option that lists the capacity information that is generated after you run the Capacity Planning operation. It lists the requirement capacity, current capacity and their differences. Date Interval In this field you should enter the date interval of which you want to get the capacity report. Workstation Code Range In these fields you should enter the range of the code that includes the stations of which you want to view the capacity plans. When you specify a certain range, then you will be able to view the capacity report only for the related stations. Operation Code Range In these fields you should enter the range of the codes that include the operations of which you want to view the capacity plans. When you specify a certain range, then you will be able to view the capacity report only for the related operations. MRP / Man. Ord. / All If you select the MRP option in this query, then the programme generates the capacity report in terms of the product and semi product requirements that are calculated by the MPR operation. If you select the Manufacture Order option, then it lists the capacity report according to the requirements of the recorded manufacture orders. If you select the All option, then the programme generates the capacity report according to both the MRP and manufacture order requirements. Term (Day / Week)

72 You can generate the capacity planning report on daily or weekly bases. You should indicate your preference in this option. Reporting Time Format (Minute / Hour) In this field you should define the Time Format in which the report results shall be listed. The times will be listed in minutes or hours according to your selection in this field. Print Cost Info When you select this parameter, the capacity report will include the requirement capacity costs, current capacity costs and the difference capacity costs by considering the unit labour cost and unit other costs according to operations. Report Format (Term Based / Workstation Based) Your report will be generated according to periods or workstations in relation to the option you select in this field. Detail Information (Do not Print / Defectives / All ) This is the report you can use if you want to get a detailed capacity report. If you select the Do not Print option in this section, then the programme lists the report according to workstations and will not show details. If you select the Defectives (those with inadequate capacity) option, then it will list the report according to product details but include only the defective rows. If you select the All option, then the programme will list all of the operations according to the product code details and include all operations both defective and normal. This information can be arranged in several different formats: Format 1 Format 2 Format 3 Format 4 WEEK-1 STATION-1 DATE-1 STATION 1 Station-1 Week 1 Station 1 Date-1 Station-2 Week 2 Station 2 Date WEEK-2 STATION 2 DATE 2 STATION 2 Station-1 Week 1 Station 1 Date -1 Station-2 Week 2 Station 2 Date Weekly Period Based Weekly Station Based Daily Period Based Daily Station Based 4.2 Routing Report

73 This reporting option lists the routings of products and semi products. The report lists the products and the semi products according to their operations (routing). Quantity This is the number of product units for which you want to list the routing report. The report will base the information to be listed on the quantity that you enter in this field. BOM Level (First Level / All Levels) If you select the First level option in this field, the report will be prepared according to only the product routing (operation). If you select All Levels, then the report will also include the routings and components in the lower levels of the product. Add BOMs to List This field will not be active if you select the All Levels option in the BOM Level section. If you select the First Level option in the BOM Level section, then you can also select the Add BOMs to List parameter to get the list of the components along with the product routing. Print Cost Info When you select this query the report will calculate and list the labour and overhead costs according to routings. Reporting Time Unit (Minute/ Hour) This field specifies if you want the time information in the report to be in minutes or hours. The report will be generated according to the following titles: Inventory code, inventory description, quantity, unit, explanation, workstation code, setup time, operation time, transport time, total time, production time, transport quantity, unit labour cost, labour cost and overhead cost.

74 5. Extras 5.1 NEO For production systems that employ discrete manufacturing, Neo is a planning tool that designs optimum production schedules according to specific target functions. The product targets at meeting the needs for detailed planning functions which enterprise resource planning (ERP) tools are unable to fulfil. The NEO comprises planning tools (Planning Suite), communication infrastructure and model creating (Middleware) modules and ERP adaptors. NEO planning tool: This is the component that includes the user interfaces and the business logic that aims at providing data processing and planning functions. NEO communication infrastructure: This is the messaging-based component that processes planning requests and serves as the bridge to the model creating component. NEO model creator: This is the component that creates a mathematical model according to the planning request data, sends this data to CPLEX solver and converts the solver results into planning output. NETSİS adaptor: This component builds the integration with the model creator via the NEO Communication Infrastructure. The Adaptor is used by the NETSİS package. The planning process is initiated with the NETSİS adaptor. The Adaptor prepares the data that will be sent to the model creator as XML files, sends the planning requests to the communication infrastructure, receives the answers to the requests and the planning data and integrates them into the NETSİS database. The planning outputs can be viewed/processed with NETSİS application interfaces NEO Middleware NEO Middleware comprises the communication infrastructure, the Test/Administration Console that is designed to administer and test the communication infrastructure, and the planning model creator (Modeller) modules. The communication infrastructure fulfils the planning request, operation information request and operation deletion request processing functions. Service programmes, which fulfil each of these functions, are available. Middleware receives the operation requests from the message queues and sends the operation results again to the message queue. Microsoft Message Queuing (MSMQ) is used for the message queue.

75 NETSİS - NEO Middleware integration workflow is as follows: NETSİS sends a message to Middleware for the planning request. It generates the required ERP main data (materials, workstations, business plans, suppliers), demands, purchase orders and manufacture orders as a text file in XML format and writes in a location which Middleware can read (Neo Middleware\ Repository\Input Files). The name of the data file is given in the request message. Middleware verifies the data in the Planning data pack and converts it into a relevant data model and sends it to the model creator, then again converts into a data pack in a certain format as a result of optimization and sends back the reply message. It writes the data pack that includes the planning result in a location (Neo Middleware\ Repository\Output Files), which the NETSİS software can read. The name of the data file is given in the reply message. The operation information request and the operation deletion request are read similarly in message queues. Data packs are not prepared for these messages. The messages include the message number of the planning request for which the information or deletion is requested. The result of the operation is sent to the reply message queue with the relevant message code. Middleware uses a different message queue for every type of message (NeoPlanningRequestQueue, NeoInfoRequestQueue, NeoAbortRequestQueue). But sends the reply messages for all of the request messages to the same message queue (NeoResponseQueue). Starting with when the request is read, the whole flow process is logged. Middleware uses the asynchronous log system and sends the log messages to a separate message queue. These messages are read by the log service (Enterprise Library Logging Distributor Service) and written in the log files. The log files are stored under Neo Middleware\Repository\Log Files Neo Test / Admin Console The functions that are required to test and administer the Neo Middleware software are provided by the Neo Test / Admin Console programme included in the Middleware package. This application is installed with Middleware and is added as shortcut to the Programs menu Running the Application To start the programme click Start > All Programs > Neo Middleware -> Neo Test Admin Console. The below-shown main screen of the application (Neo Test Admin Console) will be displayed.

76 Access to the operations that are available in the application is given by the menu at the top of the window. The toolbar right below the menu includes the shortcuts for various functions. You can view the screen tips by dragging the cursor on the related shortcut Message Queues The message queues, which Middleware uses, are displayed on the upper left side of the window. You can click on these message queues to view the messages queued in the in the message list (the list on the upper right side). The colour of the message queue indicates the status of the queue. If the queue name is in blue colour, this means the queue is successfully installed and accessible. If the queue name is in grey colour, the queue either could not be created during the installation or was later deleted. If this problem occurred after the installation, you should uninstall Middleware (Control Panel -> Add / Remove Programs), log in with the Administrator s ID and rerun the installation programme. If the queue is deleted manually, then it should be created manually or reinstalled. To create the queue manually, see the Queue -> Create operation. If the queue name is red, this means that the queue is created but is not accessible. To solve the accessibility problem you can delete and recreate the Queue -> Create operation.

77 If the queue name is green, this means that the queue status in unknown. This occurs when the message queue is remotely created. In the Middleware application queues are created and used locally. To solve this problem, you should create a local queue with the Queue -> Create operation. The messages stored in the message queues can be deleted at the moment they are read. To be able to store the messages, which are deleted from the queue, the queue should be journal enabled. Among the queues used in the application, NeoProcessQueue is journal enabled. The journal of the process queue provides access to the previously processed messages. The Journal related to the NeoProcessQueue is displayed on the screen. When the Journal is selected, these saved messages can also be viewed in the message list Messages The messages in the selected message queue are listed in the messages list. The list includes the Message ID, the time the message is received in the queue and the related message if there is another message associated with this message (for example, a delete message would be related to a planning request message that will be deleted) and the ID of this later message. In the main window shown, NeoRequestQueue is selected and two messages are listed in this queue. When you double-click on a message in the message list or click the View Message Content button on the toolbar, a window, which displays the message content, opens. The content of a planning request message can be viewed in the Request Message Viewer window, the content of a delete request message can be viewed in the Abort Request Message Viewer window, and the content of an information request message can be viewed in the Information Request Message Viewer window. The contents of these windows are described in the related sections below Neo Log Messages The log messages related to the operation status of the service programmes that constitute Middleware are listed in this section. The information included in the list are the Severity level of the message, the time when the log record is created, the Application that sent the log, the category of the log message and the message text. When you double click on a log in the list, a Service Log Viewer window opens. In this window users can view the messages by scrolling with the arrow keys. The messages are listed in the order of the times they are created.

78 Application Warnings and Errors This section displays the warning messages related to the status of the units that are critical in the operation of the Middleware software. Problems in message queues, cases when services are not installed or stopped are the situations when warning messages are displayed. The problems in message queues can be resolved in the Queue menu, and in the case that the services are stopped these can be resolved in the Tools / Service Management menu Services The Neo Middleware software consists of three windows services, namely the Planning Request Processor, the Information Request Processor and the Abort Request Processor. The Enterprise Library Log Distributor Service, which receives the log messages that are created by these services and writes them to the log files, is used for asynchronous log mechanism. These services have to be in operation for the healthy operation of the Middleware application. In cases such as if the application services are not installed or if they are stopped, these cases will be listed in the warning and errors lists in the Test Admin Console. When the Console application is run, if a problem concerning the services is indicated, these services should be run before the testing. To run the services, you should select Tools / Service Management in the menu or click the Service Management button. Then, the Service Management window opens. The application services and their status are displayed in the service management window. You should select the stopped services one by one, click the Start Service button and run the services. If the service does not run or is never installed indicates that problems occurred during the installation. In this case you should uninstall the application and reinstall.

79 Neo Middleware Configuration Middleware software adapts the default values during installation. To be able to run the software with the parameters that are customised according to the needs of the organisation, first the configuration should be updated. Configuration settings can be accessed either by selecting Tools -> Configuration or clicking the Configuration button on the toolbar. The information in the Configuration window should be reviewed and edited. If any modifications are made, the Save Configuration button should be used to save the last update. To be able to run the software with the new parameters, all services should be stopped and rerun General Settings The parameters included in the General Settings page are: Version: This indicates the version of the data files, which Middleware will take into consideration. For a file to be processed by Middleware, the version of that file (version information is given in the data format) has to be the same with Middleware s version. In the sample screenshot, the version is specified as 1.0 (entered as 10). Application Language: This determines the language of the messages sent from the services, the warnings included in the plan output and the test admin application. In this version of the software, the services run in Turkish and English, however the Test Admin application is not multi-lingual. Data Source: Middleware accepts test files in XML format or the database as its data source. This parameter of the configuration determines from which source Middleware shall get the data. To be able to use the database as the data source, the NEO product must be installed together with its planning tool component. Schema Uri: In case Middleware uses an XML file as data source, this shows the location of the schemas (files with.xsd extension) of the XML formats that are used. The schemas are used for controlling the formats of the XML blocks in the file.

80 Log File Path: This is the directory where the log files that are created by Middleware will be saved. During the installation a Repository/Log Files directory is created under the directory where the application is installed. If the configuration is not modified, the files are created under this directory, which is created during installation. Since the log files tend to grow, a location different than the application directory may also be identified in order to avoid disc problems. But the software should be able to directly access the given location. Xml Data Source Path: This is the directory where the XML data files that are created by ERP will be stored in order to enable Middleware to read them. During the installation a Repository/Log Files directory is created under the directory where the application is installed. Middleware uses this directory if the configuration is not modified. Xml Data Destination Path: This is the directory where the planning output (text files in XML format) that is prepared by Middleware will be written in order to enable Middleware to read them. During the installation a Repository/Log Files directory is created under the directory where the application is installed. Middleware uses this directory if the configuration is not modified. Idle Setup Group ID: This parameter is related to the source data content. Idle Setup indicates that no patterns etc are installed in the workstation. It is used for defining the times that are used for loading as necessary the workstation for various operations or for evacuating the loaded workstation. The Middleware setup number, which corresponds to the idle installation, should be identified.

81 Order Id For Make-To-Stock: Customer demands and production orders are also taken into account as inputs for planning. If the customers of these demand and orders are known, then order numbers are sent. This parameter is defined to distinguish between the productions whose customers are unknown and those, which are manufactured for the inventory. Demands whose customers are the company itself are corresponded with these order number in the planning output. Max. number of messages to keep in Process Journal Message Queue: As explained in the Message Queues, the Process Queue, which is the queue to which the message in process is sent, is created as journal enabled. A copy of every message taken from this queue is sent to the journal. The number of the messages kept in the journal should be limited in order to avoid exhaustion of the disc capacity. This parameter specifies the maximum number of messages that can be kept in the queue. If the number of messages in the queue exceeds this number, then this parameter enables the exceeding number of messages to be erased. Process journal queue cleanup interval: This specifies the time interval in minutes when the process queue journal will be cleared. For example, if this parameter is specified as 60 minutes, then the journal will be scanned every 60 minutes and starting with the oldest, the number of messages that exceed the maximum limit will be deleted Company Settings

82 The parameters included in the Company Settings page are: Company code: This is the customer code, which stands for the company that is doing the planning. In the planning data, the company itself should be indicated as the customer for the production planned to be taken to the inventory. This parameter is defined to enable the discrimination of the company code from the customer numbers. The code that will be sent from the ERP should correspond to the value of this parameter. Middleware creates a virtual customer that corresponds to the company with this code. Order Fulfillment Rule: This specifies the rule for fulfilling the orders of the virtual customer that corresponds to the company. The Order Fulfillment Rule may take the As Much As Possible or the Fulfill All values. If no rules are assigned, then this is undefined. During the planning, production for the inventory is made according to this rule. Priority: This specifies the priority of the virtual customer that corresponds to the company. In planning, the customers are prioritized and in cases when sources are insufficient, the orders for the customers with higher priorities are fulfilled first. Thus, in order to avoid that the productions planned for the inventory do not affect the other orders, the company should be assigned low priority. Traceable Orders: In planning, it is possible to trace the orders of some customers, as desired. In the planning output, the related quantities to be produced will be assigned to the customers for whom orders will be traced. Orders of the customers, which shall not be traced, will be placed in total according to their dates. This parameter in the Company Settings specifies whether or not the order for the virtual customer that corresponds to the company will be traced.

83 Timer Intervals The services in Middleware (Planning Request Processor, Information Request Processor and Abort Request Processor) run asynchronously. The parameters identified on this page determine the time intervals in which the services should run. The services run in the specific time intervals and process the tasks they receive and go on stand by for the time period (milliseconds) specified in the parameter. If this time period is too short, it can reduce the performance of the computer. If it is too long, then it can prolong the waiting time when a request is received and cause the request to expire. Therefore, in order to be able to identify the most appropriate settings, it is first recommended that the default values are specified, and the values are decreased or increased in line with the requirements. Plan Processor: The timer interval for the Planning Request Processor should be entered. Info Processor: The timer interval for the Information Request Processor should be entered. Abort Processor: The timer interval for the Abort Request Processor should be entered.

84 Namespaces In the Schema Namespaces you should enter the schema names for the XML data source and the XML output. On the page, there are separate sections for the output XML formats and the input XML formats. Every title on the page corresponds to a data block in the text file. The XML block schema for every XML block in the input and output files are different. These XML blocks should be in the file even if they do not contain any data. It is recommended that the default values be accepted on this page.

85 Message Queues The application queues that are used in Middleware are administered on this page of the configuration. The window displays the information for the queue names, full addresses for accessing the queues, and whether or not the messages are private. For the healthy operation of the application, it is recommended that the default values be accepted for this information. If there are any queues, which could not be created during installation due to any problem, the related queue can be created by pressing the create queue button next to the related queue row on this page. If there are any queues that are created but display problems in accessing, then these can again be deleted with the delete queue operation on this page. The access problem can be resolved by re-creating the queue on this screen.

86 C-Plex Parameters Neo Middleware uses the CPlex mathematical solver for creating a model from the source data and for the optimization of this model. The parameter values that will be sent to this solver are indicated on this page. Temporary files are created during the operation of CPlex. The directory for these files (Temporary File Path) can be specified according to the disc utilization of the computer. The Memory Limit parameter can be modified according to the disc memory. Default values are recommended for the other parameters.

87 Testing Neo Middleware Functions The Neo Middleware Test/Admin Console provides functions for testing the software after the installation or exploring the problems and monitoring logs. These functions aim at monitoring Middleware services operations, testing message exchange, controlling formats, viewing and reporting planning outputs Planning Request Message Request Message Planning request message is sent for the testing of the planning processor and the flow is monitored. To create a planning message request, you should select the Send -> Planning Request Message option on the menu or click the New Planning Request Message button on the toolbar and open the data entry window. Then you should enter the data for the planning request and press the Send button to send the message. Then you can start to monitor the message in the message queues. The specifications of the request message and the explanations are given below. Version: This is the version of the request message. The Plan Request Processor processes the messages that are versioned with the version indicated in the Middleware configuration. This control is designed to

88 provide the consistency between the application and the message content. Data File: If Middleware is set to use XML text file as the data source (see, Middleware Configuration), then the name of the data file, which will be used in the request message, should be entered. Request Owner Name: The name of user who sends the planning request should be entered. This field is used for information purposes in reviewing the logs related to the planning request. Request Owner Location Name: This is the name of the branch/unit/production location to which the user who sends the planning request is related. This field is used for information purposes in monitoring the message. Request Owner Location ID: This is the number of the production location to which the user who sends the planning request is related. This field indicates by which production location s data the planning will be made. Reference ID: This field is used by Netsis ERP. Since this field is not used in the planning operation, it is not a required field in manual entries.

89 Schedule Start Date: This is the period start date of the detailed planning schedule. It is possible to prepare future plans by entering a date later than the date on which the message is created. Time: This indicates the hour when the planning schedule will start. In the example shown in the window, the planning schedule starts at 0800 hours on 13/04/2006. Detailed Schedule Duration: This is the number of days in the detailed planning schedule. In the example shown in the window, the planning schedule includes a plan from starts at 0800 hours on 13/04/2006 until 0800 hours on 27/04/2006. Completion Type: This indicates how the planning operation will end when the defined maximum operation period is over. If the Stop On Time option is selected, the planning operation runs the best result it calculated. If the Continue option is selected, then the planning

90 operation continues until the planning operation gets the best result and runs the optimum result without considering the time limitation. Planning Preferences: The below-given preferences are queried for the planning operation. Trace customer orders: You should select this option if you want the products, which are produced in the planning to be distributed according to the customer demands. Distribution will be made among the customers, whose orders you wish to monitor at the end of the planning (this information is given in the customer data). Fix production orders: The manufacture orders that are generated in the ERP are taken into the NEO planning tool as input. This option provides that the manufacture orders are fixed and planning is made accordingly. Use current state: This option specifies whether or not the current situation that is indicated in the source data for the workstations should be considered in the planning. When the planning operation is initiated (the planning data is prepared), the current situation of the workstations indicates the setup group they are in. Setup Groups are defined to group the operations, which can be successively realized in the same workstation without loading. Because the planning tool tends to reduce the workstation loading times to minimum, it tries to place the operations in the same setup group back-to-back. Goal Function: The Neo planning tool produces the optimum results according to the given goal. The goal functions that are defined by the product are as follows. Satisfy Constraints: When you select the Satisfy Constraints goal, the planning tool calculates the constraints in the data (customer orders, manufacture orders, current inventory, workstation capacity, etc.) and creates the optimum planning schedule (in the way that the operation can be realised in the soonest time possible with the given resources). Maximize order fulfillment: When this goal is selected, it abides the constraints that emerge in the workstation and tries to maximize the fulfilment level for the customer orders. The optimum result is the maximum number of demands that can be fulfilled according to the resources. Minimize production costs: When this goal is selected, it abides the constraints that emerge in the workstation and tries to minimize the total production cost that is generated by the supply of semi products, keeping inventories onhand, etc. Minimize setup times: When this goal is selected, it abides the constraints that emerge in the workstation and tries to minimize the time spent for loading the workstations during the production. Neo Middleware Version 1.0 provides only the Satisfy Constraints function. Maximum run time: This is the planning tool s maximum run-time for a single planning request. If the optimum result is not achieved at the end of this time, then the system proceeds according to the defined Completion Type.

91 Request Message Viewer A newly sent planning request message is kept in NeoRequestQueue. When a message in the queue is double-clicked, the message content will be displayed in the Request Message Viewer window as shown below. The Message Arrival Time is the time when the message arrives in the message queue (NeoRequestQueue). Operations that can be processed in the Request Message Viewer window: Delete: When the Delete button is pressed, the displayed message is cleared from the Request queue. Move to Process: When the Move To Process button is pressed, the displayed message is cleared from the Request queue and sent to the process message queue (NeoProcessQueue). This operation is added for testing purposes. Message Logs: When the Message Logs button is pressed, the log messages related to the displayed message will be displayed in the log viewer window (see, Message Logs Viewer).

92 Send Inquiry: When the Send Inquiry button is pressed, the Information Request Message Sender window related to the displayed message will be displayed for querying the status of the message. The ID of this message is automatically transferred to the reference message ID of this Information Request Message. Send Abort: When the Send Abort button is pressed, an Abort Request Message Sender window will be displayed for cancelling the displayed message. The ID of this message is automatically transferred to the reference message ID of this Abort Request Message Information Message Request Message To send an Information Request Message, the planning message for which the information will be requested should be selected in the message list. If the related message is not shown in the list, the message ID should be entered when creating the Information Message. The Information Message Window can be opened either by selecting the Send -> Information Message option on the menu or clicking the New Information Message button on the toolbar. If the message for which the information will be requested is selected, the related Message ID will be displayed in the Reference Message ID field. If not selected, then the ID should be entered in this field. Other information should be entered as explained in the Planning Request Message section and the Send button should be pressed to send the message. Whether or not the message is successfully queued will be indicated in the related window Information Message Viewer A newly sent information request message is kept in NeoInfoQueue. When a message in the queue is double-clicked, the message content will be displayed in the Information Message Viewer window as shown below. The Properties button next to the Ref. Message Id field in this window opens the window that displays the content of the planning request with which this message is related.

93 Other operations that can be processed in the Information Message Viewer window are: Delete: When the Delete button is pressed, the displayed message is cleared from the information queue. Message Logs: When the Message Logs button is pressed, the log messages related to the displayed message will be displayed in the log viewer window (see, Message Logs Viewer) Abort Message Request Abort Message To send an Abort Request Message, the planning message for which the information will be requested should be selected in the message list. If the related message is not shown in the list, the message ID should be entered when creating the Abort Message. The Abort Message Window can be opened either by selecting the Send -> Abort Message option on the menu or clicking the New Abort Message button on the toolbar. If the message, which will be aborted, is selected, the related Message ID will be displayed in the Reference Message ID field. If not selected, then the ID should be entered in this field. Other information should be entered as explained in the Planning Request Message section and the Send button should be pressed to send the message. Whether or not the message is successfully queued will be indicated in the related window.

94 Abort Message Viewer A newly sent abort request message is kept in NeoAbortQueue. When a message in the queue is double-clicked, the message content will be displayed in the Abort Message Viewer window as shown below. The Properties button next to the Ref. Message Id field in this window opens the window that displays the content of the planning request with which this abort message is related. Other operations that can be processed in the Abort Message Viewer window are: Delete: When the Delete button is pressed, the displayed message is cleared from the Abort queue. Message Logs: When the Message Logs button is pressed, the log messages related to the displayed message will be displayed in the log viewer window (see, Message Logs Viewer).

95 Message Logs Viewer The phases (for information purposes) and the warning and errors are logged when the request messages are processed by the processors. The message logs can be viewed by transferring the message logs from the windows that display the request messages to the message logs window. Log messages can be read without applying filters or by filtering the error logs. The below-shown example lists all of the logs. It is possible to scroll through the log list by using the keys on the screen. All of the details that are related to a log record, which is selected from the list, are displayed in the Log Item Details panel.

96 Response Messages After the planning, information and abort request messages are processed by the Processors, the process results are sent to the requesting user with a Response Message. The Abort messages sent in response to every type of request message are in the same format. The fields that are used in the message format may differ according to the message type. To enable that the sender identifies the message to which the response message relates to, Reference MSMQ message ID field and Response Message Type (Request result, inquiry result, abort result) are added in the ID field of the response message. The requesting user and the user s location information are included in the response message Plan Response Messages

97 The window that displays the Plan Response Message is shown in the screenshot below. Fields that are specific to the plan response in the Response Message and their explanations are as given below. Input Data File: This is the data file, which enters the planning process as the source. Output Data File: This is the data file to which the planning output is written. Log file: This is the text file to which logs, which are generated during the operation, are written. Response Status: This field indicates the planning result type. Planning request response types are: Produced (the process is successfully completed and planning output is created), Error (an error occurred during the process), Absent (the process is completed but planning output could not be created), PlanningUnfinished (the planning process could not be completed)

98 The operations that can be processed in the planning response message viewer window are: Delete: When the Delete button is pressed, the response message is cleared from the response message queue. Show Plan Output: The Plan output viewer window opens. (See, Show Plan Output) Information Response Message The window that displays the Information Response Message is shown in the screenshot below. The fields that are used in the information response message are as given in the sample message. The content of these messages are similar to that of the planning response messages. The Response Status field involves types that are specific to the related information message. Response Status: Indicates the status of the message for which the response is requested. Information response types are: Waiting (the planning request message for which the information is requested is lined in the request queue), Processing (the planning request message for which the information is requested is in process),

99 Processed (the planning request message for which the information is processed), Unknown (the status of the planning request message for which the information is requested is unknown) Abort Response Message Abort requests are processed only for planning messages, which are queued in the request queue. If the message, which will be aborted, is currently processed by the Processor, then the Abort process cannot be performed. The Abort response will be sent to the requesting user whether or not the abort process is successful. The window that displays the Plan Response Message is shown in the screenshot. The fields that are used in the information response message are as given in the sample message. The content of these messages are similar to that of the planning response messages. The Response Status field involves types that are specific to the related abort message. Response Status: Describes the status of the message about which you request information. Information response types: Aborted (abort operation is successful), NotAborted (abort operation cannot be completed because the planning request message is in process), Unknown (request message to be aborted not found)

100 5.2 Neo Middleware Installation Guide The Middleware installation is made by running the setup programme. The setup programme consists of the NeoSetup.msi, Setup.Exe and Setup.Ini files. The Setup.Exe file should be run to start the installation. The installation programme installs all of the modules, message queues and application directory structure that are included in Middleware. The setup programme interfaces and the operations to be performed for every interface are described below in their related sequence. Setup programme start interface. Press the Next button to move to the next page.

101 License agreement page. When the I Agree option is selected, the Next button moves to the next page. Information page for the Neo Middleware package. Information is not provided in this version of the installation programme. Press the next button to move to the next page.

102 Customer information page. The name of the user who performs the installation should be written in the Name section, and the title of the organization should be written in the Organization section. Press the next button to move to the next page. License Register page. This operation is not active in this version of the installation programme. Press the next button to move to the next page.

103 This is the page where the message queue names, which will be used by Middleware, are defined. Entering the below listed information and pressing the Next button will move to the next page. Default values are recommended for queue names. Request Queue Path: The name of the message queue, to which the planning requests will be sent, should be entered in this field. Process Queue Path: This is the message queue where the planning message will be kept until the process is completed. The related queue name should be entered. Response Queue Path: This is the queue where the response messages that are sent in response to the request messages are kept. The related queue name should be entered.

104 Info Queue Path: This is the message queue to which the information requests related to the planning requests will be sent. The related queue name should be entered. Abort Queue Path: This is the message queue to which the request messages related to the planning abort requests will be sent. The related queue name should be entered. Log Queue Path: This is the message queue, which the Middleware modules use for collecting error or information logs. Error or information logs messages are sent to this queue. Log messages are read by the logs service. This is the interface where the installation directory location is entered. The default value is recommended. The installation programme will create KoçSistem directory under the Program Files. After the directory is specified, the Everyone option should be selected. Press the Next button to move to the next page.

105 Installation confirm page. Pressing the Next button will start the installation operation. This is the interface that displays that the installation is successfully completed. Press the Close button to close the setup programme.

106 5.3 Calculating MPS Values Example: 1- If Minimum inventory < Forecast Quantity: Previou s Period Period 1 Forecast Quantity 231 Quantity calculated by converting forecast quantities into MSP periods Minimum inventory 50 Inventory Planning Records/Minimum inventory MPS Quantity 261 =Forecast Quantity- Previous Period Balance Quantity +Minimum Inventory) =( ) Inventor y Balance Quantity =MPS Quantity + Previous Period Balance Quantity - Forecast Quantity) =( ) ATP 251 =Forecast+ Previous Period Balance Quantity Order Quantity =( ) 2- If Minimum inventory > Forecast Quantity: Previou s Period Period 1 Forecast 231 Quantity calculated by converting forecast quantities into

107 Quantity MSP periods Minimum inventory 250 Inventory Planning Records/Minimum inventory MPS =(Forecast Quantity- Previous Period Balance Quantity Quantity 461 +Minimum Inventory) =( ) Inventor y Balance Quantity =MPS Quantity + Previous Period Balance Quantity - Forecast Quantity) =( ) ATP 251 =Forecast+ Previous Period Balance Quantity Order Quantity =( ) 3- If Previous period inventory balance > Forecast Quantity: Previou s Period Period 1 Forecast Quantity 231 Quantity calculated by converting forecast quantities into MSP periods Minimum inventory 50 Inventory Planning Records/Minimum inventory MPS Quantity 0 =(Forecast Quantity- Previous Period Balance Quantity +Minimum Inventory) =( )<0 Inventor y Balance Quantity =MPS Quantity + Previous Period Balance Quantity - Forecast Quantity) =( ) ATP 531 =Forecast+ Previous Period Balance Quantity Order Quantity =( ) 4- If Lot Size exists: Previou s Period Period 1 Forecast Quantity 231 Quantity calculated by converting forecast quantities into MSP periods Minimum Inventor y 100 Inventory Planning Records/Minimum inventory Lot Size 50 =(Forecast Quantity- Previous Period Balance Quantity MPS Quantity 350 +Minimum Inventory) =( )=331 is rounded off because this has to be multiple of. Inventor y Balance Quantity =MPS Quantity + Previous Period Balance Quantity - Forecast Quantity) =( ) ATP 231 =Forecast+ Previous Period Balance Quantity Order

108 Quantity =( ) 5- If Maximum inventory is calculated and Inventory Balance > Maximum inventory: Previo us Period Period 1 Forecast Quantity 231 Quantity calculated by converting forecast quantities into MSP periods Minimum Inventor y 50 Inventory Planning Records/Minimum inventory Lot Size 20 Maximu m Inventor y 60 MPS Quantity 300 Inventor y Balance Quantity 0 69 =(Forecast Quantity- Previous Period Balance Quantity +Minimum Inventory) =( )=281 is rounded off because this has to be multiple of 20. =MPS Quantity + Previous Period Balance Quantity - Forecast Quantity) =( ) In this case, since the remaining onhand will be higher than the maximum inventory onhand, modification should be made. This is to say that the difference between the maximum inventory quantity and the inventory onhand quantity should be added to the forecast value of the related period. The Forecast Modified Quantity in any period indicates the excess inventory quantity that should be sold in the related period. Period Previo us Period 1 Forecast Quantity 231 Forecast Modified Qnty. 9 New Forecast Quantity 240 Quantity calculated by converting forecast quantities into MSP periods =Inventory Balance Quantity - Maximum Inventory =69-60 =Forecast Quantity +Forecast Modified Qnty. =231+9 Minimum inventory 50 Inventory Planning Records/Minimum inventory Lot Size 20 Maximu m inventory 60

109 MPS Quantity 300 Inventor y Balance Quantity 0 60 ATP 231 =( Forecast Modified Qnty. - Previous Period Balance Quantity +Minimum Inventory) =( )=290 is rounded off because this has to be multiple of 20. =MPS Quantity + Previous Period Balance Quantity - Forecast Modified Qnty.) =( ) =Forecast+ Previous Period Balance Quantity Order Quantity =( ) 6- If Total order quantity > 0 and Total Order < Forecast Quantity: then Previo us Period Period 1 Forecast Quantity 231 Quantity calculated by converting forecast quantities into MSP periods Total Order 30 Minimum inventory 50 Inventory Planning Records/Minimum inventory Lot Size 20 Maximu m Inventor y 60 MPS Quantity 300 Inventor y Balance Quantity 0 69 ATP 201 =(Forecast Quantity- Previous Period Balance Quantity +Minimum Inventory) =( )=281 is rounded off because this has to be multiple of 20. =MPS Quantity + Previous Period Balance Quantity - Forecast Quantity) =( ) =Forecast+ Previous Period Balance Quantity Order Quantity =( ) Since the remaining onhand will be higher than the maximum inventory onhand, modification should be made. Period Previo us Period 1 Forecast Quantity 231 Forecast Modified Qnty. 9 Quantity calculated by converting forecast quantities into MSP periods =Inventory Balance Quantity - Maximum Inventory =69-60

110 New Modificati on Quantity 240 =Forecast Quantity+Forecast Modified Qnty. =231+9 Total Order 30 Minimum Inventor y 50 Inventory Planning Records/Minimum inventory Lot Size 20 Maximu m Inventor y 60 MPS Quantity 300 Inventor y Balance Quantity 0 60 ATP 210 =(New Forecast Quantity- Previous Period Balance Quantity +Minimum Inventory) =( )=290 is rounded off because this has to be multiple of 20. =MPS Quantity+ Previous Period Balance Quantity-New Forecast Quantity =( ) =New Forecast+ Previous Period Balance Quantity Order Quantity =( ) 7- If Total order quantity > 0 and Total Order > Forecast Quantity: then, first difference between the order quantity and forecast quantity should be written in the modified quantity field. Period Previo us Period 1 Forecast Quantity 231 Forecast Modified Quantity 69 New Modificati on Quantity 300 Quantity calculated by converting forecast quantities into MSP periods =Total Order - Forecast Quantity = =Forecast Quantity+ Forecast Modified Qnty. = Total Order 300 Minimum Inventor y 50 Inventory Planning Records/Minimum inventory Lot Size 20 Maximu m Inventor 60

111 y MPS Quantity 360 Inventor y Balance Quantity 0 60 ATP 0 =(New Forecast Quantity- Previous Period Balance Quantity +Minimum Inventory) =( )=350 is rounded off because this has to be multiple of 20. =MPS Quantity+ Previous Period Balance Quantity - Forecast Modified Qnty.) =( ) =New Forecast+ Previous Period Balance Quantity Order Quantity =( ) In the above-given example, because the order quantity in the related period is higher than the forecasted quantity, and therefore planning is required according to the minimum order quantity, the difference between the order quantity and the forecast quantity is added in the forecast modified quantity field. Thus the Forecast modified quantity is calculated as 69. Furthermore, in case that the inventory onhand quantity at the end of the period exceeds the maximum inventory onhand level, if the inventory onhand quantity were calculated as 100 units instead of 60, since the maximum inventory quantity is 60, the difference (40) would be added to the forecast modified quantity and the new forecast would be 340. This means that in this planning the 340 units should be considered as the forecast quantity. 5.4 Using the Production Planning Information in Customer Orders In MPS information, which is calculated and monitored in the MRP module (see, Generating MPS Charts of Inventories, Monitoring/Updating MPS Information), can be later viewed in the Invoice Module Customer Orders section. To provide this facility, the Main Production Scheduling Information entry is added to the shortcuts that are displayed when you right-click on the Customer Orders/Item Info. Section. In the window that opens when you select this option, you can view the Available to Promise inventory quantity (ATP) that is calculated according to periods in the MPS results, enter order quantities for different periods, monitor the updates according to the information that you enter and record the quantities that you enter in this window.

112 After entering the inventory code for which the order record will be created, when you right-click on the upper part of the window, you will see the Main Production Scheduling option among the option that are displayed. When you select this option, the Inventory Main Production Scheduling Information window opens. In this window, the MPS information related to the inventory, which is entered in the order, will be displayed according to the periods after the delivery date entered in the order information. This is to say that the periods before the order delivery date will not be shown in this window. You can view the

113 Available to Promise inventory quantity in the ATP field during the order record process. It is possible to enter new quantities in this window by considering this quantity information. The New Order Quantity row is used for new quantity entries. This field will be activated when you double-click on this row or press the shift key on your keyboard and will allow for quantity entry. For example, let us assume that on , a customer requested units of an inventory that displays the above-given planning details. This date coincides in the 3 rd period. In the planning, the Available to Promise inventory quantity for the 3 rd period is calculated to be In other words, any quantity more than this will generate problems in the inventory onhand. Therefore, some portion of this order of units can be recorded for the 3 rd period and the remaining portion can be recorded for the other periods. According to the below-given example, units are entered in the 3 rd period and units in the 4 th period. Add to List: When the Add to List button is pressed after entering the order quantities, the inventory code will be moved to the left hand side of the window. To be able to record the quantity information in the order, you should first press this button. Reflect Changes to Window: This button is used for updating the displayed MPS information according to the new quantities that are recorded. This button recalculates the modified values only for viewing purposes. Save to Order: This button is used for recording the quantities, which are recorded according to periods in the same way according to the related periods. At this stage, in order to be able to arrange the delivery dates of the order quantities, which are entered according to different periods, again in the related periods, you should select the Ask delivery date for each order line parameter in the Sales Invoice parameters. Otherwise, all order quantities will

114 be recorded for the same delivery date. When you press the Add to Order button, the system transfers the entered information to the order entries and also recalculates the MPS values. Thus, when you view in this menu or in the MRP/Main Production Scheduling/ Monitoring/Updating MPS Information menu, the order quantities, which you entered in the above-described way, will also be added to the value in the Total Order Quantity row. As shown above, it is possible to use the Main Production Scheduling option and record the order quantities, which are entered for different periods, in the related periods with the help of the order delivery field that is queried on row basis. The first day of the related period will be inserted as the order delivery date by the programme. However, when later the order quantity is recorded not by using the Main Production Scheduling Information option but by using the classical method from the item information section, when the Main Production Scheduling Information is retrieved these quantities will not be included in the Total Order Quantity value, thus in turn in the MPS calculations. The order quantities, which are entered with the classic method, will be included in the Current Order Quantity row. The calculation operation must be processed in order to provide that the order quantities, which are entered with the classical method, are included in the MPS.

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