Alternate Components in MRP—Extended Exercises
IMPORTANT |
It is extremely important
that you set up and work within your own site to maintain your
data integrity. If you work within any other site, you will
compromise your own exercise data as well as the data of other
students. Predictable exercise results require that your data
be isolated in your own site. |
Basic Data Setup
MRP Extended Data Setup
Purpose: The purpose of this exercise is to set up the
required prerequisite data needed for the extended Material Requirements Planning exercises. You
must
do this exercise once to support the extended MRP exercises in the current
database. (If the database has been refreshed since the time you set up the data
for the MRP extended exercises, you will need to set up the data again.)
- If you haven't done so already, create your own site and set up the
extended MRP data (for the Alternate Components in MRP extended exercise) in
that site.
General exercise
for Overview of Extended MRP Data
Main Exercise
Purpose: The purpose of this main exercise is to perform MRP on the parts that you have already defined and evaluate the result. After
evaluating results, convert shop requisitions to shop orders, and then issue
alternate components planned by MRP to material allocation lines.
Windows:
Material Requisition
Perform Site MRP
Background Jobs
MRP Part Information
Shop Order Requisitions
Alternate Component
- Open the
Material Requisition window,
and create a material requisition at your site due a month out from today.
For the Internal Customer field, select an appropriate value from the
list of values.
- In the table window, create a record, enter 90-110
in the Part No column, and 5 in the Qty Due column. The Due
Date column should default to the Due Date in the header section.
Save the record.
- Create another record for part 90-110, this
time for a quantity of 20, due two months out from today. Save the record.
- Open the
Perform Site MRP window and
enter your site in the Site field. Check the Plan Alternate Component
checkbox. Click OK to start the MRP process for your site.
- Check that the process completed with state Ready in the
Background Jobs window.
- Go to the next section when the process is done.
Evaluating MRP Result
- Open the MRP Part Information
window and query for part 90-110 at your site.
- On the Receipts and Deliveries tab, verify
that the Net Requirement column shows 5 and 20 on the dates that
correspond to the dates of the material requisition line due dates. Also
verify that the MRP Make Receipt column shows 5 and 20 as supply in
response to the material requisition demands.
- In the same window, query for part 90-111 at your
site. Since the product structure for part 90-110 calls out for a qty
per of 2 of 90-111 for each 90-110, verify that the Receipts and
Deliveries tab shows values of 10 and 40 in the Net Requirement
column, corresponding to demand from the 90-110 parent part. Also verify
that there is an MRP Buy Receipt of 30 for the second demand of 40 from the
90-110 parent, but not for the first demand of 10. Since the 90-111 part is
a purchased part, only buy receipts should be generated for this part.
- The 90-111A1 part is defined as an alternate part
for the 90-111 part with a substitution sequence value that makes it
preferred for substitution over the 90-111A2 part. Recall that there is a
qty of 10 of this alternate part in inventory. This is used to satisfy the
first demand of 10 for the 90-111 part. Verify that the Alternate Receipt
column for this record shows a value of 10.
- The 90-111A2 part is defined as an alternate part
for the 90-111 part with a substitution sequence value that makes it the
second choice for substitution for the 90-111 part. Recall that there is a
qty of 10 of this alternate part in inventory. This is used to partially
satisfy the second demand of 40 for the 90-111 part. Verify that the
Alternate Receipt column for this second record shows a value of 10.
This leaves a qty of 30 remaining to be satisfied for part 90-111, which
is met by an MRP Buy Receipt of 30.
- Navigate to the Shop
Order Requisitions
window and query for part 90-110 at your site. You should find two
records in state ProposalCreated.
- Select the shop requisition for quantity 5 which
is represents supply for the earlier demand for this part from the material
requisition. Right click on this record, then click
Create Shop Order.
Click Yes when system asks if shop order should be created even if no
operations exist.
- While this record is still selected, right click,
then click Show Shop Order Requisition. When the
Shop
Order Requisition window is displayed with the shop requisition
queried up, click on the
Shop Order tab. Highlight the single
record displayed, right click, then click Show Shop Order.
- When the
Shop Order window is
displayed with the shop order queried up, click on the
Material
tab. Verify that two records are displayed, one for part 90-111, and another
for part 90-112.
- Highlight the record for part 90-111, right click,
then move cursor over Alternate Component, then click
Select.
- When the Replace Main Component
dialog is displayed, verify that two records are displayed, one for
alternate part 90-111A1, and another for alternate part 90-111A2. Also
verify that the Total Qty Available column for both records
shows a qty of 10. Recall that this is the qty on hand for each of these
alternate parts.
- In the record for 90-111A1, enter a qty of 10 in
the Quantity to Replace column. Click OK. Verify
that in the
Material tab, there are now three records. There
should now be a new record for the 90-111A1 part, with values in the
Qty Per Assembly column of 2, and Qty Required column
of 10. These same columns for the record for the original 90-111 component
part should show as zero.
- Navigate to the
Alternate Component
window and query for part 90-111 at your site. You should find two
records in the table window corresponding to the two alternates you
previously defined for the 90-111 part. For the record corresponding to the
first preferred alternate, i.e. 90-111A1, verify that the
Quantity
Substituted column shows a value of 10. This is the qty of the
90-111A1 part that you substituted for the 90-111 part on the material
allocation line in the shop order for the 90-110 part.
- Repeat steps 2 through 8, this time for the second
Shop Order Requisition for a qty of 20 for the second demand for part 90-110 from
the material requisition for this part. In step 5, instead of clicking
Select, click Replace All. This replaces the main
component 90-111 with as many alternate parts as are available. In this
case, there is only a qty of 10 available from alternate part 90-111A2. If
for example there was a third preferred alternate defined, say 90-111A3 with
an on hand qty of 10, then for the second demand of 40, the Replace
All method would first use the qty of 10 on hand of the second
preferred alternate 90-111A2, followed by the qty of 10 of the third
alternate 90-111A3.