estelplan Inventory Planning Release 4.0a

Transcription

1 Inventory Planning Release 4.0a February 15,

2 Copyright 2016 Invera Inc. All Rights Reserved. Invera Inc. (hereinafter referred to as Invera) has prepared this document for use by its personnel, licensees and customers. The information contained herein is the property of Invera and shall not be reproduced in whole or in part without prior written approval from Invera. Invera reserves the right to make changes in specifications and other information contained in this document without prior notice, and the reader should in all cases consult Invera to determine whether any such changes have been made. The terms and conditions governing the licensing of Invera software consist solely of those set forth in the written contracts between Invera and its customers. No representation or other affirmation of fact contained in this document, including but not limited to statements regarding capacity, response-time performance, suitability for use, or performance of products described herein shall be deemed to be a warranty by Invera for any purpose or give rise to any liability of Invera whatsoever. is a Trademark of Invera Inc. Web: info@invera.com Phone: (514) Fax: (514) Invera Corp Luther Lane, #425 Dallas, TX U.S.A. Invera Inc St. Catherine Street West, Westmount, Quebec H3Z 1P9 Canada

3 Table of Contents 1. OVERVIEW... 1 FEATURES... 2 INVENTORY MANAGEMENT INFORMATION REQUIREMENTS... 3 Company File Options... 3 Inventory Management Warehouse Types... 3 Standard Dimensions PRODUCT STATISTICS... 5 OVERVIEW... 5 Updating of Product Statistics... 5 Statistics File Update Programs... 6 Usage and Production Update Options... 7 END OF MONTH... 9 INVENTORY BALANCE Average Cost On-Hand Vs Received Material Creation of the Inventory Balance File Rebuilding the Inventory Balance Table <inbpmb> EQUIVALENT PRODUCTS Equivalent Product Printing Sequence BRANCH PRODUCT SALES FORECAST Restrictions STANDARD SELECTIONS ABOVE/BELOW INDX OBJ [_] INVENTORY POSITION OVERVIEW Product Installation Options Group/Size/Grade Summary Negative On-Hand Quantity SELECTION SCREENS Selection Options Minimum Stocking Quantity Incoming Material Demand Periods Selection Option Restrictions Sample Report Field Descriptions Report Calculations End of Month Inventory Position Calculation Options Example of End of Month Forecast Calculations Calculation of End of Month Inventory Position Calculations CRC/18/DQ To Buy Calculation... 48

4 Table of Contents Page ii Calculation Options Example of To Buy Forecast Calculations Calculation of To Buy Calculations BA/2214/ EQUIVALENT PRODUCTS MONTHLY USAGE OPTION INVENTORY REQUIREMENTS FORECAST OVERVIEW Product Installation Options Suppression of Report Lines Negative On-Hand Quantity Average Demand Months Historical Months Weighting Factors SELECTION SCREENS REPORT SEQUENCING Sequence by Group and Product Master Equivalent Products Variable Sections SAMPLE REPORTS REPORT FIELDS AND CALCULATIONS Company Standard Dimension Heading Fields (1st line of information) Branch Standard Dimension Information (2nd and 3rd line of information) Inventory Forecast Detail Inventory Statistics Section On Order Selection Open Purchase Order Detail Last Sales Carry Forward of Negative Available PROGRAM MATERIAL PART SPECIFICATION FORECASTING Overview Prerequisites Using the Program Material Part Specification Forecasting Feature Restrictions and Assumptions Report Selections Selection Restrictions Part List Report Fields Not Printed Report Calculations INVENTORY PLANNING OVERVIEW Product Installation Options Branch Definition Branch Total Line Suppression Monthly Usage Receipt Date of Standard Product Usage Printing Vendor Replacement Cost/Minimum Purchase Quantity Option to Print Report in Feet Instead of Pounds SELECTION SCREEN Report Printing REPORT SAMPLE REPORT FIELDS Months in Inventory Calculation Incoming Detail... 84

5 Table of Contents Page iii 8. BRANCH REPLACEMENT COST MAINTENANCE OVERVIEW BRANCH REPLACEMENT COST MAINTENANCE Action Bar Options Select Displayed Fields Action Bar Options BRANCH REPLACEMENT COST INQUIRY REPLACEMENT COST UPDATE BRANCH REPLACEMENT COST REPORT Selection Screen INVENTORY USAGE REPORT OVERVIEW Selection Screen REPORT PRINTING Report Fields Report Totaling Computing Net Usage Quantity Sample Report INVENTORY PLANNING REPORT BY SALESPERSON OVERVIEW Restrictions and Assumptions REPORT SELECTIONS REPORT SAMPLES REPORT FIELDS AND CALCULATIONS REPORT SEQUENCING Page Breaks Totals INVENTORY PLANNING REPORT BY CUSTOMER OVERVIEW Report Selections Prerequisites Restrictions and Assumptions Formatting Sequence of Consumed Inventory within Dimension Special Cases Consumed Product Not Entered Consumed Dimension Not Entered Inventory Planning Report by Customer Sample Report Sorting Page Breaks Totals VENDOR MANAGED INVENTORY EXTRACT OVERVIEW PRODUCT/VENDOR LINK Introduction Branch Standard Dimension Setup Branch Standard Dimension Sample VENDOR MANAGED INVENTORY EXTRACT Overview Extract Program Purchase Order Types Included Warehouse Types Included

6 Table of Contents Page iv Program Functions Requirements Product Installation Options VMI EXTRACT TABLE Extracting Data to Send to Your Vendor Structured Query Language (SQL) Commands to Extract VMI Data Informix unload SQL Command Oracle unload SQL Command APPENDIX A OVERVIEW OF BAR PRODUCTS Inventory Planning Report Inventory Position Report Inventory Forecast Report Inventory Usage Report FILES USED Inventory Management Warehouse Types Product Statistics File Standard Dimensions Company and Branch COMPANY STANDARD DIMENSION Explanation of Fields Turnover Objective Index Objective Product ABC Class BRANCH STANDARD DIMENSIONS Explanation of Fields ABC Class Forecast Factor Turnover Objective Index Objective Mths Demand Min Max Stocking Quantity Purchase Quantity Preferred Vendor Alternate Rep Cost Material Rep Cost Frt Cost Total Repl Cost Market Factor Remarks Update Frequency Next Cost Alternate Vendor INVENTORY PLANNING REPORT SAMPLES Explanation of Fields INVENTORY POSITION REPORT SAMPLES Explanation of Fields INVENTORY REQUIREMENT FORECAST REPORT SAMPLES Explanation of Fields INVENTORY USAGE REPORT SAMPLE APPENDIX B OVERVIEW OF COIL PRODUCTS Inventory Planning Report

7 Table of Contents Page v Inventory Position Report Inventory Forecast Report Inventory Usage Report FILES USED Inventory Management Warehouse Types Product Statistics File Standard Dimensions Company and Branch COMPANY STANDARD DIMENSIONS Explanation of Fields Turnover Objective Index Objective Product ABC Class BRANCH STANDARD DIMENSIONS Explanation of Fields ABC Class Forecast Factor Turnover Objective Index Objective Mths Demand Min Max Stocking Quantity Purchase Quantity Preferred Vendor Alternate Rep Cost Material Rep Cost Frt Cost Total Repl Cost Market Factor Remarks Update Frequency Next Cost Alternate Vendor INVENTORY PLANNING REPORT SAMPLES Explanation of Fields INVENTORY POSITION REPORT SAMPLES Explanation of Fields INVENTORY REQUIREMENTS FORECAST REPORT SAMPLES Explanation of Fields INVENTORY USAGE REPORT SAMPLE APPENDIX C PRODUCT STATISTICS ADJUSTMENT Manual Entry to Update Product Statistics <inapra> Entry Screen Index

8 Table of Contents Page vi

9 1. OVERVIEW The purpose of the Inventory Planning functions is to provide you with the information needed to efficiently manage your inventory. There are three main objectives: To consolidate decision making information about inventory on based reports that can be reviewed on demand for material purchasing requirements. To provide a common basis of comparison between products having different units of inventory control. To include inventory analysis facilities to calculate a recommended purchasing quantity and due date based on current inventory, projected demand, committed purchases and a desired minimum number of months of inventory to be kept.

10 1. Overview Page 2 FEATURES Provides reporting at the individual Branch and total Company level. Supports detailed reporting by product at the Product Group, Size, Grade and Standard Dimension level or summarized reporting at the Group, Size and Grade level only. Provides the ability to combine products of specific Groups and Grades that are functionally equivalent so that they can be analyzed together. Provides easy update of the various factors used in the calculation and reporting functions to allow for projecting the impact of market changes on inventory requirements. Provides a large enough planning window to suit the rolling schedules of different mills and foreign purchases. Provides a facility to control whether a particular product s demand figures are to be based on sales or on production usage. For example, for sheet sizes that are leveled from coil, the sheet product demand would be based on sales, while the coil product is based on usage. Provides product and Vendor reference information that the purchasing agents can use when deciding which supplier to call for quotations on the material. Provides a Vendor Managed Inventory Extract function to help vendors manage their own inventory levels and create delivery schedules that meet your inventory needs.

11 1. Overview Page 3 INVENTORY MANAGEMENT INFORMATION REQUIREMENTS To support the Inventory Planning reports, several special files are maintained. These files contain the base reference information such as standard purchasing dimensions, lead times and minimum order quantities, as well as consolidated inventory movement and sales data that is required to produce the reports. Company File Options Inventory Management Warehouse Types When Warehouses are set up in, each is given a designation type. This is used to group warehouses together for inventory control and reporting purposes. Additionally, they determine which transactions update the usage statistics. The different warehouse types are: C D F M O P R Customer-Owned Material Drops/Returns-to-Stock Finished Goods Mill Claims Outside Processing Prime and Stock Material Rejected Material For Inventory Planning and Forecasting functions, continually updates the Product Statistics file (explained in chapter 2) based on transactions taking place in Warehouse Types defined in the Company file. The Inventory File Update function that records inventory transactions uses the Inventory Invt Mgmt Whs Types field to determine whether to add the transaction to the Product Statistics file. You can include any combination of valid Warehouse Types in this file. Invera recommends including the following Warehouse Types: P, D, O and F. This setting can vary by site and your installation analyst will verify which are applicable to your location. In addition to determining whether to update the usage files, the Invt Mgmt Whs Types also determine which open Orders and Purchase Orders are to be included in the forecast reports. Standard Dimensions Products that are purchased for stock-keeping purposes are defined in terms of a Standard Dimension so that information about the different sizes can be kept on a perpetual basis for comparative purposes. The Standard Dimension includes a Group, Size and Grade as well as Dimension and Gauge ranges (if the product is Gauge Required). The concept of grouping products into standard purchasing dimensions is used to provide a consistent basis for analyzing material requirements. Standard Dimensions consist of a two tiered set of files. The most general level is the Company Standard Dimension. It is set up for each stock keeping Product Master and contains basic reference and variable information to provide criteria for inventory valuation and purchasing. For each Branch stocking a product, a Branch Standard Dimension is created. This is the second level. It contains additional

12 1. Overview Page 4 information regarding inventory levels and purchasing requirements pertaining to the particular Branch. NOTE: You MUST create the Company Standard Dimension before creating the Branch Standard Dimensions. You only need to create a Branch Standard Dimension for those products that are purchased for a specific Branch. Standard Dimensions are stored in Imperial or Metric measurements depending on the Base Measure of the system. Reporting options and print format of the Inventory Requirements Forecast reports are also determined by the Base Measure. Product Activity Statistics are kept based on the Branch Standard Dimensions set up for a product. If there are no Branch Standard Dimensions on file, the system automatically creates a Product Statistics record for each Branch with a Dimension of 0.00 X 0.00 and a Gauge of This provides the total activity for the product for reconciliation against other inventory or sales reports. New Company and Branch Standard Dimensions can be created whenever the purchasing department feels it is necessary. However, historical Product Statistics which have been accumulated under a specific Standard or the Zero X Zero Dimension are not rebooked under the new Standard Dimension. Accumulation of data begins as soon as the Standard Dimensions are created.

13 2. PRODUCT STATISTICS OVERVIEW The Product Statistics file is updated on-line daily based on the activity for a Standard Dimension product. This file is also updated in batch during the End of Month closing procedure. It contains product activity statistics for each Company Standard Dimension and Warehouse Type as well as an automatically created record for each non-standard Dimension. The non-standard Dimension record is created with a Standard Width/Length/Gauge of Each record in the file relates to all of the activity for a month for the product so that statistics regarding the inventory activity can be obtained for comparison and analysis. Daily transactions are updated on-line during the Inventory File Update, which is called by most programs. At the end of the month, the Ending Inventory balance is added to the file so that it can be used for computations in the Inventory Requirements Forecast report. Update programs use the Company and Branch Standard Dimension files as well as the Inventory Management Warehouse Types (Prime, Drop, Finished and Outside Processing) to determine which records to update. If a product does not fall within the range of any of the Standard Dimensions for the product, it is automatically classified as various by various (0.00 X 0.00) so that the total product statistics always balance with the Sales, Usage or Inventory Transaction analysis files. If a Standard Dimension is made Inactive or Deleted, no further updates are done to the Product Activity file. New statistics are accumulated as various by various, until a new Standard Dimension is created. Once it is created, the historical usage and Sales History remain booked for the inactive or deleted dimension and new information is accommodated for the newly added dimension. Updating of Product Statistics This file is updated anytime a Product Item record is created, modified or deleted in inventory. There are individual fields that record the different types of transactions.

14 2. Product Statistics Page 6 The different types of transaction fields and the programs that update them are the following: A + indicates the transaction quantity is added to the record A - indicates the transaction quantity is subtracted from the record A +/- indicates a transaction that can add or subtract quantity depending on the transaction (such as Adjustments). Some transactions allow you to control the update of the Production or Usage fields based on a Product Installation Option. Refer to the Inventory Handling chapter of the User s Guide for details. Fields from the Product Activity Statistics File Programs that Update the Statistics File Receipts + Receipts* Adjustment Transfers* Process Sales* Inventory Applications RCT RET PCA IAJ IN OUT CSM PRN ALC STK NST WIN Adjustments - +/- +/- - +/- Transfers In + + Transfers Out + + Usage *+ *= *+ + *+ *+ *+ Production *+ *+ + Stock Sale + Non-Stock Sale + Windfall Sale + Returns *+ * For these Transactions you can control the update of the Usage and Production fields. A discussion of these transactions follows. Statistics File Update Programs Receipts RCT - Inventory Receipts types O RET - Inventory Receipts type R Adjustment PCA - Purchase Cost Adjustments IAJ - Inventory Adjustments Transfers IN - Transfers received at the Branch OUT - Transfers shipped to all other Branches Process CSM - Consumption on all production transactions PRN - Production on all production transactions

15 2. Product Statistics Page 7 Sales ALC - The allocation of all sales orders STK - Order Items coded as Stock NST - Order Items coded as Non-Stock WIN - Order Items coded as Windfall Usage and Production Update Options Receipts (Outside Processing), Receipts (Returns), Transfers, Sales Orders (ALC) Non-stock (NST), Windfall (WIN), Material shipped from another Branch (Oth Brh), Sales Order (Stk) Direct Shipments and Inventory Applications have Product Installation Options controlling the update of Usage and Production fields. The table below indicates which Product Statistics files fields are updated when usage is selected and when it is not selected. Transaction Update Usage Do not Update Usage Receipt (Outside Processing) Receipt (Returns) Production + Usage + Receipt + Adjustment - (no entry) Usage (no entry) Returns Transfers Production + Usage + Transfer In + Transfer Out - Sales Ord-ALC (Stock sale) S stock N Nonstock W Windfall Oth Brh Sales Ord- STK (Direct Ship) S stock N Nonstock W Windfall Sales + Nonstock sales Windfall sales Sales + Sales + Nonstock sales Windfall sales Usage + Usage + Adjustments + Usage + Usage + Usage + Adjustments + Sales + Nonstock sales Windfall sales Transfer In + Sales + Nonstock sales Windfall sales Usage + Adjustments Adjustments - Transfer Out - No update No update No update Inventory Applications Production + Usage + (no entry) Adjustments +/-

16 2. Product Statistics Page 8 Example of the effect of Transactions on the Product Statistics files 1. Received 100 tons 2. Purchase Cost Adjust receipt to 99 tons 3. Transferred 20 tons to another Branch 4. Processed 50 tons and produced 49 tons of finished goods 5. Sold 45 tons on a stock sale 6. Customer returned 2 tons of material Receipts Adjustment Transfers Process Sales RCT RET PCA IAJ IN OUT CSM PRN ALC STK NST WIN Receipts 100 Adjustments 1- Transfers In Transfers Out 20 Usage 50 45* Production *49 Stock Sale 45* Non-Stock Sale Windfall Sale Returns 2* * Indicates the transaction affects the Product Statistics file for the Finished Goods Standard Dimension.

17 2. Product Statistics Page 9 END OF MONTH In the End of Month procedure, the ending inventory balance for each Standard Dimension is stored in the Product Statistics file. The records are kept by accounting period.

18 2. Product Statistics Page 10 INVENTORY BALANCE The Inventory Balance file records all inventory activity within a Branch by a product s Standard Dimension and Warehouse Type. It is used in Inventory Planning reports and the estelview Stock List Inquiry. If there are no Standard Dimensions for a product, then the transaction is recorded as Various by Various, with zero for the dimensions and Gauge (0 x 0). The table below shows the information maintained within the Inventory Balance File. Field Name Warehouse Type On-Hand Quantity On-Hand Value Allocated against On-Hand Transient Allocated against Transient Incoming Quantity Incoming Value Reservations against Incoming Description The Warehouse Type code describes the type of material that is kept in the warehouse. The different types are: P D F O M R C Prime and Stock Material Drops/Returns-to-Stock Finished Goods Outside Processors Mill Claims Rejected Material Customer-Owned Material The total Pieces, Quantity, and Weight of the material On-Hand. Transient material is not included in the total. The total value and average cost of the material On-Hand. The total Pieces, Quantity, and Weight reserved against the material On-Hand. Reservations against Transient material are not included in this total. The total Pieces, Quantity, and Weight of Transient material. This includes pre-production tags created in estelpro, estelman, and estelmill. The total Pieces, Quantity, and Weight reserved against Transient material. The total Pieces, Quantity, and Weight of Incoming Transfer and Purchase Order material, including Direct Ship Purchase Orders. The total Value and Average Cost of incoming material. The total Pieces, Quantity, and Weight reserved against incoming material. Average Cost The Inventory Balance table tracks two different sets of average costs: On-Hand reflects average cost of material that has already been purchased. E.g., Used in Uniquote. Incoming reflects average purchase cost of material that is on order. Used in Purchasing. Some of the Purchasing inquiries and Inventory Planning Reports (such as the Purchase Position Inquiry) that are based on Standard Dimensions, calculate an Average Cost using both On-Hand plus Incoming values.

19 2. Product Statistics Page 11 On-Hand Vs Received Material Non-Tag Master Required material briefly disappears from the estelview Stock Inquiries when it is placed on a Purchase Order Receipt, since at the time of receiving, the Incoming quantity is reduced. As soon as the receipt is updated, the material is added to the On-Hand Quantity. This situation does not occur with Tag Master Required material since a Transient Tag record is created as soon as the material is received. The On-Hand Quantity in the Inventory Planning reports has been adjusted to include both final On-Hand material, as well as any material that is on an open Receiver. This eliminates the chance of ordering too much non-tag Master Required material because the material has been received but not updated. Creation of the Inventory Balance File The Inventory Balance file is updated whenever you purchase, produce or receive material. A record is also created by the end of month utility for any product item that has a Minimum Stocking Quantity in the Branch Standard Dimension file. For critical product items that you need to track using the various Inventory Planning reports, you must enter a Minimum Stocking Quantity in the Branch Standard Dimension file. This will ensure that shortfalls in the stocking levels for this product item are included in your reports. The reason for this requirement is that many of the reports only include material if there is an entry in the Inventory Balance file. Rebuilding the Inventory Balance Table <inbpmb> The Product Master Balance Utility must be run after adding or modifying Standard Dimensions to resync the Inventory Balance Table. The script is located on the Periodic Procedures menu. The utility writes to a session log PMB Rebuild Session Log, which can be viewed from the CS/IRIS print controller. The utility can run with users logged on, but may adversely impact system performance if run during peak periods. The utility locks inventory records by Product Master, one Product Master at a time. An error message Product is currently locked. Please try again later. is displayed if a user tries to update a product that is already being updated by the Inventory Balance Rebuild utility. If the utility is unable to establish a lock on the Product Master, a message is written to the session log and those records are skipped. Example: While the utility is processing PRD records for CRC/18/CQ, you cannot add, change, delete, consume, reserve or modify any material that is coded as CRC/18/CQ until the utility moves on to the next Product Master.

20 2. Product Statistics Page 12 EQUIVALENT PRODUCTS Equivalent Products are used to group similar products on the Inventory Position and Inventory Requirements Forecast Reports in order to analyze their total requirements. The groupings are userdefined and are entered at the Product Master level. The Equivalent Product could be used if for example, your company sells carbon sheet and purchases coil which is then leveled to sheet. In order determine the correct stock position, it is necessary to look at both the sheet and coil. If they are related by Equivalent Product, the forecast reports would print the coil and sheet statistics together and then provide a summary total by Equivalent Product. Another use for the Equivalent Product would be to link products that can be substituted. In carbon plate for example, you could be able to substitute grade A-36 for CQ. By linking these two products with an Equivalent Product, they can both be printed together on a forecast report. When an Equivalent Product selection is requested, all dimensions for the Equivalent Products are grouped together and printed in one section of the report so they can be reviewed together. The Branch Standard Dimensions are shown individually on the report and a total of each Equivalent Product is printed. In order for the Equivalent Product feature to work properly, you must set up parallel Company and Branch Standard Dimensions for each Product Master that is to be reported. This is necessary because the Inventory Requirements Report only prints information for products having Standard Dimensions and Product Statistics records which are maintained at the Branch level.

21 2. Product Statistics Page 13 Equivalent Product Printing Sequence Below is an example of the Equivalent Product option. The sample report shown is the Inventory Position report. You have the option of printing only the totals or both the details and total for each Equivalent Product Group. For example: Product Master (PRM) HRC HRS HRC HRS HRC HRS Totals Equivalent Product Group HR18 HR18 HR18 HR18 HR18 HR18 HR18 HRC HRS HRC HRS HRC HRS Totals HR16 HR16 HR16 HR16 HR16 HR16 HR16 The detail option prints the Equivalent Product code and description followed by the details for each Standard Dimension, by Branch that has the same Equivalent Product code. Any Standard Dimensions that do not have an Equivalent Product are printed first, followed by the Equivalent Products. When setting up the Equivalent Product groups, they are sorted alphabetically. Within each Equivalent Product Group, the Standard Products are sorted by common dimension, Group Sequence number, and Product Master Sequence number.

22 2. Product Statistics Page 14 RUN: 18May04 17:04 METAL COMPANY inript PAGE: 3 Inventory Position --Incoming-- --Mths Inv Avg Mthy Demand To Buy or EOM Stock Position Brh OnHand Avail Curr Long Min Obj Curr Long 1/ 8 Aug Sep Oct Nov Dec Jan Total Equivalent Product: CRC18 Cold Rolled 18 gauge CRC 18 CQ PHI CRC 18 DQ PHI CRS 18 CQ PHI CRS 18 DQ PHI CRC PHI* CRC 18 CQ PHI CRC PHI* CRC 18 CQ PHI CRC 18 CQ PHI CRC 18 DQ PHI CRC PHI* Sequence by Equivalent Product Details

23 2. Product Statistics Page 15 RUN: 26Apr04 inript Page: 1 INVENTORY POSITION REPORT --Incoming- --Mths Inv Avg Mthy Demand To Buy or EOM Stock Position Brh OnHand Avail Curr Long Min Obj Curr Long 04/03 04/06 04/06 04/12 Sep Oct Nov Dec Jan Feb Total Product Equivalent: HR18 Hot Rolled Steel - 18 Gauge HRC HRC HRC HRS HRS HRS CHI A MTL C PHI A *** A CHI A PHI A Product Equivalent Totals CHI A MTL C PHI A *** A Product Equivalent: HR16 Hot Rolled Steel - 16 Gauge HRC HRC HRC HRS HRS HRS PHI A PHI A CHI A PHI A *** A Product Equivalent Totals CHI A MTL C PHI A *** A Equivalent Product Totals Only

24 2. Product Statistics Page 16 The Equivalent Product Totals Only option lists the Product Masters sharing the same Equivalent Product code. Totals for the Equivalent Product are printed by Branch and common Standard Dimension, followed by a total for all dimensions for each Branch.

25 3. BRANCH PRODUCT SALES FORECAST The Branch Product Sales Forecast file contains the monthly sales forecast figures by Branch and Year for each Branch Standard Dimension. The records are created manually using the Branch Product Sales Forecast Entry program. This file provides another option other than sales and usage to forecast inventory requirements. It is especially helpful during the first year using as there is little historical data. Usage or sales statistics from your prior system can be entered to provide some history. Use of this forecast option is only available with the Inventory Requirement Forecast Report. Each record is stored by Branch, Standard Dimension and Accounting Year, and contains the forecast usage/sales quantity for Accounting Periods 1 through 12. Branch Product Sales Forecast 1. Branch Product Group Size Grade Standard Width Standard Length Standard Gauge Century/Year Sales Forecast Qty.. ( ) Item No : 1-Alter 2-Copy 3-Delete Branch Product Sales Forecast screen If the Standard Dimension has a Usage Status of I or D, you cannot enter or maintain a Branch Product Sales Forecast record. The Sales Forecast is based on the Month and Year. You can enter forecast information for the prior year, current year, or the next year. The current year defaults from the Accounts Receivable Company file. Enter the forecast year if the forecast is for the prior or next year. An error message is displayed if the fiscal calendar has not been set up. The months are displayed as calendar months. Internally, the calendar month is converted to an Accounting Period if different from the calendar year.

26 3. Branch Product Sales Forecast Page 18 Field Name Default Validation Description Branch Product Group Size Grade Standard Width Standard Length Standard Gauge Century/Year Sales Forecast Qty ( ) Print Quantity UM for Product MmmYY XXXXXXXXXXXX Month and Year for Periods 1 through 12. Branch Reference Group Reference Gauge Table Product Master Reference Branch Standard Dimension Branch Standard Dimension Branch Standard Dimension AR Current Year +/- 1 Forecast Branch. Product Group. Enter a Branch Standard Product for the Forecast. Product Size. Product Grade. Standard Width from the Branch Standard Dimension reference file. Standard Length from the Branch Standard Dimension reference file. Standard Gauge from the Branch Standard Dimension reference file. The Forecast Year. You can enter the current year, the prior year, or the next year. The Print Quantity Unit of Measure defaults based on the Product's Inventory Logic Control (ILC) code. It cannot be changed. Table of 12 Accounting Periods, starting with Period 1, and ending with period 12 for the selected Forecast Year. The Month and Year are determined from the Current AR Period ending date. Example: If the Current AR Period is 0101, and the ending date for the Current AR Period is 07/31/00, then the Forecast for 2001 starts with Jul00 and runs through Jun01 (Period 1 through 12). The forecast quantity for the accounting period. There are twelve entries, one for each accounting period.

27 3. Branch Product Sales Forecast Page 19 Branch Product Sales Forecast 1. Branch... PHI 2. Product Group... BA 3. Size Grade Standard Width Standard Length... 40' " 7. Standard Gauge Century/Year Sales Forecast Qty.. (LBS) Jul LBS Jan LBS Aug LBS Feb LBS Sep LBS Mar LBS Oct LBS Apr LBS Nov LBS May LBS Dec LBS Jun LBS Item No : 1-Alter 2-Copy Completed Branch Sales Forecast screen Action Bar Alter Copy Action Allows you to change the forecast quantities. Used to create a new record by copying the current record. Restrictions You cannot change the Branch, Standard Dimension, Forecast Year or Quantity Unit of Measure once the record is written. You can only change the forecast quantities.

28 3. Branch Product Sales Forecast Page 20

29 4. STANDARD SELECTIONS The following selections are used in the Inventory Planning functions. ABC Classification... [_] _ Enables you to select products based on the Standard Dimension ABC Classification. If the report selection is for a specific Branch, the Branch Standard Dimension ABC Classification is used. If the report selection is for all Branches or Corporate, the Company Standard Dimension ABC Classification is used. Options are: N Y - (Default.) The ABC Classification is not verified when selecting products. - Allows entry of a single ABC Classification (A through Z) for the Inventory Position Report. The Inventory Requirement Forecast allows up to 5 selections. ABC Ranking... [_] _ Used to select products based on the ABC Ranking. Up to 5 ABC Ranking codes can be included. If the report is run as a Corporate report, the Company Standard Dimension ABC Ranking code is used. If it is a Branch report, the Branch Standard Dimension ABC Ranking code is used. Options are: N Y - (Default.) The ABC Ranking code is not verified when selecting products. - Allows you to enter up to five ABC Ranking codes. Above/Below Indx Obj... Above/Below Turn Obj... [_] [_] Used to select products that are above or below the Branch Standard Dimension Objective when a Branch report is selected, or the Company Standard Dimension Objective if a Corporate report is requested. Options are: A B N - Only products with an Objective greater than the Standard Dimension Index/Turnover Objective are selected. - Only products with an Objective less than the Standard Dimension Index/Turnover Objective are selected. - (Default.) The Objective is not verified when selecting products.

30 4. Standard Selections Page 22 Above Maximum Qty... [_] Used to select products where the On-Hand Quantity is greater than the Branch Standard Dimension Maximum Stock Quantity. Options are: N Y - (Default.) The Branch Standard Dimension Maximum Stock Quantity is not verified when selecting products. - The On-Hand Quantity must be greater than the Branch Standard Dimension Maximum Stock Quantity. Adjustment Method... [_] Options are: P R V - Percentage If you choose P, the system prompts for a percentage change. The field is a percentage, therefore, the factor is actually Rate If you select R, you are prompted for a Rate change: and a UM XXX. You can indicate a change such as /TON or.50/cwt. The Unit of Measure does not have to be the same as the Replacement Cost Unit of Measure. Therefore, if the product is a Pipe which has a Replacement Cost in CFT, you can specify the change in CWT, TONS or any other weight based UM. - Value If selected, you must enter a new cost and a weight based Unit of Measure. This cost automatically overwrites the Replacement Cost in the Branch Standard Dimension record for the selected record(s). Avg Cst Whs Type... [_] Allows you to select Average Costs by Warehouse Type. Options are: N Y - All Warehouse Types are used in the calculation of the Average Costs. - (Default). The Average Cost defaults from a specific Warehouse Type. The Warehouse Type code defaults to P but can be changed to any valid warehouse type as required. Below Minimum Qty... [_] Used to select products where the On-Hand Quantity is less than the Branch Standard Dimension Minimum Stock Quantity.

31 4. Standard Selections Page 23 Options are: A E - Products are included if the Available Quantity is less than the Branch Standard Dimension Minimum Stock Quantity. - Equivalent Products are included if the Total On-Hand Quantity of the Products grouped within the same Equivalent Product code is less than their Total Branch Standard Dimension Minimum Stock Quantity. Product Groups without Equivalent Products are included if their On-Hand Quantity is less than their Branch Standard Dimension Minimum Stock Quantity. N O Q - (Default.) The Branch Standard Dimension Minimum Stock Quantity is not verified when selecting products. - Products are included if the On-Hand Quantity is less than the Branch Standard Dimension Minimum Stock Quantity. - Equivalent Products are included if the Total Available Quantity of the Products grouped within the same Equivalent Product code is less than their Total Branch Standard Dimension Minimum Stock Quantity. Product Groups without Equivalent Products are included if their Available Quantity is less than their Branch Standard Dimension Minimum Stock Quantity. Bought For... [_] For Owned material, enables you to products by Bought For Customer number. Options are: N Y - (Default.) The Bought For code is not verified when selecting products. - Allows entry of a valid Customer number. Only products whose Bought For Customer number matches the entered Customer are selected. Branch... [_] Allows you to select one, all, or a table of Purchase Order Branches. You can also enter a table of Branches for inclusion on the report. Options are: N T Y - All Branches are selected. - Allows you to enter up to ten Branches. - (Default.) Your User ID Branch is displayed automatically. However you can override the Branch code if you have multi-branch access.

32 4. Standard Selections Page 24 Branch/Corporate... [_] Determines the format of the report. The Branch/Corporate selection entry option enables you to select a Corporate report that prints the totals for all Branches. Options are: B C - (Default.) Branch. Allows entry of a single Branch code. Your User Branch is defaulted to the Branch selection and can be modified if you have multi-branch access. - Corporate. If C is selected, the Branch selection is by-passed. Buyer... [_] Enables you to select Purchase Orders by Product Master Buyer code. The Buyer selection entry option allows you to select products by Buyer based on the Product Master table Buyer code. Options are: N Y - (Default.) All Buyers are selected. - Allows you to select a specific Buyer. Compute Pieces... [_] Options are: N Y - (Default.) - Compute pieces. For example, Usage Weight/weight per piece. If weight per piece equals zero, the calculation is not made. Cost Type... [_] Valid Codes are: F - Freight If you select F, the Replacement Cost adjustment only applies to the Freight portion of the Replacement Cost. In both cases, the Total Replacement Cost is recomputed. M - Material If you choose M, the Replacement Cost adjustment only applies to the Material Portion of the Replacement Cost. T - Total If you select T, the Replacement Cost adjustment only applies to the Total Replacement Cost.

33 4. Standard Selections Page 25 The Material portion is then recalculated, keeping the Freight figure as the constant. Demand Periods... [_] From: To: Enables you to select up to four date ranges to calculate a Demand or sales figure which is then printed on the Inventory Position Report. The periods are entered as a range, by Year (YY) and Month (MM). For example: From 0001 To 0003 (period from Jan 2000 to Mar 2000). At least one period must be entered. The dates of the periods can overlap. Period Month Range 1 YYMM to YYMM 2 YYMM to YYMM 3 YYMM to YYMM 4 YYMM to YYMM Demand Type... [_] Allows you to select the source of the Demand figures to be used in the Demand forecast for the product. Options are: 1 Average Sales (Default.) Average of sales for the specified number of months. 2 Monthly Sales Derived from the Product Statistics table, this represents the actual monthly sales from the same accounting period of the prior fiscal year. 3 Average Usage Derived from the Product Statistics table, this represents the average Usage for the specified number of months. 4 Monthly Usage Derived from the Product Statistics table, this represents the actual Usage from the same accounting period of the prior fiscal year. 5 Sales Forecast This uses the Branch Product Sales Forecast table. 6 Program Material The report is a forecast of the future inventory requirements of Program Material Part Spec inventory. You must have previously purchased estelspec in order to use this feature. Equivalent Products... [_] Allows you to specify one equivalent product group. This option is only available if the report is sequenced by Equivalent Product. If you specify an Equivalent Product, it takes precedence over entries made in the Product Selections window. Options are: N Y - (Default.) All Equivalent Products are included in the report. - You must enter a valid Equivalent Product code. The Product Selection options are still used to filter out the Sizes, Grades, Dimensions and Gauges to be printed for Equivalent Products.

34 4. Standard Selections Page 26 Equiv Prd Dim Totals... [_] Allows you to print sub-totals by common dimensions. This selection is only available when you answer Y to the Seq by Equiv Prd option. Options are: N Y - (Default.) Sub-totals by common dimensions are not included in the report. - Sub-totals by common dimensions are not included in the report. Equiv Prd Tot Only... [_] Allows you to print only the totals for the Equivalent Products. This option is only available if the report is sequenced by Equivalent Product. Options are: N Y - (Default.) Prints each of the products that belong to the Equivalent Product Group. - Prints only the totals. Equivalent Weight UM... [_] Used to control the printing of the product quantity or equivalent weight on the report. By default, all products are printed according to their Inventory Logic Control Print Unit of Measure. If this option is used, all products are printed in a weight based Unit of Measure to ensure that there is a standardization for products in the same grouping but having different Inventory Logic Control factors. Options are: N Y - (Default.) Product quantities are not printed by equivalent weight. - You must enter a weight based unit of Measure. If the Base measure is Imperial, you can use any Imperial or Metric Weight Unit of Measure. If the Base Measure is Metric, you can only use a metric Weight Unit of Measure. Exclude Grades... [_] Allows you to exclude up to 10 grades from the report. The Excluded Grades apply to the selection of On-Hand inventory, Incoming inventory and Sales. Options are: N Y - (Default.) All Grades are included on the report. - Allows entry of up to ten Grades to be excluded from the report. Forecast Demand Period... [_] Indicates which period is to be used to compute the End of Month or To-Buy figures. Only one of the four periods can be specified as the Demand Period and it must have a date range.

35 4. Standard Selections Page 27 Valid options are: Period 1 (Default) Period 2 Period 3 Period 4 Forecast Type... [_] Determines whether the Inventory Position report prints the recommended quantity To Buy or the estimated Ending Inventory. Options are: B E - (Default.) To Buy. The report prints the quantity that must be purchased or produced to meet projected demand. - End of Month Inventory position is based on previous months Sales or Usage. Forecst Wgtg Factor... [_]. Allows you to enter a weighting factor to be applied to the average Demand. The adjusted Demand figure is used in the Forecast calculation. Options are: N Y - (Default.) No weight factor is used in the calculation of the Average Demand. - Allows you enter a weight factor to adjust the Average Demand. The weight factor is used when there was an unexpected increase or decrease in demand of a product and you want the report to reflect the expected change in the demand figure. Enter the weighting factor to be used. You can enter a value from 0.00 to If you enter zero, only Actual Demand is used in forecasting the available inventory at the end of each month. Incl General Invent... [_] Controls whether or not inventory not specifically bought for the customer will be included in the report. Options are: N Y - (Default.) Inventory not specifically bought for the customer is not included in the report. - The report will include inventory not specifically bought for the customer. This general inventory is also included in the totals calculations. If the same consumed group/size/grade is used by another customer, the general inventory is repeated. Include Incoming in Avl... [_] / / This option allows you to include or exclude incoming Product Items from the Available material

36 4. Standard Selections Page 28 calculation. Options are: N Y - (Default.) The Incoming Material Purchase Orders, Transfers and Outside Processing Orders are not included in the Available material. - The Incoming orders are included in the calculation of the Available material. When you enter Y, you are able to enter a cut-off date. This date determines which Incoming orders are included in the calculation of Long-term Incoming inventory based on the Order Due Date. The default is to include all Incoming material. Entry of a cut-off date does not affect the calculation of the Current Incoming material. Refer to the Incoming Stock Days selection option for details. Include Incoming Up To.... [_] Access to this field is allowed only when the Include Incoming in Avl selection is Y-Yes. Options are: N - (Default.) All incoming quantities (Material Purchase Orders, Transfers and Outside Processing Orders) are included in the Incoming columns regardless of due date. Y - Only incoming quantities, due on or before the specified date, are included in the Incoming columns. Include Non-Std Dim... [_] Allows you to include non-standard (Various by Various) products in the Inventory Planning report. A non-standard dimension product is one that falls outside the range of a standard dimension. Options are: N Y - (Default.) The non-standard Dimensions are excluded from the report. - The report prints the non-standard Dimensions. Incoming Stock Days... Allows you to determine the Current Incoming inventory. The number of days entered in this selection is added to the current system date. Incoming material due before this date is considered Current Incoming. Material due to arrive after this date is considered Long Term. Enter a number from 0 to 999. The default is 0, which means that all incoming material (including overdue material) is considered Long Term. If the Incoming Stock Days is set to 1 then all incoming material that is past due or due today will be considered Current and incoming material due after today will be considered Long Term.