MPS Review

You use this program to create master production schedules on-line.

Toolbar and menu

Field Description

File

 

Exit

This exits the program.

Options

 

Preferences

Configure preferences to apply when reviewing the Master Production Schedule.

Warehouse

Enter the warehouse to use for the review.

Alternatively, you can use the Review Options pane to indicate multiple warehouses to use for the review.

This field is disabled if you select to consolidate warehouses or use a warehouse selection from the Review Options pane.

Stock code

Enter the item you want to review for the selected warehouse(s).

Once you have indicated the stock code, you use the Review Options pane to indicate the criteria you require for running the review.

Change Rev/Rel

Uses the ECC Revision Release program to indicate the specific revision/release of the stock item you want to review.

This option is only enabled for ECC-controlled items.

Use current

Uses the current revision/release of the ECC-controlled item for the review.

Start Review

Display information according to the options and preferences you indicated.

Review Suggestions

Reviews suggested build schedules and optionally creates build schedules.

Query

 

Forecast

View and maintain details of forecasts for the selected stock item using the Forecast Maintenance program.

Build Schedule

View and maintain details of the build schedule for the selected stock item using the Build Schedule Maintenance program.

Preferences

Configure preferences to apply when reviewing the Master Production Schedule.

Preferences

This screen is displayed when you select the Preferences function or you select Preferences from the Options menu.

Field Description

Criteria selection

 

ATP negative in first period

View stock codes for which the available-to-promise is negative in period 1.

Proj avail less than safety within PTF

View stock codes for which the projected available is below safety within the planning time fence.

Proj avail less than safety within PH

View stock codes for which the projected available is below safety within the planning horizon.

Past due build schedules

View stock codes for which build schedules are past the due date.

Inclusion selection

 

Include past due forecasts

Select this to include stock codes for which the forecasts are past the due date.

Include forward orders

Select this to include stock codes for forward orders in the review.

Forward orders are entered in the Sales Order Entry program and are customer orders that require stock allocations to be made at a future date.

Include orders excluded from MRP

 Select this to include stock codes which were excluded from the Material Requirements Planning calculation in Sales orders.

This option must be added using the Show Captions option as it is not displayed by default.

Limit periods up to selection

 

Date selection

No limit is placed on the number of periods to include.

Indicate a specific cut-off date on which the periods must end.

Limit periods to the period following the planning horizon (PH) provided it does not exceed the maximum number of periods entered.

Period limit

 

Period selection

 

Period length

Enter the number of days required in a period.

Number periods

Enter the maximum number of periods (in the range 1 to 98) required to be viewed.

Review Options

This pane is enabled once you have indicated the stock item for which you want to review the schedules.

Field Description

Run date

Indicate a valid date from which viewing must commence.

Number periods

Indicate the maximum number of periods (in the range 1 to 98) required to be viewed.

Use warehouse selection

Uses your warehouse selection below for the review.

Use warehouses defined in setup

Uses the warehouse selections made within the Requirements Planning Setup program for the review.

Warehouse selection

Indicate the warehouse(s) to use for the review (if you selected the Use warehouse selection option).

Consolidate warehouses

Consolidates the values of all warehouses in which the selected item is stocked.

Include ECC deplete oldest

Include the job allocations using the ECC consumption method Deplete oldest (Structures and Routings).

Warehouse values

Column Description

Warehouse

Indicates the warehouse selected for the review.

The word 'Consolidated' is displayed if more than one warehouse was included in the review.

Qty on hand

Indicates the quantity of the item physically in the warehouse (including quantities on hold).

Qty on back order

Indicates the sales order back order quantity (excluding unallocated scheduled order back order quantities).

Qty allocated to S/O

Indicates the quantity on back order together with the sales order ship quantity (excluding unallocated scheduled order back order and ship quantities).

Ship quantities for credit notes are not included in the sales order ship quantity (these quantities are only available once the credit has been fully processed).

Qty available

Indicates the quantity on hand less the quantity allocated to sales orders for the item in the selected warehouse.

It includes stock on hold, stock in expired lots, stock locked by ECOs and stock in bins that are on hold (the quantity on hand used in the calculation is the quantity physically in the warehouse and includes quantities on hold).

Qty in inspection

Indicates the quantity of purchased items awaiting inspection (i.e. receipted into inspection, but not receipted into stock).

Qty in transit to be received

Indicates the outstanding non-immediate warehouse transfers shown against the target warehouse.

Qty on order

Indicates the quantity of outstanding purchase orders, made-in jobs and supply chain transfers.

Qty allocated to WIP

Indicates the outstanding materials to be issued to jobs (including allocations to both confirmed and unconfirmed jobs).

Deplete oldest WIP qty

Indicates the total quantity of job allocations for the item using the ECC consumption method Deplete oldest (Structures and Routings).

Production Information

Field Description

Gross requirements rule

This indicates the gross requirements rule defined against the stock item when calculating the demand for a stock code/warehouse.

Batching rule

This indicates the batching / buying rule for the stock item that is used by the Requirements Planning system and indicates how quantity shortages for the stock item are addressed.

The order quantity is the shortage quantity.

All sub jobs are automatically created as lot for lot.

You would typically select this batching rule when implementing MRP (Requirements Planning) in SYSPRO for the first time. The rule simply generates planned supply (jobs, purchase order requisitions and purchase orders) for the actual net shortage in demand for each period.

Once you have familiarized yourself with SYSPRO's Requirements Planning module, you can implement the other batching rules as required.

To calculate the order quantity, the shortage quantity is rounded up to the next multiple of the economic batch quantity.

For example:

If the Economic batch quantity is 10 and the shortage is 32, then the order quantity will be 40. 4 x EBQ (10) = 40.

The system will always exceed and never short manufacture/buy.

When a shortage is encountered, the order quantity is calculated by adding all the shortages in the fixed time period ahead (i.e. a consolidation of all orders in the chosen time period into a single order quantity).

For example:

If the shortage is 32 today and 14 tomorrow, and the fixed time period is 1 day (1 future working day) then the order quantity will be 46 (32 + 14).

When a shortage is encountered, the order quantity is calculated to increase the stock holding up to the maximum quantity defined against the warehouse.

For example:

If the shortage is 32 and the maximum quantity is 100, then the order quantity will be 132 (32 + 100). This is because the shortage of 32 must be filled, plus 100 are required to bring the stock holding up to its maximum of 100.

As soon as the result field falls below the minimum quantity (during netting-off) an order quantity is calculated to order enough to increase the quantity available up to the maximum quantity.

For example:

If the minimum quantity is 50 and the maximum quantity is 200 and the result field is 12, then the order quantity will be 188 (200 - 12).

When you select this option, the MPS Review and MRP Master Production Schedule programs use the minimum and maximum quantities defined against the warehouse to calculate the suggestions made. Safety stock is not taken into account.

This rule is identical to rule B, except that the pan quantity is used instead of the economic batch quantity.

To calculate the order quantity, the shortage quantity is rounded up to the next multiple of the pan size.

For example:

If the Pan size is 10 and the shortage is 32, then the order quantity will be 40.

If a shortage occurs, then multiple orders are created to satisfy the shortage, each the size of the Economic batch quantity.

For example:

If the Economic batch quantity is 10 and the shortage is 32, then 4 orders (each having an order quantity of 10) are suggested.

This rule is identical to rule G, except that the pan quantity is used instead of the economic batch quantity.

If a shortage occurs, then multiple orders are created to satisfy the shortage, each the size of the pan.

For example:

If the Pan size is 10 and the shortage is 32, then 4 orders (each having an order quantity of 10) are suggested.

If a shortage occurs, the order quantity is the quantity required to meet the shortage, unless this is less than the Economic batch quantity (in which case the EBQ is used).

For example:

If the Economic batch quantity is 10 and the shortage is 8, then the order quantity is 10 (the 8 required to meet the shortage is less than the EBQ, so the EBQ is used). However, if the shortage is 32 and the Economic batch quantity is 10 then the order quantity is 32.

This rule is identical to rule I, except that the pan quantity is used instead of the Economic batch quantity.

If a shortage occurs, the order quantity is the quantity required to meet the shortage, unless this is less than the Pan size (in which case the Pan size is used).

For example:

If the Pan size is 10 and the shortage is 8, then the order quantity is 10 (the 8 required to meet the shortage is less than the Pan size, so the Pan size is used). However, if the shortage is 32 and the Pan size is 10 then the order quantity is 32.

This rule is a combination of rules B and C.

The order quantity is calculated by adding all the shortages in the fixed time period ahead.

Once this total shortage quantity has been calculated, then this is rounded up to the next multiple of the Economic batch quantity.

This rule is a combination of rules F and C and is identical to rule K, except that the pan quantity is used instead of the economic batch quantity.

The order quantity is calculated by adding all the shortages in the fixed time period ahead.

Once this total shortage quantity has been calculated, then this is rounded up to the next multiple of the Pan size

This rule is a combination of rules G and C.

The order quantity is calculated by adding all the shortages in the fixed time period ahead.

Once this total shortage quantity has been calculated, then multiple orders (each the size of the Economic batch quantity) are suggested.

This rule is a combination of rules H and C and is identical to rule M, except that the pan quantity is used instead of the Economic batch quantity.

The order quantity is calculated by adding all the shortages in the fixed time period ahead.

Once this total shortage quantity has been calculated, then multiple orders (each the size of the pan) are suggested.

If a shortage occurs, the order quantity is at least the Economic batch quantity. However, if the EBQ is insufficient to satisfy the shortage, then the remaining shortage is rounded up to the next multiple of the pan quantity.

For example:

If the Economic batch quantity is 10 and the pan quantity is 5, a shortage of 3 would cause an order quantity of 10 (the shortage is less than the EBQ). A shortage of 23 would cause an order quantity of 25.

Demand generated for this item won't result in any suggested replenishment orders, unless you have indicated that batching rules must be overridden (Setup Options > Preferences > Manufacturing > Requirements Planning).

This is the default batching rule for an item defined as a By-product and cannot be changed.

In addition, when you set the Stock code status to Clear, the batching rule for that stock code is automatically set to P - Suppress MRP ordering. This cannot be changed until the Stock code status is changed to either Normal or Temporary.

This indicates that you want to define the order policies against the individual warehouses in which the item is stocked, using the Warehouse Maintenance for Stock Code program (Program List > Inventory > Setup).

Different order policies can be defined for each warehouse in which the item is stocked. The following order policies are available:

  • C - Cover shortages

  • I - Cover shortages if less than min

  • M - Order to max if less than min

  • O - Cover shortages less than min overages up to max

  • P - Suppress MRP ordering

  • S - Order to max if shortage

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.

Minimum quantity

This indicates the minimum quantity of the item required to be stocked in the warehouse at any point in time.

It is used as a stock control feature, and you can report on items where the on hand quantity is less than this figure using the Warehouse Exception program.

This field is updated by the calculation performed by the Inventory Minimum Quantity Calculation program.

Maximum quantity

This indicates the maximum quantity of the item required to be stocked in the warehouse at any point in time.

It is used as a stock control feature, and you can report on items where the on hand quantity exceeds this figure using the Warehouse Exception program (providing that the entry made here is non-zero).

It is also using together with batching rule D (i.e. order to maximum quantity) within the Requirements Planning module.

SYSPRO does not allow any order policy (Stock Code Maintenance) to exceed the Maximum quantity defined.

Safety stock level

This stock control feature highlights instances where stock falls below a prescribed level and is used within the Requirements Planning module.

The safety stock level is usually set to be above the minimum stock level. It is the quantity of stock kept in the warehouse to protect against fluctuations in demand or supply.

You can report on items where the on hand quantity falls below this figure, using the Warehouse Exception program.

Percent yield

 This indicates the percentage of an item that is lost in the manufacturing process so that a shortfall in actual production does not cause an unexpected inability to meet demand on time.

Lead time (days)

 This indicates the lead time defined against the warehouse.

Demand time fence (days)

 This indicates the number of days required to fulfill the order.

Review Suggested Build Schedules

This screen is displayed when you select the Review Suggestions option to review the suggested build schedules and optionally create build schedules.

Field Description

Reference

Indicate the reference you want to assign to the build schedule.

Resource

Indicate the resource code for the item. This defaults to the resource code defined against the stock code.

Create Build Schedules

Creates build schedules for the suggested build schedules you have highlighted.

For items defined with a batching rule of E - Order to maximum if less than minimum (Stock Codes) the minimum and maximum quantities defined against the warehouse are used to calculate the suggestions made.

Safety stock is applied to the time fence selected in the Requirements Planning Setup program if you selected to include it in the requirements calculation.

Notes and warnings

Bought-out at warehouse level considerations

  • If reviewing an item that is defined as bought-out at warehouse level (Inventory Warehouse Maintenance for Stock Code) then the Stock Information pane shows the supplier, lead time and dock to stock days defined against the warehouse instead of the values held against the stock code. The Production Information pane shows the lead time defined against the warehouse instead of the value held against the stock code. This is ignored if using consolidated warehouses.