Handling Spare Parts—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 two sites and set up all the Make to Stock required data in those sites.  

General exercise for Overview of Make to Stock Data

Spare Parts

Purpose: The purpose of this exercise is to set up existing inventory parts for use as spare parts.

Windows:
Inventory Part

1. Open the Inventory Part window and query for the 90-110 and 90-120 parts.
2. With the 90-110 part selected, click on the Misc Part Info tab. Under Control Values, select the Forecast Consumption check box and save the record.
3. Repeat step 2 for the 90-120 part.

Sales Part

1. Set up the 90-110 part as a sales part.

General exercise for Sales Part

Main Exercises

Purpose: The purpose of these exercises is to create a spares family, enter forecasts for it, and perform the disaggregate forecast process. One exercise will import forecasts from IFS/Demand Planning.

Windows:
MRP Spare Part Family Forecast
Background Jobs
MRP Spare Part Forecast
Sales Part
Customer Order
Sales Quotation
Exported Forecasts
Import Demand Planning Forecasts for Spare Parts

Creating a Spare Part Family

1. Open the MRP Spare Part Family Forecast window.
2. Create a new record and enter the data in the table below.

3. In the Family Parts tab, define the 90-110 part as a spare part in this family with quantity percentage of 50%.
4. Define the 90-120 part as a spare part with a quantity percentage of 50%.
5. Save the spares family.

Entering Family Forecasts

1. Open the MRP Spare Part Family Forecast window and query for the Woofer Box family components (Family Code: 001).
2. Click the Family Forecasts tab.
3. Create new records in this tab with the forecasts shown in the table below.

Disaggregating Family Forecasts

1. In the MRP Spare Part Family Forecast window, select the Woofer Box family (Family Code: 001).
2. Right-click in the window's header area and click Disaggregate Forecast for Current Spare Part Family.
3. Open the Background Jobs window and wait until the disaggregate process finishes.
4. Open the MRP Spare Part Forecast window and query for the 90-110 and 90-120 parts.
5. Select the 90-110 part. The forecast lines displayed for this part were created by the disaggregation process. Check that all forecasts for the family appear except the one that had the Allow Disaggregation field set to Do not disaggregate.
6. The forecast quantity from the family is distributed by the percentage for part 90-110, which is 50%. The first forecast quantity is 5, on the next month it is 6, and the last quantity is 9.
7. Select the 90-120 part. The forecast lines for this part were also created and they display with the same dates and quantities as for the 90-110 part.
8. Note the record type in each forecast is Disaggregated.  

Note: You can also create a new forecast from the MRP Spare Part Forecast window.

9. Create a new forecast for the 90-110 part with a quantity of 10.  Set the forecast date one month after the date on the last forecast line. This new forecast will have a Manual record type.
10. You can update the forecast quantity in each line. (The forecast dates are read-only.)

Note: You can schedule this disaggregation process to be performed automatically by the system.

11. Open the Disaggregate Forecasts for Spare Part Families dialog and either select to Aggregate All Families or specify a specific family code.

12. Click Schedule , it will open New Database task Schedule window

13. Enter the time (in 24 hour format) and then select the day on which the process should be performed. You will need to ensure that this process does not overlap with existing scheduled jobs.

14. If you have previously done the MRP key exercise, Perform MRP and Evaluate Results, you will see that two jobs are already scheduled: the MRP process and the MRP reporting process. If they are scheduled, you will need to ensure that their schedule is appropriately aligned with the disaggregation process schedule.

Tracking Forecast Consumption

1. Create a customer order for the 90-110 part with a date after the first forecast and before the second forecast. Enter a 3 pieces as the quantity. Open the MRP Spare Part Forecast window to check the forecast date. Save the order when you are done.

General exercise for Customer Order

2. Open the MRP Spare Part Forecast window and query for the 90-110 part.

3. You now can see a new line created by IFS/Customer Order with an actual demand of 3 pieces. This demand consumed forecast that was available on that date and this is the first forecast line.

4. Open the Sales Quotation window. Create a new sales quotation for the 90-110 part with a date that is 4 months after today's date. Enter a quantity of 10 pieces.

5. Select the Release for Planning check box in the quotation line and save the record. 

6. The quotation is created in a Planned state. Right-click in the window's header area and click Release Quotation. The sales quotation is now released.

General exercise for Sales Quotation

7. Go back to the MRP Spare Part Forecast window and re-query for the 90-110 part.

8. Another line created by Customer Order  has been created with a planned demand of 10 pieces.

9. The forecast with the nearest date for this demand has only 9 pieces, so the system consumes the last piece from the forecast before it.

10. In the Sales Quotation window, clear the Release for Planning check box in the quotation line, and save the record. 

11. In the MRP Spare Part Forecast window, re-query for the 90-110 part. The line that came from the sales quotation is gone and the forecast is back to being unconsumed.

Note: In the Sales Quotation window, if you change the sales quantity, the Release for Planning field or the quotation date, the corresponding line in the MRP Spare Part Forecast window also will be updated. 

Importing Forecasts for Spare Parts from IFS/Demand Planning

1. Set up the 90-110 part as one of the forecasted parts in IFS/Demand Planning and attach the part to the master flow forecast.

General exercise for Forecast Part

2. Using the Forecast Client application in IFS/Demand Planning, enter several forecasts for the 90-110 part as shown in the table below.

General exercise for Forecasting Models

3. To review the forecasts you have exported, open the Exported Forecasts window and query for the 90-110 part in your site. All records populated here can be imported to the spare part forecasts.
4. Open the Import Demand Planning Forecasts for Spare Parts dialog.
5. Select the 90-110 part by placing your cursor in the Part No. field and clicking List.
6. The Begin Date field defaults to today's date, which you should use. 
7. In the End Date field, enter the date that is the 15th day of 4 months ahead of today's date .
8. Leave the forecast type as Regular.
9. Leave the forecast distribution as Start Date.
10. Leave the process method as Background.
11. Click OK.
12. Open the Background Jobs window and check to see if the import forecast has finished.
13. Re-query for the 90-110 part in the MRP Spare Part Forecast window. You will see that the previously existing forecast was removed and the forecast in line 1 (see the table above) is added with a quantity of 40 pieces on the first date that month. (If the first date is not a working day, the working day before that is used.) Forecasts for line 2 and 3 were also added with quantities of 40 pieces. 
14. The forecast for line 4 was inserted with a quantity of only 20 pieces (half the forecast quantity) since the end date of the import process was a half of a month before this forecast.
15. Open the Import Demand Planning Forecasts for Spare Parts window again and select the 90-110 part.
16. Leave the Begin Date field as it defaults.
17. Set the forecast type to Budget.
18. Set the forecast distribution to Weekly.
19. Set the processing method to On-line.
20. Click OK. The import process is executed immediately.
21. Re-query for the 90-110 part in the MRP Spare Part Forecast window. You can see that the budget quantity is imported to the spare part forecast and distributed weekly. The forecast is created every Monday of each week. (If Monday is not a working day, the previous work day is used.)
22. Use the import window once more and set the forecast distribution to Daily to see the difference.

Note: You can schedule this import forecast process to be performed automatically by the system.

23. Open the Import Demand Planning Forecasts for Spare Parts dialog and click Schedule button.

24. Set all import parameters ( the Begin Date and End Date fields are not there because for a scheduled job), which will run weekly, you only need to specify the period length. The execution date will be used as the begin date and the period length is used to determine the end date.

25. Specify the time and select the day when this process should be performed. Save when you are done.