Performing PMRP and Evaluating Results—Key Exercises

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 all Make to Stock exercises. You need to do this exercise only once to support the key Make to Stock exercises in the current database.

1. If you haven't done so already, create a site and set up all the Make to Stock required data in that site.

Note: For PMRP exercises only one site is required. When creating product structures make sure in the component line Std Planned Item flag is cleared. Otherwise you will not see the component being planned by PMRP.

General exercise for Overview of Make To Stock Data

Sales Part

Purpose: The purpose of this exercise is to define a part as a sales part for use in the PMRP exercises.

Windows:
Sales Part

1. Define part 90-100 as a sales part in your primary site. Enter 100 in the Price field. You can use the existing values in the Sales Price Grp, Sales Group, and Tax Code fields.

General exercise for Sales Part

PMRP Message Controller, Action Messages

Purpose: The purpose of this exercise is to set up a message controller, to configure which PMRP action messages will be used.

Windows:
PMRP Basic Data

1. Set up yourself as an PMRP message controller.
2. Set up all available PMRP action messages to display when you run the PMRP process.

General exercise for Make to Stock Basic Data 

Project

Purpose: The purpose of this exercise is to set up a Project and its activities for use in the PMRP exercises.

1. Define Project XX100, where XX is your initial, and set the material allocation to Within Activity status.
2. Select a customer for your project in Customer Info tab. You can use any existing customer.
3. Register your primary site to project XX100 by entering the record in the Site window.

Windows:
Project/Plan/Project Details

General exercise for Creating Projects

Sub Project and Project Activities

Purpose: The purpose of this exercise is to set up Sub Project and Project Activities for use in the PMRP exercises.

1. Under project XX100 define sub project XXSP100

2. Under sub project SP100 define activities XXA100 and XXA200

3. Release activities XXA100 and XXA200.

Windows:
Project/Project Info

General exercise for Building a Project Plan

Required Data

Purpose: The purpose of these required data exercises is to create supply and demand for inventory parts that will affect the result of the PMRP process. 

Customer Orders
Shop Order

Note: The following required data exercises must be done in the order shown.

Create Project Miscellaneous Demand

1. In your primary Project XX100, create project miscellaneous part demand for 90-100 in activity XXA100 with quantity of 20 on a valid date (35 days from today). Set the supply option to Project MRP and Std Planned Item flag is cleared.
2. Create another project miscellaneous part demand line for 90-100 in activity XXA200 with quantity of 5 on a valid date (35 days from today). Set the supply option to Shop Order and Std Planned Item flag is cleared.

Windows:
Project Navigator/Demand/Misc. Parts

General exercise for Registering Project Demand

Create a Customer Order

1. In your primary site, create a customer order for the 90-100 part with a quantity of 10.  The date should be 40 days from today. This will be the other demand source for the parent part. You can use an existing customer or create a new customer for this. Then save the record.
2. Select the customer order line created on step 1 above. Right-Click, click Project Connection, then click Connect to Activity. In the dialog enter Project XX100 and use List of Values in Activity Sequence field to select activity XXA100, then click OK. This will connect the customer order line to the project XX100, activity XXA100

General exercise for Entering Customer Orders

Create Shop Orders

1. In your primary site, create a shop order for the 90-110 part with a quantity of 20. The shop order must have a need date that is 10 days before the project miscellaneous parts demand date. Leave the shop order in a Planned state.
2. On the Tracking tab, right-click and then click Project Connection, then click Connect to Activity. In the dialog enter Project XX100 and use List of Values in Activity Sequence field to select activity XXA100, then click OK. This will connect the shop order to the project XX100, activity XXA100.
3. Click the Material tab, check that Supply Code for the material is now changed to Project Inventory. If they are still set to Inventory Order this means you still set the Std Planned Item flag for these material in the product structure.

General exercise for Creating Shop Orders Manually   

Main Exercises

Performing PMRP

Windows:
Perform PMRP per Activity
Background Jobs

1. Open the Perform PMRP per Activity dialog box.
2. Select the site you created as your own primary site. 
3. Enter project XX100 in the Project ID field.
4. Use the default run date. The default date is based on today's date on the selected site. Note that this date is affected by the time zone defined for the site.
5. Select the Stop PMRP on error check box and clear the other check boxes in the dialog box.
6. Click OK. The PMRP process is ordered and logged in the background process list.
7. Open and populate the Background Jobs window.
8. Note that the PMRP process is listed in this window. Check the state of the process. The state will be Posted when first logged and Executing when actually processing. (You will need to refresh the window to display the current state.) When the process is done, it will have either a Ready state if no error occurred or an Error state if any error occurred. If all the basic data and required data has been set up properly, you should not receive errors during the process.

Note: If the Stop PMRP on error check box is cleared, PMRP will always end up in a Warning state (even if errors occurred, PMRP will skip the errors and continue processing). You can select the appropriate row for the process, right-click, and then click View Details to see more information.

Scheduling PMRP

Purpose: The purpose of this exercise is to schedule PMRP with netting per activity to run at a specific time weekly (for example at 12:00am every Saturday).

Windows:
Perform PMRP per Activity
Background Jobs
New Database Task Schedule

1. Open the Perform PMRP per Activity window.
2. Click Schedule. Then New Database Task Schedule appears.
3. Enter a specific time and date when the PMRP process will be executed.
4. Enter your site in the Site field and project XX100 in the Project ID field.
5. Save to execute the scheduled task, you can query for the process in the Background Jobs window.

Notes:

• The scheduled PMRP process will not run if there are problems that prohibit the job performing as scheduled. Such problems might be that the system (server machine) does not have enough resources to run the process, there are invalid packages in the database system, etc.

• If you want to remove or modify existing scheduled tasks, use the New Database Task Schedule window.

Reviewing and Taking Action on PMRP Action Proposals

Purpose: The purpose of this exercise is to evaluate the result of the PMRP process, sorted by planner.

Windows:
PMRP Action Proposals

1. Open the  PMRP Action Proposals window and populate the window with all records from your site. (Perform a query in the window, entering your site ID in the query window.)
2. Since all parts are attached to planner '*' and your user ID is linked to this planner, the PMRP message configuration defined for planner '*' is effective. (You will receive only PMRP action messages that are selected in the message configuration for planner '*'.)
3. Note that the 90-110 part has one record with a PMRP message of Early Order. This is because the shop order for this part exists before it actually is required to satisfy the demand that comes from its parent part (90-100). Therefore PMRP suggests moving the order forward.
4. The 90-100, 90-111, 90-112, 90-120, 90-121, 90-122, and 90-130 parts have PMRP messages of Need Order. These messages were generated because those parts do not have any supplies to satisfy their demands. In this case, PMRP created purchase requisitions for them as they are purchased parts. Parts that have no existing demands will have a No Demand Exist PMRP message.
5. To take action on the PMRP message, select the row where part 90-110 has message Early Order, right-click, and then click Follow Up. The Shop Order window for the 90-110 part displays. You can adjust the need date of the shop order. If you adjusted the need date, save the record.
6. Close the Shop Order window and return to the PMRP Action Proposals window. If you adjusted the need date on the shop order, select Action taken from the list in the Action Taken field and enter today's date in the Action Taken Date field. Save the changes.
7. Review the action messages for the 90-111 part. Both have an PMRP action messages of Need Order. Right-click and click on Follow Up.
8. A new, empty Purchase Order window is displayed. You can create a new order for the 90-111 part in this window to follow the PMRP suggestion.

Note: You have probably noticed that the Follow Up method reacts appropriately for each selected PMRP message. It will display the appropriate window for the planner to make the necessary adjustment.

Evaluating PMRP Part Information

Purpose: The purpose of this exercise is to evaluate the PMRP results on planned receipts, deliveries, and gross demand for parts. 

Windows:
PMRP Part Information

1. Open the PMRP Part Information window and query for all the parts in your primary site. 
2. Click Detail tab, which contains general information about the selected part. You can see the total demand and the total order here.
3. Click the next tab, Receipt and Deliveries. Select part 90-100 from the list. Note that the Project ID is XX100 and Activity ID  is XXA100.
   • It has 2 lines in the table which display net requirement of 20 and 10. The demand of 20 is the project Misc. Parts demand you have entered in the Project XX100, activity XXA100.
   • The demand of 10 is the Customer Order which you have connected to Project XX100, activity XXA100.
   • You also created Misc. Parts demand for activity XXA200, however the supply option was set to Shop Order. Therefore PMRP ignored this demand and you can not query part 90-100 in activity XXA200 in this window because PMRP did not find any transaction that can be processed for activity XXA200.

   Check the records for the 90-110, 90-120, and 90-130 parts. 

   • Each part will have a net requirement on the parent 90-100 demand dates. The net requirement quantity depends on the quantity per assembly, component scrap, and the scrap factor defined for this part in the product structure. 
   • There is a planned Shop Order for 90-110 in project activity A100. The shop order quantity is displayed in the Firm Plan Receipt field on the shop order need date. The shop order quantity also displayed in the Firm Planned Release field on the date when this shop order need to be released. This shop order is enough to supply the demand of 20 from the project Misc. Parts. But customer order demand of 10 requires additional supply, PMRP created planned receipt with quantity of 10 for this.
   • The PMRP process created planned receipts for the 90-120 and 90-130 parts because they need supplies for their net requirements. You will notice that there is also a row with an MRP plan release created; this is the schedule when the supply should be released. 
   • Net requirement for the 90-120 part are 41 and 21 because the component scrap is 1 and quantity per assembly is 2.
   • Net requirement for the 90-130 part is 22.22 and 11.11 because the scrap factor is 10%  and quantity per assembly is 1. You can set the system only to display certain decimal numbers by setting it in the Inventory Part/Planning tab window.

   Also check on the components of the 90-110 and 90-120 parts, and note:

   • Demand for the 90-111 and 90-112 component parts have been created from shop order material allocations because the 90-110 parent part has an open shop order.
   • There are also demands for the 90-111 and 90-112 which are planned by PMRP because of the new planned receipt created for parent part 90-110.
   • PMRP released the supply for the 90-111 part one day before the demand date, with a quantity of 40, but the supply for 90-112 part is released two days before the demand date, with a quantity of 40. Check the lead time for these parts, which caused these difference.
   • Demands for the 90-121 and 90-122 component parts have been created because PMRP released the supply for the 90-120 parent part with a quantity of 41 and 21.
   • Part 90-121 has demand and supply with a quantity of 82  and 42, the supplies are released on the previous working day (lead time is 1 and quantity per assembly is 2).
   • Part 90-122 has demand and supply with a quantity of 41 and 21, the supplies are released two working days before the demand's date (lead time is 2 and quantity per assembly is 1). 
     
4. Click the Gross Requirements tab. Select part 90-100 on from the list box in the header.
   • In this tab, you can perform a side-by-side comparison of the demand quantity and the supply quantity for the selected part.
   • You can see demand of 20 with MRP Source Project Misc Demand. The Order No field displays the project ID where the demand came from. Supply is on the same date with MRP Source MRP.
   • Demand of 10 with MRP Source Order Entry and the Order No field displays the customer order number. Supply is on the same date with MRP Source MRP.

   Check the result of the PMRP process on the 90-110, 90-120, and 90-130 parts.

   • Each part has demands because they are components of the 90-100.

   • Each part has a supply quantity that satisfies the demand above. One of the supplies for the 90-110 part comes from a shop order, in this case the MRP Source field is set to Shop Order and Order No filed displays the shop order number. Supplies for the  90-120 and 90-130 parts are created by PMRP with MRP Source MRP.

   Note: If you select the Add 1 day leadtime backoff to planned receipts check box in the Perform PMRP window, the planned receipts will be created 1 day earlier.

   Also check on the components of the 90-110 and 90-120 parts, and note that:

   • Demands for the 90-111 and 90-112 component parts are created because they are needed to supply the shop order for 90-110 part.
   • Demands for the 90-121 and 90-122 component parts are created by PMRP as PMRP planned supply for the 90-120 parent part.
   • Since there is no existing supply for these components, PMRP created supplies for these component parts.
     
5. Select the 90-110 part and click the Gross Requirements by Template tab. For the first time the system will populate the data using the default period template (template ID 1). 
6. Right-click in the window header and then click View Data by Period Template. A window to choose the template ID appears.
7. Enter the period template ID 2 or select from the List of Values (click the List button).  Click OK. The Gross Requirements by Template tab is repopulated and displays supply and demand based on the period template ID 2. Supply and demand for the 90-110 part may appear at the same period number because you have defined one period as one month.
8. Right-click on the Gross Requirements by Template tab header and then click Recalculate Current Template Details. This action displays a dialog box that allows you to recalculate the selected period template using a new starting date or a different calendar ID.

Note: You can quickly access some related windows by right-clicking in the header portion of the window and then clicking the appropriate option. You can jump to the following windows: 

• Multilevel Structures window populated for the selected part. 
  (Right-click and click Part Structure).

• Inventory Part Availability Planning window populated for the selected part. (Right-click and click on Inventory Part Availability Planning.)

• PMRP Material Plan window populated for the selected part. 
  (Right-click and click View Material Plan.)

• PMRP Material Plan Graph window populated for the selected part.  
  (Right-click and click Material Plan Graph.)

Note: Pegged Supply and Created MTR tabs are used only in extended exercise for Multi Project MRP.

Evaluating the Material Plan

Purpose: The purpose of this exercise is to view a comprehensive display of the supply and demand details for PMRP-planned parts. 

Windows:
PMRP Material Plan

1. Open the PMRP Material Plan window and populate it with all the parts in your site.
2. In this window you can query for all the supplies and demands along with the detailed information for each supply/demand (for example, supply demand type, supply/demand quantity, order number, line number, release number, line item number, and status).
3. Select the 90-100 part. In the Material Planning tab, you can see the Project Misc Demand, Customer Order demand, and 2 Shop Order Req which were created by PMRP to supply those demands.
4. Select the 90-110 part.  you can see the created shop order and demand from parent part 90-100. 
5. Right-click and then click Supply/Demand Details to see the details for each supply and demand.
6. Select the row that displays Shop Order in the Order supply demand field, right-click, and the click Supply/Demand Details. The Shop Order window for the 90-110 part is displayed.
7. Close the Shop Order window and return to the PMRP View Material Plan window.
8. Select the row that displays Shop Order Req in the Order supply demand field, right-click, and then click Supply/Demand Details. The Shop Order Requisition window displays the shop proposal in question. Return to PMRP Material Plan window.
9. Click the Material Planning by Template tab. This tab will display the same information as the first tab, but now the information is displayed based on the period in the selected period template.
10. At first, the system will populate the window using the default period template (template ID 1). You can select your own template by right-click on the tab header and then click Select Template. A dialog box displays in which you can select a period template. 
11. Enter Template ID 2 and click OK.

12. The Material Planning by Template tab is repopulated using the selected template.

Note: You can quickly access some related windows by right-clicking in the PMRP Material Plan window and then clicking the appropriate option. You can jump to the following windows: 

• Recalculate Period Template Details window, which is used to recalculate the existing period template using a new starting date or a different calendar ID.
  (Right-click and click Recalculate Template.)

• PMRP Part Information window with the selected part populating the window.
  (Right-click and click PMRP Part Info.)

• PMRP Material Plan Graph with the selected part populating the window. 
  (Right-click and click Material Plan Graph.)

Evaluate Material Plan by Part and Project

Purpose: The purpose of this exercise is to evaluate a comprehensive display of the supply and demand details about PMRP-planned parts, grouped by part number and project regardless of the site.   

Windows:
PMRP Material Plan Multi-Site..

1. Open the PMRP View Material Plan Multi-Site  window and query for the 90-110, 90-111, and 90-112 parts. This window is similar to the PMRP Material Plan window except that it is grouped by part number and project ID regardless of the site. If one part is defined in several sites, then all supplies and demands for that part will be displayed here. 
2. Click the Material Planning by Template tab and query the result using your defined period template (using the period template you have defined).
3. Click the Site Level Details tab to see detailed information from each site. 

Evaluating the Material Plan in a Graph

Purpose: The purpose of this exercise is to evaluate the PMRP results from a 2-D bar graph.  

Windows:
PMRP Material Plan Graph

1. Open the PMRP Material Plan Graph window and query for all parts in your primary site.
2. In the Period Template field, enter your period template ID 2.
3. Right-click and then click Show Graph. A dialog box displays in which you can select the period range. The beginning period displays as 0 because the start date defaults to the period template recalculation date. The end date defaults to today's date.
4. Update the end period number to 12. Click OK.  A 2-D bar graph of supply and demand is calculated and then displayed. The axis shows the period number from the selected period template.

Printing a PMRP Report    

Purpose: The purpose of this exercise is to order and preview an PMRP report, as well as to schedule automatic PMRP reports.

Windows:
Perform PMRP Report
New Database Task Schedule

1. Open the Perform PMRP Report window. It displays with default parameter values.
2. Enter your primary site in the Site field and project XX100 in the Project ID field.
3. Leave the Activity Seq field with default value 0.
4. If you want, you can select Yes from the Show Orders Created list to include all orders created by PMRP in the report.
5. You also can click Yes from Show Orders Changed list to include all orders that the PMRP process suggested be rescheduled.
6. Enter a valid date 5 months ahead from today's date in the Up to Date field. The report will include all orders up to this date.
7. Click OK when you are done.
8. The Report Print dialog box appears. Set the format layout and select the printer to be used. Click Preview.
9. The preview window appears. You can study the report result here, using the button bar to move forward and backward.
10. Use the print icon if you want this report printed. (Make sure your computer is connected to the printer you selected in the Report Print dialog box.)
11. Close the preview window when you are done.

Note: You can schedule PMRP reports to be printed weekly just as you can schedule the PMRP process.

16. Open the New Database Task Schedule  window and search for Task Name Perform PMRP Report
17. Enter scheduling parameters and save.