Performing Level 1 Master Production Scheduling—Key Exercises

Basic Data Setup

Overview of Master Production Scheduling Data

Purpose: The purpose of this exercise is to create the required data that is used in the master production scheduling exercises. This sets up data for your site that only needs to be done once for master production scheduling. 

If you have already set up the master production scheduling data on your site, use that data instead.

Note: If using only level 1 and MRP parts, parts with planning methods O and T are not required.

1. Set up your site for master production scheduling planning data for racing engines.

General exercise for Master Production Scheduling Planning Data Overview

MS Sets 2 through 6

Purpose: The purpose of this exercise is to verify that MS sets 2 through 6 are available for use with Sales and Operations forecast planning of these exercises.

Windows:
MS Basic Data /Master Schedule Set

1. Open the MS Basic Data window and click the Master Schedule Set tab.
2. Populate the window.
3. Verify that the following MS sets exist: 

   MS Set	MS Set Description
   0	Base plan
   1	Planning table for MRP and CRP
   2	Sales and operations plan
   3	Aggregated demand
   4	Proposed total forecast
   5	Eastern region forecast
   6	Western region forecast

General exercise for Creating MS Sets

Main Exercises

Calculating MS Schedules for Level 1 Parts

Purpose: The purpose of this exercise is to manually calculate an MS schedule for a level 1 part.

Windows:
Calculate MS Level 1
Background Jobs
MS Level 1 Part
MS Level 1 Part /Register Forecast

1. Open the Calculate MS Level 1 window.
2. Enter MS set 1, your site, and part 24-104.
3. Verify that the run date is today's date.
4. Click OK.
5. Open the Background Jobs window.
6. Populate the window.
7. Verify that the state for the Level 1 Master Scheduling background job is Ready.
8. Open the MS Level 1 Part window.
9. Query for part 24-104 at your site.
10. Click the Register Forecast tab.
11. Verify that the value in the Last Run Date field is today's date and that the Master Schedule column following values appear in the :

Scheduling MS Jobs for Level 1 Parts

Purpose: The purpose of this exercise is to automatically schedule an MS batch job to calculate a level 1 part.

Windows:
Calculate MS Level 1

1. Open the Calculate MS Level 1 dialog.
2. Click the  Schedule button, it will open the New Database Task Schedule window
3. Enter scheduling parameters.
4. Verify that the job you just scheduled is displayed in the Scheduled Database Tasks window.

Reviewing Disaggregated Forecasts from Level 0 Parts

Purpose: The purpose of this exercise is to review disaggregated results in the level 1 part in table and graphical formats, and in action proposals  format.

Windows:
MS Level 1 Part
MS Level 1 Part /Register Forecast
MS Level 1 Part /Action Messages
Detailed MS Graph
Cumulative MS Graph
MS Action Proposals
Shop Order Requisitions

Table Format:

1. Open the  MS Level 1 Part window.
2. Query for part 24-104 at your site.
3. In the header, review level 1 settings, which were inherited from the level 0 part.
4. Click the Register Forecast tab for MS set 1.
5. Verify the total value in the Forecast 0 column is 206.5.
6. Click the  Action Messages tab for MS set 1.
7. Verify that the the Message Description field displays Negative Projected Available.

Graphical Detailed Format:

1. Open the Detailed MS Graph window.
2. Click MS level One, part 24-104, your site, and MS set 1.
3. If not using level 0 MPS, right-click in the header, click Recalculate Template, and then click OK. Note: This synchronizes the graph start date with the period template start date.
4. In the header, right-click and then click Show Graph.
5. Change the end period number to 12.
6. Click OK and view detailed results.

Graphical Cumulative Format:

1. Open the Cumulative MS Graph window.
2. Click MS level One, part 24-104, your site, and MS set 1.
3. In the header, right-click and then click Show Graph.
4. Change the end period number to 12.
5. Click OK and view cumulative results.

Action Proposals Per Planner:

1. Open the MS Action Proposals window.
2. Query for your site.
3. Verify that the Message field for part 24-104 displays Negative Projected Available.

Resetting the PTF and DTF Settings for Level 1 Parts

Purpose: The purpose of this exercise is to simulate the transition of elapsed time in order to activate the crossing of the PTF calculations.

Windows:
MS Level 1 Part
MS Level 1 Part /Register Forecast
Shop Order Requisitions
Perform MRP
Note: This exercise is only performed for this class and once during initial system setup.

1. Open the  MS Level 1 Part window.
2. Query for part 24-104 at your site.
3. In the Demand Time Fence field, enter 3.
4. In the Planning Time Fence field, enter 7.
5. Save the changes.
6. In the header, right-click and click Run MS—One Part.
7. Verify part 24-104 and MS set 1, and then click OK.
8. Click the Register Forecast tab.
9. Verify that Fixed is displayed in the Proposed column for periods 3, 4, and 5.
10. Open the Shop Order Requisitions window.
11. Query for part 24-104 at your site.
12. Verify that the shop order requisitions have been created for part 24-104.

Aggregating Level 1 Parts and Creating a Sales and Operations Plan

Purpose: The purpose of this exercise is to aggregate a level 1 part and create an S&OP.

Windows:
Aggregate Level 1 to Level 0
Background Jobs
Aggregate Inventory Transactions per Period
Sales and Operations Planning

1. Open the Aggregate Level 1 to Level 0 window.
2. Verify that the Source Item Plan MS set is 1.
3. Enter your site, part 24-000, and MS set 3 under Target Family Plan. 
4. Click OK.
5. Open the Background Jobs window.
6. Populate the window.
7. Verify that the state for the Level 1 Item Plan Aggregation background job is Ready.
8. Open the Aggregate Inventory Transactions per Period window.
9. Verify that your site is displayed.
10. Click OK.
11. Open the Background Jobs window.
12. Populate the window.
13. Verify that the state for the Aggregate Inventory Transactions per Period job is Ready.
14. Open the Sales and Operations Planning window.
15. Verify that your site is used, and then enter 3 in the MS Set field.
16. Click OK.
17. Click Yes in the confirmation prompt.
18. Verify that the following results are displayed:

Reviewing Level 0 Results

Purpose: The purpose of this exercise is to review MS level 0 results in table and graphical  formats. 

Windows:
MS Level 0 Part
MS Level 0 Part /Register Forecast
MS Level 0 Part /Action Proposals
Detailed MS Graph
Cumulative MS Graph

Table format:

1. Open the MS Level 0 Part window.
2. Query for part 24-000 at your site.
3. Click the Register Forecast tab for MS set 1.
4. Verify that the the last run date is equal to today's date, and that the values in both the Available To Promise and Cumulative Available fields is 0.

Graphical format:

1. Open the Detailed MS Graph window.
2. Click MS level Zero, part 24-000, your site, and MS set 1.
3. In the header, right-click and then click Recalculate Template. This synchronizes the graph start date with the period template start date.
4. Click OK.
5. In the header, right-click and then click Show Graph.
6. In the End No field, change the number to 12.
7. Click OK and view graphical results.

Cumulative format:

1. Open the Cumulative MS Graph window.
2. Click MS level Zero, part 24-000, your site, and MS set 1.
3. In the header, right-click and then click Show Graph.
4. In the End Period No field, change the number to 12.
5. Click OK and view cumulative results.