Requirements Planning Query

You use this program to view the results of the Requirements Calculation for each stock code/warehouse combination.

Menu and Toolbar

Field Description

File

 

Exit

This exits the program.

Options

 

Preferences

Configures options that will determine the detail displayed in the query.

Reload Query after Pegging Change

Automatically reloads the query whenever you make changes to the pegging using the Change icon in the Material Requirements Pegging listview.

Non-stocked

View demand requirements for a non-stocked item.

When you select this option, the Warehouse is set to ** and cannot be changed. The code you enter in the Stock code field must be a non-stocked item.

Stock code

Enter the stock code for which to view demand requirements.

If you selected the Non-stocked option, then you need to enter a non-stocked code.

You can use the Browse icon to use the MRP Stock Codes with Demand program to view a list of all stocked and non-stocked items for which a demand was created.

Warehouse

Indicate the warehouse for which to display the demand requirements for an item.

You cannot access this field when the Consolidate selected warehouses option is enabled (Requirements Planning Setup).

MPS view

This option only applies to master production scheduled items.

Displays the build schedule information for MPS items.

Displays the actual demand information for MPS items. Actual demand for MPS items can only be viewed at a single level of pegging.

Change Rev/Rel

Change the revision/release for an ECC-controlled item.

Refresh

Refreshes the information displayed.

Preferences

Field Description

Save

This saves the details you entered or changed.

Close

This returns you to the previous screen.

Preferences

 

Pegging levels to display

Displays all levels of a pegging (up to 14 levels).

When viewing all levels and pegging is dependent on higher level demand, then these levels are displayed in the Material Requirements Pegginglistview.

Displays a single level of a pegging.

Actual demand for MPS items can only be viewed at a single level.

Warehouse information to display

Displays the Snapshot warehouse information from the Requirements Calculation program.

Displays the live warehouse information.

Only display direct parent demand

When viewing all pegging levels and pegging is dependent on higher level demand, then only the direct parent source of the demand is displayed.

MRP Graph

This displays a graphical representation of the available quantity and the minimum and maximum quantities for the selected stock code.

If you are not using the Inventory Optimization module, then the static minimum and maximum quantities from the warehouse are used (Inventory Warehouse Maintenance for Stock Code).

Information

This enables you to indicate various options according to which to display the information as well as displaying stock code and warehouse information.

Options

Field Description

Master production Schedule

 

Include forecasts

Includes forecasts when viewing actual demand.

Include sales orders

Includes sales orders when viewing actual demand.

Build Schedule

Select Show to use the Build Schedule Maintenance program to manually create and adjust build schedule records for the stock item.

Periods

 

Period selection

Indicate the period for which to display material supply and demand information.

View material supply and demand information for a single day.

View material supply and demand information for a number of days. All supply and demand within the specified range of dates is indicated on a single line.

View material supply and demand information for weekly intervals. You are prompted to indicate the first day of the week.

All supply and demand within the specified range of dates is indicated on a single line.

View material supply and demand information for monthly intervals.

All supply and demand from the current system date until the end of the month is indicated on the first line. Subsequent months are each indicated on single lines.

Use the IO forecast calendar periods.

Number of days

Enter the number of days required to be used if you selected a period selection of Multiple days.

For all other period selections, the system displays the defaults number of days for that period and these cannot be changed.

First day of the week

Indicate the first day of the week for the period selected.

Stock information

Details defined in the Stock Codes program for the stock item are displayed in this pane.

Refer to Time Fences for details on Time Fences.

Warehouse information

This pane indicates details for the selected warehouse.

You can view the material demands for ECC controlled components with WIP allocations (against which the Deplete oldest rev/rel first (Component) setup option is enabled - Setup Options > Configuration > Manufacturing > Bill of Materials) in the Deplete oldest WIP field.

Field Description

Warehouse

This indicates the warehouse of the selected stock item.

Warehouse description

This indicates the warehouse description.

Current cost

This indicates the current cost of the selected stock item.

Cost uom

This indicates the unit of measure associated with the current cost of the selected stock item.

List price

This indicates the list price of the selected stock item.

Quantities

This section lists information regarding the stock quantities on hand, available, in transit, etc.

Order Policy Details

This section lists information regarding the order policy of the stock item.

Order policy

This indicates the order policy for the stock item, which depends on the equivalent batching rule.

The order policy defined against the warehouse to use (Stock Code Maintenance) is applied when the Consolidate selected warehouses option is enabled (Requirements Planning Setup).

The following order policies are available:

This order policy covers shortages irrespective of any other settings specified for the warehouse like minimum quantity, etc.

For example:

If the available is 7, the demand 40 and the minimum 20, then MRP will suggest supply of 33. This is the 33 required to meeting the demand (7 - 40 = 33).

The 20 to meet the minimum is ignored.

The 33 will be determined by the other options selected like pan size, multiples of pan, economic batch quantity (EBQ), etc.

This order policy is basically the same as I - Cover shortages if less than min, except that it ignores the minimum, i.e. the order point is reached when available is insufficient to meet the demand (effectively, the minimum is taken to be zero, even if it isn't).

If the quantity available minus the demand is less than the minimum level, then MRP will recommend supply to meet demand and to top up to the minimum level.

For example:

If available is 7, demand is 40 and minimum is 20, then the suggested supply will cover the shortage of 40, less the quantity on hand (7 - 40= -33). This is the shortfall that will be added by the system.

As the warehouse minimum is 35, a further order for 35 will be produced to get to the warehouse minimum.

The minimum warehouse quantity should be the minimum stock level being retained in the warehouse. If the available drops below the minimum stock level, suggestions will be raised to achieve the minimum stock level. If demand is raised causing the available quantity to fall below the minimum stock level, suggestions will be raised to satisfy the demand without compromising the minimum stock level.

This ignores the Fixed time period (days) option defined in the Stock Code Maintenance program.

This rule can be used with the Inventory Optimization module. Dynamic safety stock levels can be applied, i.e. minimum stock levels per period, without the need for a maximum stock level. The rule orders up to the minimum regardless of whether the min/max levels are defined against the warehouse or against the Inventory Optimization module.

This ignores the minimum. The order point is reached when the quantity available is insufficient for the demand.

This ignores the Fixed time period (days) option defined in the Stock Code Maintenance program.

If demand causes available to be less than the minimum, then MRP will recommend supply up to the maximum.

This ignores the Fixed time period (days) option defined in the Stock Code Maintenance program.

When using the Inventory Optimization module, the goal of this policy is to suggest supply that will satisfy the target service level defined against the IO policy defined in the IO Policies program.

If the business needs to increase stock in preparation for an event, this order policy will allow them to build stock to the maximum, irrespective of how much stock there is in the warehouse. The stock level may go slightly over the maximum quantity, depending upon batch size, but will never go below.

This caters for raising a suggestion when the minimum stock level in the warehouse is greater than the demand. Further supplies can be raised outside of MRP until the maximum is reached, at which time a cancel action is raised (i.e. when the supply quantity exceeds the warehouse maximum for that stock code). This could be used where demand is seasonal and supply can't match demand until a later stage, resulting in an increase in the stock holding level until the maximum has been reached.

This order policy was developed to allow building stock for an event like a promotion and ignores all quantities except maximum quantity and batch size.

For example:

If the warehouse minimum is 100 and the warehouse maximum is defined as 200, the policy will keep 100 in stock using MRP suggestions while taking all demand into account.

Supply created in the form of purchase orders or internal jobs will be kept to a maximum of 200 while considering all demands, stock on hand, etc. The purchase orders or internal jobs in excess of the maximum will be canceled by MRP.

This policy can also be applied to co-products that are produced via a notional part, as the notional part is the driver for the order policy.

If you manufacture a co-product without a notional part, it is handled like a normal made-in item.

Considerations:

  • This feature is not applied to ECC depletion.

  • This option applies to sites that are not licensed for the Inventory Optimization modules, but which are using warehouse order policies in MRP.

  • This rule can only be used if the Schedule jobs and purchase orders setup option is enabled (Setup Options > Configuration > Manufacturing > Requirements Planning) and when running the Requirements Calculation in legacy mode.

  • When this order policy is applied to co-products, it must be applied to the notional part and use the min/max levels defined against the notional part (i.e. ignore the min/max levels defined against the co-product).

Demand generated for this item will not result in any suggested purchase orders.

Major order multiple

If this field is set to anything other than zero, then the order quantity is calculated as a multiple of the entered value.

Minor order multiple

If this field is set to anything other than zero, then the order quantity is calculated as a multiple of the entered value.

Minimum order quantity

If this field is set to anything other than zero, then the order quantity is at least the entered value even if the requirement is for less.

Maximum order quantity

If this field is set to anything other than zero, then the order quantity will not exceed the entered value. If the requirement is greater than the entered value, then multiple orders will be required.

IO Min/Max Levels

The information in this pane only applies if you are using the Inventory Optimization module.

The module is used to calculate and output minimum and maximum (min/max) stock levels for stock items by calendar period. The IO current min/max levels (in the IopStockLevel table) are copied to the snapshot MRP min/max stock level table (MrpStockLevel) and used by the Requirements Calculation to derive an optimal requirement.

Multi-grade co-products are not supported in the context of min/max levels in Inventory Optimization.

No min/max levels are displayed for Notional parts; only for their Co-products.

Material Requirements

This indicates the Material Requirements Details and Material Requirements Pegging information for the stock code/warehouse combination selected.

Material Requirements Details

The title of this pane indicates your selection at the Periods option in the Options section of the Information pane.

For MPS items, you can select to view the Build schedule or the Actual demand at the MPS View option.

Column Description

Period

Indicates the period of the demand/supply. The date is relevant to your selection at the Periods option.

Not loaded is displayed for any supply falling into the date range January 1st, 2040 to December 31st, 2045.

This column cannot be sorted as it contains both text and date fields. To sort by date, you need to sort on the Start date column.

Available

Indicates the stock on hand less the allocated stock plus the stock in transit due to be received plus stock in inspection, for each stock code/warehouse combination (i.e. it is the quantity available netted off with the supply and demand from the previous period).

This is zero for MPS items where you enabled the Build schedule option at the Include in requirements calculation field (Requirements Planning Setup). The available quantity on lines after the first line will be the previous line's result carried forward.

The calculation of the quantity available depends on the Requirements Planning Setup options selected. The calculation begins with the warehouse quantity on hand and adjusts this quantity depending on what you included in the MRP calculation.

For example:

  • If you include jobs and you are reserving lots and serials, then the quantity reserved is removed from the quantity on hand.

  • If you include jobs and you are reserving material allocations (Work in Progress Setup) then the quantity reserved is removed from the quantity on hand.

  • If you are not including sales orders, then the quantity allocated to sales orders is removed.
  • If you are not using the full Goods in transit system, then the quantity in transit is removed.

The quantity in inspection (less the quantity scrapped) is added to the quantity on hand.

Supply

Indicates one or more of the following (depending on the Requirements Planning Setup options selected): quantity in transit, existing job, existing purchase order, estimate, suggested job, suggested purchase order requisition, existing purchase order requisition, IO min/max levels and associated batching rules if Inventory Optimization is in use.

When using Inventory Optimization, the Target Service Level - defined against the policy (IO Policies) - is crucial in determining the resultant min/max levels.

The higher the Target Service Level, the higher the suggested Minimum, and by implication, the higher the suggested Maximum. The current min/max levels are used by the MRP calculation to address demand, in conjunction with Batching Rules set against the Inventory Master.

Therefore, the higher the target service level, the higher the suggested supply made by MRP. Suggested MRP supply must be critically reviewed for feasibility in relation to the target service level set.

Therefore, suggested supply generated via min/max levels are a sensitive issue in MRP, potentially affecting the profitability of your company. Suggested MRP supply must therefore be critically reviewed for feasibility in relation to the target service level set before any action is taken.

Demand

Indicates one or more of the following (depending on the Requirements Planning Setup options selected): safety stock, sales orders, existing job allocations, suggested job allocations, build schedules, estimate allocations, forecasts.

Result

Indicates the available quantity plus the supply less the demand. The Result for the current period is equal to the Available for the following period.

Start date

Indicates the start date of the selected period (for example for Months, it is the first day of the month).

When MRP calculates that a supply should be canceled, the date is moved out beyond 31/12/2045 and therefore the Start date is displayed as 01/01/2046.

End date

Indicates the end date of the selected period (for example for Months, it is the last day of the month).

Material Requirements Pegging

Field Description

Change

Change the pegging for the line currently highlighted in the listview.

When changing requisition stores transfers, both the supply and demand side of the pegging are updated.

When you change a component or a sub-assembly of a job, you are prompted to indicate whether you want to update the Job Header (see Job Entry) or to Change the Available Date (see WIP Move Material Available Date).

Zoom

View additional information on the line currently highlighted in the listview.
Listview columns

This listview displays the reason for the supply or demand over the time period for the line currently highlighted in the Material Requirements Details listview.

When viewing all levels of pegging (i.e. when Pegging levels to display is set to All):

  • The supply date of the higher level pegging causing the demand on the current level is filtered on at the higher level. This will continue up the chain.

  • If a parent source key is duplicated on the current level, then only the first occurrence of the higher level source is exploded.

  • The Requirements Calculation ignores any purchase order (it actually physically deletes the lines from snapshot) that is part of a Call off single P/O which is not fixed and not in a status of completed or canceled and therefore no supply is recognized against active live lines and no pegging is output.

    Because no existing supply is output, all demand raised is satisfied by raising a suggested requisition. Thus the MRP Requirements Planning Query can only reflect the pegging as suggested requisitions.

Column Description

Where-used structure

This column can be selected as the default sequencing column. If you sequence on this column in ascending order, then all the higher level where-used structures will occur after the current level pegging.

Date

Indicates the period in which the demand or supply occurred. This column cannot be sorted.

Quantity

Indicates the quantity affected. A negative quantity indicates demand and positive quantity indicates supply.

Pegging source

Indicates the reason for the demand or supply and can be one of the following:

Demand caused by an allocation within estimate.

Supply caused by the finished part to make of estimate.

Demand caused as a result of an allocation within job number.

Demand caused as a result of an allocation within a suggested job.

Supply caused by the finished part to make of job number.

Supply caused by the finished part to make of suggested job number.

Demand as a result of sales order.

Supply as a result of purchase order.

Supply as a result of existing requisition. The requisition originator code is MRP.

Supply as a result of suggested requisition.

Demand as a result of a requisition stores issue.

When viewing all levels, both the source warehouse pegging and the target warehouse pegging is displayed.

This indicates the safety stock level.

This indicates the quantity in transit between warehouse as a result of an inter-warehouse transfer.

This message indicates that a demand has been made due to a forecast for the date indicated.

The Plan bill no: part of the message is only displayed for a planning bill part.

This message indicates that a demand has been made due to a build schedule record for the date indicated

Source ID

Indicates the number for the item displayed in the Source column (for example the job number, sales order number, etc.)

Level

Indicates the level at which the demand/supply occurred.

This is only displayed when you select to view All Levels in Pegging from the View menu.

Notes and warnings

  • The warehouse where the stock code is located is used by default if no default warehouse is defined for the operator or the warehouse is invalid for the current company.

Restrictions and limits

  • Although this program changes pegging and demand records according to changes made to the source transactions, it will not re-schedule the associated supply/demand.

    For example, if the Requirements Calculation program creates a job suggestion (supply) in response to insufficient stock being available for a sales order (demand) and you change the delivery date of the order, then the delivery date of the job remains unchanged.

  • Past due forecasts will generate past due supplies as displayed in the Material Requirements Pegging listview.