Performing Availability Analysis—Key Exercises

IMPORTANT
It is extremely important that you set up and work within your own site(s) 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(s).

The Make to Stock course requires that you set up two different sites.

Basic Data Setup

Make to Stock Course Data Setup

Purpose: The purpose of this exercise is to set up the required prerequisite data needed for the key Make to Stock exercises. You need to do this exercise only once to support all key Make to Stock exercises in the current database.

  1. If you haven't done so already, create two sites and set up all the Make to Stock required data in those sites.  

General exercise for Overview of Make to Stock Data

Required Data

Create Purchase Order

Purpose: The purpose of this exercise is to create a new purchase order for use in the Availability Analysis exercises. Skip this if you are doing only the PMRP exercises.

Windows:
Purchase Order

  1. Open the Purchase Order window and create a new order for the 90-111 part. Define the receipt date three months from today's date and specify a quantity of 50 pieces.  Leave the purchase order in a planned state. 

General exercise for Purchase Order

Perform MRP

Purpose: The purpose of this exercise is to set up the required data and perform MRP. The results of this exercise will provide the basis for the Availability Analysis exercises. Skip this exercise if you are doing only the PMRP exercises.

  1. If you haven't done so already, go through the Performing MRP and Evaluating Results exercise.  

General exercise for Performing MRP and Evaluating Results

Main Exercises

Purpose: The purpose of these exercises is to perform availability analysis on existing MRP parts. Skip this exercise if you are doing only the PMRP exercises.

Windows:
MRP Part Availability
MRP Order Availability

Performing Part Availability Analysis

  1. Open the MRP Part Availability window and query for the 90-110 part in your primary site. This part is used in the MRP key exercise, it should have a shop order for 20 pieces created for it. 
  2. In the Quantity field, enter 21.
  3. In the window header, right-click and click Perform Availability Analysis.
  4. In the window that displays, enter today's date as the end date (you can only enter either start date or end date at a time).  Click OK. The availability analysis is processed online, and the result is immediately displayed on the screen. A window displays containing the message: The Calculated Date is before today's date. Part 90-110 cannot be made available on today's date. This is because the existing supply for the 90-110 part is the shop order for 20 pieces, but the quantity required was 21 pieces, so the existing supply cannot satisfy the demand. The system then calculated the lead time in an attempt to produce the additional supply for the part, but the start date falls before today's date, which means that the part cannot be made available.

Note: MRP will use the fixed and variable lead times, defined in the routings for a manufactured part, to calculate the total manufacturing lead time. This calculated lead time will override the manufacturing lead time defined in the inventory.    

  1. Look at the table, where all the required components to produce this part should be listed. 
  2. Note that the 90-111 part has an open purchase order that is used in the analysis process. If you look at the analysis message column for this part, the system suggests rescheduling the supply.
  3. The quantity required for the 90-111 part is zero because there is a purchase order for 50 pieces. (In fact this order exceeds the required quantity, which is 21 pieces, so you still have 29 pieces left that can be planned to supply another demand.) 
  4. Update the Quantity field to 20 pieces.
  5. Perform the availability process again, this time entering today's date as the end date. Click OK.
  6. A message appears that reads 'Part 90-110 is available on today's date. Supplies need to be rescheduled'. Since the existing shop order can satisfy the quantity required, the system suggested rescheduling the shop order instead of producing new supply for the demand.

Performing Order Availability Analysis

  1. Open the MRP Order Availability window and query for the 90-110 part in your primary site.
  2. The existing shop order  with a quantity of 20 pieces populates the window.
  3. Look at the Shop Material Allocation tab, where you can see all the components required for this shop order.
  4. Click on the Multilevel Availability tab.
  5. Right-click on the table and click Perform Availability Analysis.
  6. The availability analysis process performed in this tab is similar to the availability analysis performed in the MRP Part Availability  window except here the quantity and the start date already are defined in the shop order. The system displays a message that the 90-110 part is available. This is because the start date is beyond the cumulative lead time of the 90-110 part structure.

Create Purchase Order

Purpose: The purpose of this exercise is to create a new purchase order for use in the Availability Analysis exercises for PMRP. Skip this if you are doing only the MRP exercises.

Windows:
Purchase Order

  1. Open the Purchase Order window and create a new order for the 90-111 part. Define the receipt date three months from today's date and specify a quantity of 50 pieces. Enter XX100 in the Project ID field, and XXA100 in the Activity ID field. Leave the purchase order in a planned state. 

General exercise for Purchase Order

Perform PMRP

Purpose: The purpose of this exercise is to set up the required data and perform PMRP. The results of this exercise will provide the basis for the Availability Analysis exercises. Skip this exercise if you are doing only the MRP exercises.

  1. If you haven't done so already, go through the Performing PMRP and Evaluating Results exercise.  

General exercise for Performing PMRP and Evaluating Results

Main Exercises

Purpose: The purpose of these exercises is to perform availability analysis on existing PMRP parts.  Skip this exercise if you are doing only the MRP exercises.

Windows:
PMRP Part Availability
PMRP Order Availability

Performing Part Availability Analysis

  1. Open the PMRP Part Availability window and query for the 90-110 part in your primary site. This part is used in the PMRP key exercise, it should have a shop order for 20 pieces created for it. 
  2. In the Quantity field, enter 21. In the Project ID field, enter XX100 (XX refers to your initials) or select it from the list of values. You should have created this project in the PMRP Basic Data exercise. In the Activity Seq field, select the activity sequence that corresponds to activity id XXA100 from the list of values (again XX refers to your initials, you should have set up this activity during the PMRP basic data exercise).
  3. In the window header, right-click and click Perform Availability Analysis.
  4. In the window that displays, enter today's date as the end date (you can only enter either start date or end date at a time).  Click OK. The availability analysis is processed online, and the result is immediately displayed on the screen. A window displays containing the message: The Calculated Date is before today's date. Part 90-110 cannot be made available on today's date. This is because the existing supply for the 90-110 part is the shop order for 20 pieces, but the quantity required was 21 pieces, so the existing supply cannot satisfy the demand. The system then calculated the lead time in an attempt to produce the additional supply for the part, but the start date falls before today's date, which means that the part cannot be made available.

Note: PMRP will use the fixed and variable lead times, defined in the routings for a manufactured part, to calculate the total manufacturing lead time. This calculated lead time will override the manufacturing lead time defined in the inventory.    

  1. Look at the table, where all the required components to produce this part should be listed. 
  2. Note that the 90-111 part has an open purchase order that is used in the analysis process. If you look at the analysis message column for this part, the system suggests rescheduling the supply.
  3. The quantity required for the 90-111 part is zero because there is a purchase order for 50 pieces. (In fact this order exceeds the required quantity, which is 21 pieces, so you still have 29 pieces left that can be planned to supply another demand.) 
  4. Update the Quantity field to 20 pieces.
  5. Perform the availability process again, this time entering today's date as the end date. Click OK.
  6. A message appears that reads 'Part 90-110 is available on today's date. Supplies need to be rescheduled'. Since the existing shop order can satisfy the quantity required, the system suggested rescheduling the shop order instead of producing new supply for the demand.

Performing Order Availability Analysis

  1. Open the PMRP Order Availability window and query for the 90-110 part in your primary site.
  2. The existing shop order  with a quantity of 20 pieces populates the window. Verify that in the Project group box, the Project ID field shows XX100 and the Activity ID field shows XXA100 (where XX refers to your initials).
  3. Look at the Shop Material Allocation tab, where you can see all the components required for this shop order.
  4. Click on the Multilevel Availability tab.
  5. Right-click on the table and click Perform Availability Analysis.
  6. The availability analysis process performed in this tab is similar to the availability analysis performed in the PMRP Part Availability  window except here the quantity and the start date already are defined in the shop order. The system displays a message that the 90-110 part is available. This is because the start date is beyond the cumulative lead time of the 90-110 part structure.