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.
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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.
- 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
- 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.
- 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
- 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.
- In the Quantity field, enter 21.
- In the window header, right-click and click Perform Availability
Analysis.
- 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.
- Look at the table, where all the required components to produce
this part should be listed.
- 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.
- 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.)
- Update the Quantity field to 20 pieces.
- Perform the availability process again, this time entering today's date as the
end date. Click OK.
- 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
- Open the MRP Order Availability window and query for
the 90-110 part in your primary site.
- The existing shop order with a quantity of 20 pieces populates the window.
- Look at the Shop Material Allocation tab, where you can see all the components
required for this shop order.
- Click on the
Multilevel Availability tab.
- Right-click on the table
and click Perform Availability Analysis.
- 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
- 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.
- 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
- 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.
- 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).
- In the window header, right-click and click Perform Availability
Analysis.
- 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.
- Look at the table, where all the required components to produce
this part should be listed.
- 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.
- 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.)
- Update the Quantity field to 20 pieces.
- Perform the availability process again, this time entering today's date as the
end date. Click OK.
- 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
- Open the
PMRP Order Availability window and query for
the 90-110 part in your primary site.
- 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).
- Look at the Shop Material Allocation tab, where you can see all the components
required for this shop order.
- Click on the
Multilevel Availability tab.
- Right-click on the table
and click Perform Availability Analysis.
- 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.