MPS - Apresentação e Exercicios Baan IV.PPT

Planejamento, MPS, Baan IV

1. Ref: 126/02/25
Master Production Scheduling
(MPS)

2. Ref: 226/02/25
Master Production Schedule (MPS)
A logistic plan of Forecasted Demand, Planned Inventory
and Planned Production, per time period

3. Ref: 326/02/25
Master Production Schedule (MPS)
Demand Plan
(Demand Forecast
+ Extra Demand)
Inventory Plan
Safety Stock
(Planned Inventory)
A logistic plan of Forecasted Demand, Planned Inventory
and Planned Production, per time period

4. Ref: 426/02/25
Master Production Schedule (MPS)
Demand Plan
(Demand Forecast
+ Extra Demand)
Inventory Plan
Safety Stock
(Planned Inventory)
Production Plan
(Planned Receipts)
A logistic plan of Forecasted Demand, Planned Inventory
and Planned Production, per time period

5. Ref: 526/02/25
Master Production Schedule (MPS)
Demand Plan
(Demand Forecast
+ Extra Demand)
Inventory Plan
Safety Stock
(Planned Inventory)
Production Plan
(Planned Receipts)
A logistic plan of Forecasted Demand, Planned Inventory
and Planned Production, per time period
Demand Forecast
Extra Demand
Planned Receipts
Planned Inventory
1
100
20
170
50
2
125
0
135
60
3
40
0
0
10

6. Ref: 626/02/25
MPS Overview
MPS
Plan CodeActual
Plan Item 12345
Plan Level___1

7. Ref: 726/02/25
MPS Overview
Continued
MPS
Period 1 Period 2 Period X
Plan CodeActual
Plan Item 12345
Plan Level___1

8. Ref: 826/02/25
MPS Overview
Continued
MPS
Period 1 Period 2 Period X
Plan CodeActual
Plan Item 12345
Plan Level___1
Demand Forecast +
Extra Demand

9. Ref: 926/02/25
MPS Overview
Continued
SLS Module
Open Orders
MPS
Period 1 Period 2 Period X
Plan CodeActual
Plan Item 12345
Plan Level___1
Customer Orders
Demand Forecast +
Extra Demand

10. Ref: 1026/02/25
MPS Overview
Continued
SLS Module
Open Orders
MPS
Period 1 Period 2 Period X
Plan CodeActual
Plan Item 12345
Plan Level___1
Customer Orders
Planned Receipts
Demand Forecast +
Extra Demand

11. Ref: 1126/02/25
MPS Overview
Continued
SLS Module
Open Orders
MPS
Period 1 Period 2 Period X
Plan CodeActual
Plan Item 12345
Plan Level___1
Customer Orders
Planned Receipts
Demand Forecast +
Extra Demand
Planned
Production
OrdersPlanned
Purchase
Orders
Generate MPS
Planned Orders

12. Ref: 1226/02/25
MPS Overview
Continued
SLS Module
MPS
Period 1 Period 2 Period X
Plan CodeActual
Plan Item 12345
Plan Level___1
Demand Forecast +
Extra Demand
Customer Orders
Planned Receipts
Scheduled Receipts
Generate MRP
Planned Orders
MRP
Planned
MPS
Production
Orders
Planned
MRP
Purchase
Orders
Planned
MRP
Production
Orders
Transfer
Orders
Planned
MPS
Purchase
Orders

13. Ref: 1326/02/25
MPS Overview
Continued
SLS Module
MPS
Period 1 Period 2 Period X
Plan CodeActual
Plan Item 12345
Plan Level___1
Demand Forecast +
Extra Demand
MRP
Transfer
Orders
Planned
MPS
Production
Orders
Planned
MPS
Production
Orders
Planned
MPS
Production
Orders
Planned
Orders
SFC

Production
Orders
PUR
Module
Open Orders
Customer Orders
Planned Receipts
Scheduled Receipts

14. Ref: 1426/02/25
MPS Overview
Continued
SLS Module
MPS
Period 1 Period 2 Period X
Plan CodeActual
Plan Item 12345
Plan Level___1
Demand Forecast +
Extra Demand
MRP
Transfer
Orders
SFC

Production
Orders
Issue
Material
Production
Complete
to Stock
I
n
v
e
n
t
o
r
y
INV
or
ILC
PUR
Module
Open Orders
Customer Orders
Planned Receipts
Scheduled Receipts
Planned Inventory
Planned
MPS
Production
Orders
Planned
MPS
Production
Orders
Planned
MPS
Production
Orders
Planned
Orders

15. Ref: 1526/02/25
MPS Overview
Continued
SLS Module
MPS
Period 1 Period 2 Period X
Plan CodeActual
Plan Item 12345
Plan Level___1
Demand Forecast +
Extra Demand
Planned Inventory
Customer Orders
Planned Receipts
Scheduled Receipts
MRP
SFC
PUR
Module
INV
or
ILC
I
n
v
e
n
t
o
r
y
Customer
Transfer
Orders
Planned
MPS
Production
Orders
Planned
MPS
Production
Orders
Planned
MPS
Production
Orders
Planned
Orders

16. Ref: 1626/02/25
MPS Input and Output
Generate Master
Production Schedule
Rescheduling and
Exception
Messages
Recommendations
and
Planned MPS Orders
Rough Capacity
and Material
Requirements
Input
Calculation
Output
MPS Plans
• Demand
• Production
• Inventory
Shop
Floor
Inventory
Purchase
MRP
MPS
RPL
Sales
Service
PRP

17. Ref: 1726/02/25
MPS Procedural Flow
Plan Data
 Plan codes
 Plan periods
 Plan sites
Plan Item Data
 MPS Items
 Product Families
Planning Bills Critical ResourcesSupply Chain
Planned Purchase and
Interplant Orders
Planned
Prod. Orders
Rough Material
and Capacity
Requirements
INV Projections
and ATP Data
Confirm and Transfer to PUR Confirm and Transfer to SFC
Generate Master Production Schedule

18. Ref: 1826/02/25
MPS Plan Codes
Demand Forecast
Extra Demand
Planned Receipts
Planned Inventory
1
100
20
170
50
2
125
0
135
60
3
40
0
0
10
02101
Plan code PC1

19. Ref: 1926/02/25
MPS Plan Codes
Demand Forecast
Extra Demand
Planned Receipts
Planned Inventory
1
100
20
170
50
2
125
0
135
60
3
40
0
0
10
02101
Plan code PC1
Demand Forecast
Extra Demand
Planned Receipts
Planned Inventory
1
100
0
150
50
2
100
0
10
60
3
100
0
50
10
02101
Plan code PC2

20. Ref: 2026/02/25
MPS Planning Horizon
Start
Date
Finish
Date
MPS Planning Horizon

21. Ref: 2126/02/25
MPS Plan Periods
Start
Date
Finish
Date
7 7 14 14 42
MPS Planning Horizon

22. Ref: 2226/02/25
Rolling Plan
Start
Date
Finish
Date
7 7 7 14 287
Today

23. Ref: 2326/02/25
Rolling Plan
Continued
Start
Date
Finish
Date
7 14 287
Today

24. Ref: 2426/02/25
Rolling Plan
Continued
Start
Date
Finish
Date
7 7 7 14 287
7 7 7 14 287
Today

25. Ref: 2526/02/25
Rolling Plan
Continued
Start
Date
Finish
Date
7 7 7 14 287
7 7 7 14 287
7 7 7 14 287
Today

26. Ref: 2626/02/25
Rolling Plan: Reference Date
Start
Date
Finish
Date
7 7 7 14 287
TodayReference

27. Ref: 2726/02/25
Rolling Plan: Reference Date
Continued
Start
Date
Finish
Date
7 7 7 14 287
TodayReference

28. Ref: 2826/02/25
Rolling Plan: Reference Date
Continued
Start
Date
Finish
Date
7 7 7 14 287
TodayReference

29. Ref: 2926/02/25
Rolling Plan: Reference Date
Continued
Start
Date
Finish
Date
7 7 7 14 287
TodayReference
7 7 7 14 287

30. Ref: 3026/02/25
Rolling Frequency
Start
Date
Finish
Date
7 7 7 14 287
TodayReference
7 7 7 14 287
Rolling Frequency = 7 days
No action

31. Ref: 3126/02/25
Rolling Frequency
Continued
Start
Date
Finish
Date
7 7 7 14 287
TodayReference
7 7 7 14 287
Rolling Frequency = 7 days
Roll the plan

32. Ref: 3226/02/25
Rolling Frequency
Continued
Start
Date
Finish
Date
7 7 7 14 287
TodayReference
7 7 7 14 287
Rolling Frequency = 7 days
7 7 7 14 287

33. Ref: 3326/02/25
Manual Plan
Start
Date
Finish
Date
7 7 7 14 287

34. Ref: 3426/02/25
Exercises
Interpret a rolling plan
Exercise
1

35. Ref: 3526/02/25
Demand Forecast Distribution
Forecast is divided by the number of working days per period
Plan periods = 7 days 5 working days per week
Plan Periods
Demand Forecast
123
505050
SMTW SFT SMTW SFT SMTW SFT
101010 1010 101010 1010 101010 1010

36. Ref: 3626/02/25
Current Period Consumption
Forecast is consumed within the order date’s plan period
Plan Periods
Demand Forecast
123
505050
Forecast
Orders
Consumption
SMTW SFT SMTW SFT SMTW SFT
101010 1010 101010 1010 101010 1010
85
101010 1010

37. Ref: 3726/02/25
Backward Consumption
Forecast is consumed backward from order date for the number
of calendar days in Backward Forecast Consumption field
Backward Forecast Consumption = 7 days Forward Forecast Consumption = 7 days
Forecast
Orders
Consumption
7 days
SMTW SFT SMTW SFT SMTW SFT
101010 1010 101010 1010 101010 1010
85
1010 101010 1010

38. Ref: 3826/02/25
Forward Consumption
Forecast is consumed forward from order date for the number
of calendar days in Forward Forecast Consumption field
Backward Forecast Consumption = 7 days Forward Forecast Consumption = 7 days
Forecast
Orders
Consumption
7 days
SMTW SFT SMTW SFT SMTW SFT
101010 1010 101010 1010 101010 1010
85
1010 101010 1010 105

39. Ref: 3926/02/25
Current Period Consumption Logic
Forecast is consumed on the order date first
Additional forecast is consumed forward, then backward
Forecast
Orders
Consumption
123 45
SMTW SFT SMTW SFT SMTW SFT
101010 1010 101010 1010 101010 1010
45
51010 1010

40. Ref: 4026/02/25
Consumption Logic Across Periods
Forecast
Orders
Consumption
SMTW SFT SMTW SFT SMTW SFT
101010 1010 101010 1010 101010 1010
15 35 45
1010 101010 1010 10105
Backward Forecast Consumption = 7 days Forward Forecast Consumption = 7 days
7 days
7 days

41. Ref: 4126/02/25
Exercises
Interpret forecast consumption
Exercise
2

42. Ref: 4226/02/25
Product Structure Analysis
End Items
Sub-assemblies
Purchased components
MPS
MRP
MRP/SIC
MPS
MRP
MRP/SIC
MPS
MRP/SIC
MPS/FAS

43. Ref: 4326/02/25
Product Structure Analysis
End Items
Sub-assemblies
Purchased components
MPS
MRP
MRP/SIC
MPS
MRP
MRP/SIC
MPS
MRP/SIC
Product Families MPS MPS
MPS/FAS

44. Ref: 4426/02/25
Product Family
MPS items
Plan level 3
Product family
Plan level 1
Product family
Plan level 2
CHAIRS
02101 02106
FURNITURE
DESKS

45. Ref: 4526/02/25
Plan Levels
For Plan Code 101
CHAIRS
02101 02106
FURNITURE
DESKS MATS
ROUND SQUARE
ARM
COVERS

46. Ref: 4626/02/25
Exercises
Define a plan code
Set MPS parameters
Define plan periods
Exercises
3 - 5

47. Ref: 4726/02/25
MPS Plan Items
CHAIRS
02101
02106
MPS Items
Product Family

48. Ref: 4826/02/25
Planning Bill of Material
CHAIRS
02101 02106
MPS items
Plan level 2
Product family
Plan level 1

49. Ref: 4926/02/25
Planning Percentages
MPS items
Plan level 2
Product family
Plan level 1
Planning percentages
CHAIRS
Qty = 200
02101 02106
40% 60%
Planning bill of material

50. Ref: 5026/02/25
Disaggregation of MPS Plans
CHAIRS
Qty = 200
02101
Qty = 40
02106
Qty = 160
20% 80%
MPS items
Plan level 2
Product family
Plan level 1
Planning percentages
Planning bill of material
Demand plan
Production plan
Inventory plan
Demand plan
Production plan
Inventory plan
Demand plan
Production plan
Inventory plan

51. Ref: 5126/02/25
Aggregation of MPS Plans
CHAIRS
02101 02106
75 30
MPS items
Plan level 2
Product family
Plan level 1
Planning percentages
Planning bill of material
Demand plan
Production plan
Inventory plan
Demand plan
Production plan
Inventory plan
Demand plan
Production plan
Inventory plan
105

52. Ref: 5226/02/25
Load Plan Items
02101
02106
MPS Plan Items
02101
02106
Item Master

53. Ref: 5326/02/25
Define Product Families
CHAIRS
02101
02106
Plan Items
MPS Families
02101
02106
Item Master
MPS Only

54. Ref: 5426/02/25
MPS Time Fence
Finish
Date
7 7 7 14 427
Start
Date
Time Fence
Planned Receipts
Frozen Time Fence
Planning Time Fence

55. Ref: 5526/02/25
Planned Receipts
Finish
Date
7 7 7 14 427
Recommendations
(Planned Receipts)
(Production Plan)
Start
Date

56. Ref: 5626/02/25
Frozen Time Fence
Finish
Date
7 7 7 14 427
Start
Date
No changes to MPS, only exception messages
Planned Receipts

57. Ref: 5726/02/25
Planning Time Fence
Start
Date
Finish
Date
7 7 7 14 427
Planning Time Fence = MPS Time Fence x 4 = 28
28
Planned Receipts
Planned MPS Orders
(Scheduled Receipts)

58. Ref: 5826/02/25
MPS Order Interval
Order Interval = 14 calendar days
Plan Periods
Demand
Planned Order
50 50 50 10
160
SM TW SFT SM TW SFT
21

59. Ref: 5926/02/25
Exercises
Create a new MPS item
Define a product family
Link MPS items to a plan code
Define a planning bill of material
Exercises
6 - 9

60. Ref: 6026/02/25
Critical Materials
21001
Critical Materials
Critical in MPS?
Item Master

61. Ref: 6126/02/25
Critical Capacities
100
Critical Capacities
Critical in MPS?
Work Center

62. Ref: 6226/02/25
Critical Capacity/Materials
Lead
Level Item W/C Time
0 02101B
Op 10 200 1
1 26225
Purch 2
1 05101*
Op 10 300 2
Op 20 200 3
Op 30 200 1
2 07101
Op 10 200 4
Op 20 100* 2
Op 30 400 3
1 06101
Op 10 500 1
05101 = Critical material
Material Lead Time Offset = 1
100 = Critical work center
Capacity Lead Time
for Work Center 100 = 2
Capacity Lead Time Offset
for 02101B = 13

63. Ref: 6326/02/25
Exercises
Create a bill of critical materials
Create a bill of critical capacities
Exercises
10 - 11

64. Ref: 6426/02/25
MPS Demands
Forecasted Demand
 manual inputs
 forecast algorithms
Exploded Demand
 Parent MPS orders
 Project (PRP) orders
 RPL orders
 Interplant demand
Customer Orders
 Sales Orders
 Sales Quotations
 Sales Contracts
 Service Orders
Extra Demand
 manual inputs

65. Ref: 6526/02/25
Exercises
Initialize MPS periods
Enter a demand forecast
Explode product family demand
Evaluate demand
Generate production plan
Enter a sales order
Exercises
12 - 19

66. Ref: 6626/02/25
RCCP Charts
Week 1 Week 2 Week 3 Week 4
0
5
10
15
20
25
30
35
40
Week 1 Week 2 Week 3 Week 4
RCCP
Available

67. Ref: 6726/02/25
Exercises
Review critical material and capacity
Generate planned MPS orders
Experiment with the MPS
Run MRP
Review planned inventory movements
Exercises
20 - 24

68. Ref: 6826/02/25
Processing Planned MPS Orders
Planned
Firm planned
Confirmed
Generate Planned
MPS Orders
Maintain Maintain

69. Ref: 6926/02/25
Processing Planned MPS Orders
Planned
Firm planned
Confirmed
Generate Planned
MPS Orders
Maintain Maintain
Confirm Confirm

70. Ref: 7026/02/25
Processing Planned MPS Orders
Transfer
Purchase Control
Transfer
Production Control
Planned
Firm planned
Confirmed
Planned
Generate Planned
MPS Orders
Maintain Maintain
Confirm Confirm

71. Ref: 7126/02/25
Exercises
Process planned MPS orders
Run MRP
Exercises
25 - 26