Multi-Project MRP—Extended Exercises

Basic Data Setup

PMRP Extended Data Setup

Purpose: The purpose of this exercise is to set up the required prerequisite data needed for the Multi-Project MRP exercises. You must do this exercise once to support the extended PMRP 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.)

1. If you haven't done so already, create your own sites and set up the extended MRP data (for extended exercises) in those sites. For PMRP you only need data in your primary site.

General exercise for Overview of Extended MRP Data

PNG Default Settings

Purpose: The purpose of this exercise is to specify the default settings for planned netting groups (PNGs). These default values are used to create a project PNG automatically when a project is created. You will need a project PNG if you were to use the Perform PMRP per Project dialog box instead of the Perform PMRP per PNG dialog box in the main exercise below.

Windows:
PMRP Basic Data

1. If you have not done so already, set up the default values to be used when a new project PNG is created.

General exercise for Make to Stock Basic Data

Projects for PMRP

Purpose: The purpose of this exercise is to set up multiple project activities , required prerequisite data needed for the Multi-Project MRP exercises. You must do this exercise once to support the extended PMRP exercises in the current database. (If the database has been refreshed since the time you set up the data for the PMRP extended exercises, you will need to set up the data again.)

1. If you haven't done so already, create your own project XX100 and set your primary site XX as the project site.
2. Define activity XXA100 and XXA200 in the project XX100. Release these activities.
3. Create another project XX200 and set your primary site XX as the project site.
4. Define activity XXA300 and XXA400 in the project XX200. Release these activities.

General exercise for Make To Stock Data

Create Planned Netting Group

Purpose: The purpose of this exercise is to set up the Planned Netting Groups (PNGs) which are required prerequisite data for the Multi-Project MRP exercises.

Windows:
Planned Netting Group

1. In your primary site create PNG XXP100 in Planned Netting Group window. Set it with Priority 1.
2. Leave the PNG parameters with default value. Then save the record.

3. Create new lines in PPSA's Within PNG tab as in the table below. Save these records.

3. Create a second PNG XXP200. Set it with Priority 2.
4. Leave the PNG parameters with default value, the same as step no 2 above. Then save the record.
5. Create new lines in PPSA's Within PNG tab as in the table below. Save these records.

Supply and Demand

Purpose: The purpose of this exercise is to set up supply and demand scenario for the part which will be used in the main exercise.

Windows:
PMRP Material Plan

Receive Inventory Part

Inventory Part In Stock

Project Navigator

1. In your primary site query for part 90-200 in PNG XXP100 in PMRP  Material Plan window..
2. Select the line with Qty Demand = 3  and Order Supply Demand Type = Cust Order.
3. Right Click, then click Supply/Demand Details.
4. The Customer Order created in the previous exercise is displayed. Cancel this order.

Note: If you have not done Advance PMRP Lot Sizing Technique Adjustment exercise then you may have different supply and demand situation.

4. At this point part 90-200 has no demand and only have one Shop Proposal which was created by PMRP and it will be deleted in next PMRP run.

Note: If you do not have this condition please take necessary action to remove open orders and demands. So that part 90-200 has no supply or demand.

5. Receive 10 of part 90-200 in the inventory. Use the Receive Inventory Part window.
6. Transfer part 90-200 you have received in step 5 above to project inventory. Open Inventory Part In Stock window and query for part 90-200. You can select the line and right-click Transfer to Project Inventory.
7. Transfer to Project Inventory dialog is displayed. Enter Project ID XX100 and use List of Values in Activity Sequence field to select  activity XXA200, and Qty To Transfer = 10. Click OK. Click Yes if a warning dialog appears. Now you can verify that activity XX200 now has part 90-200 in stock.
8. Open Project Navigator window. Query for your project XX100. Expand the project node in the left section and select activity XXA100.
9. Open the Demand\Misc. Parts tab in this window. Enter a new demand for part 90-200 with Required Quantity = 5, Supply Option = Project MRP, Required Date = Today + 1 month, and Std Planned Item is cleared.

Main Exercise

Purpose: The purpose of these exercises is to perform PMRP on Planned Netting Group(s) and evaluate the result. MTR will be processed and also performing PMRP with Borrow/Payback scenario.

Windows:
Perform PMRP per PNG
Background Jobs
PMRP Part Information

Material Transfer Requisitions

Material Transfer Requisition

Inventory Part In Stock

Shop Order Requisition

Performing Multi-Project MRP

1. Open the Perform PMRP per PNG dialog box. Enter Planned Netting Group XXP100. You can leave all the options as default and click OK.
2. Check the process from the Background Jobs window.
3. Go to the next section when the process is done.

Similarly, you can perform PMRP with netting per project. Use the Perform PMRP per Project dialog box and enter the ID of a project that has a PNG connected to it.

Evaluating Multi-Project MRP Result

1. Open the PMRP Part Information window and query for part 90-200 in activity XXA100. Click on Receipts and Deliveries tab. You can verify MTR Supply column value.
2. Open the Gross Requirements tab. In here you can see one line with Demand Qty = 5 and MRP Source = Project Misc Demand.
3. Another line with Supply Qty = 5 and MRP Source = Material Transfer Requisition. This means that supply in this activity is coming from another activity. The total value on the MTR supply lines accumulated per day should match with MTR Supply value you have checked in step 1. In this case there is only 1 MTR with qty = 5.
4. Click the Created MTR tab. Here you can see a line which indicates one MTR was created.
5. Select the line and right-click MTR-Detail.
6. Material Transfer Requisition window is displayed. In this window you can verify the source project activity in the From group which is XXA200 and the destination in the To group which is XXA100.
7. The MTR has Supply Source = Inventory, which means it is planning to move parts from project inventory.
8. The MTR has Transfer Type = Transfer, this is because Within Borrow/Payback = Not Required and project XXA200 does not have any demand.
9. Approval Type in source activity and destination activity were set to Manual by PMRP because that is how it is defined in PNG XXP100.
10. Close the MTR window.
11. Back to PMRP Part Information window and query for part 90-200 in activity XXA200.
12. Click on Gross Requirements tab. In here you can verify there is a line with  Demand Qty = 5 and MRP Source = Material Transfer Requisition.  And if you notice the Order No the value is the same with the Order No value in supply line for part 90-200 in activity XXA100
13. Click on Pegged Supply tab. Here you can verify how the supply was mapped by PMRP. In this case project inventory (Order No = INV) for activity XXA200 which is applied on demand in activity XXA100.
14. Click on Created MTR tab. You can verify the MTR you have queried in step 4 also displayed here.
15. Click on Receipts and Deliveries tab. You can verify MTR Demand column value.

Processing Material Transfer Requisition

1. Open the Material Transfer Requisitions window and query for your primary site.
2. Select the line of the MTR record and right click Release. This will release the MTR. Verify the State value. You can continue to process the MTR from this window but it will be easier to see the result from detail window.
3. Right-click Show Details. The Material Transfer Requisition window is displayed.
4. Right-click Giving Approve. This will approve the MTR in the source activity. Check the state is updated.
5. Right-click Receiving Approve. This will approve the MTR in the destination activity. Check the state is updated again.

Note: This exercise assumes that you are the planner for both source and destination project activity. So you can give approval on both sides. You can withdraw the approval with right-click Withdraw Approval.

6. Right-click Execute, this will transfer 5 pcs of part 90-200 from activity XXA200 to XXA100. Check the state is updated.
7. Open  Inventory Part In Stock window. Query for part 90-200. You can verify here that now activity XXA100 has 5 in stock.
8. If you re run PMRP on PNG XXP100 again, PMRP will use that quantity in stock to satisfy the demand in project activity XXA100.

Borrow/Payback Transaction

1. At this point part 90-200 should be available in project activity XXA100 and project activity XXA200 with 5 pcs in each inventory. And also there is demand for this part in XXA100 which is due today + 1 month with qty = 5.
2. Open Planned Netting Group window. Query for PNG XXP100. Set the Within Borrow/Payback = Required. Save the record.
3. Open Project Navigator window. Query for your project XX100.
4. Create Misc. Parts demand for 90-200 in activity XXA200 with quantity of 15, due 15 days from today, and Supply Option = Project MRP.
5. Perform PMRP on PNG XXP100 again.
6. Once the process is completed. Open the PMRP Part Information window and query for your primary site.
7. Select part 90-200 in activity XXA200. Click on Gross Requirements tab. On today's date + 15 there is a demand from Project Misc Demand. And also two supply lines, one is Material Transfer Requisition and the other one is MRP. What happened was PMRP found the demand of 15 then it used inventory on hand of 5 in XXA200, borrow inventory on hand of 5 in XXA100, and created new supply of 5.

8. On today's date + 1 month there is a demand line from Material Transfer Requisition and supply line from MRP. Here PMRP planned the payback for XXA100 because the inventory was borrowed as explained in step 7 above.

9. Click on Created MTR tab. You should see both Borrow and Payback MTRs. You can select both MTRs and right-click MTR Detail.
10. You can observe, the borrow MTR has a replacement date which is set to today's date + 1 month. This is the date where XXA100 needs the part. The connected Payback MTR is listed in Payback tab.
11. In the Payback MTR, the replacement date and the supply source are not set. PMRP already planned a supply by generating a requisition in activity XXA200 which is due on the same date with the Payback MTR. At this point it is up to the user, to connect the requisition to the Payback MTR now or wait until it is received to inventory. For this exercise you can set the supply source to Requisition.
12. In Order Ref 1, use List of Values to select the Shop Proposal which is due on the same date when the Payback MTR is due. Save the record.
13. Release both the Borrow and Payback MTR.
14. Open Shop Order Requisition window and query for the requisition which is connected to the Payback MTR.
15. Right-click Create Shop Order(s). This will convert the requisition to order. Click the Shop Order tab and notice the Shop Order number which is created.
16. Go back to the Material Transfer Requisition window. Query for the payback MTR. Notice that the Supply Source is updated to Order now. The source order info also updated. Notice that the Shop Order number which you have created in step 15 above is recorded here.

Note: MTR with supply source Requisition can not be executed. It will be executed automatically after the requisition is converted to order and then the order is received to inventory.

17. Rerun PMRP on PNG XXP100. Verify the result in PMRP Part Information window. The Borrow and Payback MTRs are not regenerated because they are released. The Payback MTR is now supplied by the Shop Order you created in step 15.

Connected PNG

1. In the basic data setup exercise at the beginning of this exercise you already connected PNG XXP100 to PNG XXP200. If you have not do it please do so.
2. Receive 50 pcs of part 90-200 to inventory then transfer it to Project XX200 Activity XXA300.
3. Perform PMRP on PNG XXP100 again.
4. Once the process is completed. PMRP Part Information window and query for part 90-200 in activity XXA200.
5. In the Gross Requirements tab you can see new MTR is created to supply the remaining demand of 5. (The total demand is 15, PMRP created borrow MTR of 5 pcs and used  quantity in stock of 5 pcs to supply it, so the remaining demand is 5).
6. Click on the Created MTR tab.  Select the new created MTR and right-click MTR Detail.
7. In the Material Transfer Requisition window you can see this MTR is planning to transfer 5 pcs of 90-200 from Project XX200 activity XXA300 to Project XX100 activity XXA100. The MTR Transfer Type is set to Transfer, because XXA300 and XXA100 belongs to two different PNG and Between PNG Borrow/Payback is set to Not Required.
8. Back to PMRP Part Information window and query for part 90-200 in activity XXA300. You can verify there is demand for 5 with MRP Source = Material Transfer Requisition. This is the MTR which is planning to transfer the project inventory to XXA200.