PowerPoint Presentation Best Waze to MRP.pdf · CP-81 The best ‘waze’ to get to destination ‘MRP’! Paul Whiteman –Lexell Blue Susan Pucciano –Lexell Blue

CP-81

The best ‘waze’ to get

to destination ‘MRP’!

Paul Whiteman – Lexell Blue

Susan Pucciano – Lexell Blue

©2016 Deltek, Inc. All Rights Reserved 2

Agenda

Introductions

Manufacturing Maturity and MRP Roadmap

System Configuration and Master Data Setup

Demand – Supply – Inventory

How to use MRP

New MRP features

How will we cleanup all this data?

Q&A


Lexell Blue

Lexell Blue, LLC headquartered in Northern Virginia

Comprised of four partners and a team of consultants with extensive experience with the Deltek

GovCon suite of products

Costpoint consulting services:

– Costpoint Implementations and re-implementations

– Manufacturing / Materials / Procurement

– Labor / Leave / Payroll / HR / T&E

– M&A Integration and Divestitures

– Data Migration and Restructures

– GCS Premier to Costpoint Conversions

– Project Management

– BI Reporting

– Extensibility & Interfaces

Manufacturing Maturity and the MRP Roadmap



MRP Benefits

Project based materials requirements planning tool with complex project planning algorithms help

planner buy and make decisions

Minimizes risk of material shortages

Improve on-time delivery

Minimize risk of excess inventory

Efficiency improvements: Automated generation of supply (Purchase Requisitions, Manufacturing

Orders and Transfer Reservations)


Where are you in Manufacturing Maturity?

Inventory

MRP Dynafact

Finite

Capacity

Schedule

Infinite

Capacity

Schedule

Tool Sophistication

Manufa

ctu

ring M

atu

rity

Procurement

BOM

Production

Control

ECN MPS

Routings

Sales

Orders


MRP Prerequisites

Inventory

MRP Dynafact

Finite

Capacity

Schedule

Infinite

Capacity

Schedule

Tool Sophistication

Manufa

ctu

ring M

atu

rity

Procurement

BOM

Production

Control

ECN MPS

Routings

Sales

Orders

Product

Definition


Roadmap to MRP

Data cleanup: Parts, BOM, Projects, Supply, Demand, Inventory

Implement prerequisite Costpoint modules

Testing MRP

MRP Training

Requirements

Configuration

Master Data Setup

Co

stp

oin

t

Pro

du

ctio

n

Co

stp

oin

t

Te

st

ConfigurationUpdate MRP

schedule runs

MRP

Go-Live


Tips for the MRP roadmap

Accurate MRP Input = Accurate MRP Output. It is all in the master data and setup accuracy

Keep it simple. MRP is a complex algorithm, especially with new features. The more features that are utilized, the harder to maintain and debug issues

Don’t be afraid of running MRP to view the recommendations.

Ensure all of your demand is represented in Costpoint

System Setup and Configuration



System Configuration

MRP Settings

Production Control Settings

Shop Floor Calendar

Purchase Requisition Settings

XX


Parts – Basic Part Data

Multiple v Latest

Part Revision

Part Type

Part Status

Make / Buy

Active Flag

UoM Conversion


Parts – Planning Details

MRP Planning Type Ordering Policies

– Discrete Lot Size

– Min/Mult Lot Size

– Period

TIP: Use Period to reduce number of orders

Maximum Lot Qty

Floor Stock

Common Stock

Scrap %

Yield %

Planning Types

– MRP

– MPS

– Reorder

– None


Parts - Lead Times

Stocking

Need

Date

Due

Date

Manufacturing + Insp

Planned

In-Shop

Date

Planned

Release

Date

Pick Planning

Planned

Order

Date

Receiving & Inspection

Need

Date

Due

Date

Vendor

Planned

Open

Date

Planning & Buyer

Planned

Order

Date

Make Parts

Buy Parts

TIP: Start out basic using just ‘Manufacturing’ and

‘Purchasing Vendor’ as a minimum


Parts – User Security Access

TIP: Use Result Set Security to restrict access to various part master attributes by user role

Engineering/CM: Basic Part Data

Planning: Planning Details, Lead Times, UoM Conversions, Project Requirements, Substitutes

Quality: Assign Standard Text, Basic Part Data

Procurement: Alternate Parts, Item Vendor


Bills of Material

xx XX


Inventory Project Setup


Inventory Abbrev Setup

Setting up default End Item / Subassembly / Buy Parts Inventory Abbrev relationship

Setup to support various business models

– Buy and build to project

– Buy to common, build to project

– Buy and build to common


Inventory Abbrev Peggings

Demand, Supply & Inventory



Demand

Sales Orders

MPS Forecasts

Inventory Reservations

– Issue to Project

– Issue to PO

– Transfer Reservation - demand for originating project

Safety Stock – setup in Manage Parts > Project Requirements

Manufacturing Order

TIP: All material demand should be represented in Costpoint


Supply

Purchase Requisitions

Purchase Orders

Inventory Transfer Reservation – supply for destination project

Manufacturing Order

TIP: No supply should be created independently from MRP


Inventory

Inventory Accuracy

– Cycle Counting / Physical Inventory

– Reconcile Inventory Transactions Utility

MRP Netting Location Types

– On-Hand

– Incoming Inspection

– Shipping

– MRB (Optional Configuration)

MRP Non-Netting Location Types

– On-Hold

– MRB (Optional Configuration)

How to use MRP



MRP Processing Steps

Update

MRP

Manage MRP

Action

Messages

Detailed Part

Schedule

Firm MRP

Planned

Orders

Purchase

Requisitions

Manufacturing

Orders

Transfer

Reservations

Substitute Part

Replacements

Order

Updates

(Cancel, Qty,

Schedule)

MRP Reports


Update MRP

Warehouse range selection

Full Regeneration v Net Change

Updating MRP

– Update Low Level Codes

– Deletes existing MRP Action Messages, Gross Requirements, Scheduled Receipts

– Creates new MRP Action Messages, Gross Requirements, Scheduled Receipts

TIP: Automating the processes on Costpoint Job Management

– Schedule Update Low Level Codes to run weekly (recommended)

– Schedule Update MRP to run nightly (typical)

– Provide notification for batch process success/failure


Manage MRP Action Messages

xx


Manage Detailed Part Schedule

xx


MRP Reports

Costpoint MRP Reports

Recommend Cognos MRP Reports: Gross Requirements, Scheduled Receipts, Action Messages


Firm MRP Planned Orders

xx

New MRP Features



New in Costpoint 7.1


New in Costpoint 7.1

Transfer Reservation Action Messages – option to create Transfer Reservations if there is available

inventory in another project within the planning project group

Use Common Inventory – the system will use all parts in the common stock inventory, regardless

of whether or not the parts are flagged as Common Stock.

Default MRP Action Message Types – select which action messages will default as checked when

entering the Manage MRP Action Message screen - no more unchecking boxes!

Inventory Allocations - MRP process takes into account inventory allocations when calculating

available supply

Expired Shelf Life Inventory not available for planning


Substitute Part Action Message


Substitute Part – Requirements Update

How will we cleanup this data?



Data Cleanup

Parts (Status, Planning flags, Lead Times, Safety Stock, Substitute Parts)

Manufacturing BOM (Make/Buy, Part Type, LT offset, Effective Dates)

Demand

– Closing obsolete orders: Manufacturing Orders, Sales Orders

– Closing obsolete Reservations (Issue to Proj/Transfer/Issue to PO)

– Look for orphan Reservations from SO/MO (RES_HDR, RES_LN)

– Updating to correct Part Revision on SO line, MO requirements (Multi-Revision environment)

Supply

– Closing obsolete orders: Requisitions, Purchase Orders, Manufacturing Orders

– Updating to correct Part Revision (Multi-Revision environment)

Inventory

– Accuracy

– Common Inventory designation


Data Cleanup Methods

Manual updates

– Find/Replace function on queried datasets

– Expedite PO and MO screens

– Tip: Run MRP after all demand is clean, and review Cancel Order and Decrease Qty

messages

Preprocessors/Imports:

– Item: Most part data can be updated for Oracle db, but limited for sql db

– BOM, Purchase Order, Sales Order

Database update scripts

– Perform high volume data updates

– Able to update status on closed/inactive projects


Summary

Manufacturing maturity and the MRP roadmap

Key system configuration and master data setup

Demand – Supply – Inventory

MRP processing steps

New MRP features

Data cleanup


Questions?

Paul Whiteman

– [email protected]

– Phone: 571-214-9613

Susan Pucciano

– [email protected]

– Phone: 703-608-9483

PowerPoint Presentation Best Waze to MRP.pdf · CP-81 The best ‘waze’ to get to destination ‘MRP’! Paul Whiteman –Lexell Blue Susan Pucciano –Lexell Blue

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