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Running MRP

You can manually run MRP via the Run button when viewing any of the MRP lists.

Note: This button will only be enabled when viewing the MRP lists. You can also automate MRP to run at a pre-defined time.

The Run MRP screen contains the following controllable options:

MRP Mode: This will always display ‘Full’. The original specification from MRP in Cim50 also included a ‘Simple’ mode which is now currently under consideration as a wish.

Planning Horizon Date: The date you wish MRP to read up to. Any demands or replenishments beyond this date would be excluded from MRP.

Note: This value is defaulted based on the planning horizon defined in the planning settings.

Replenishment Horizon: This setting determines what replenishment horizon should be used for items that do not have a replenishment horizon specified. Depending on the settings this may show ‘Lead Time’, in which case either the suppliers lead time or the manufacturing lead time, as specified on the stock record, will be used, or you can enter a number of days as required.

Note: If an item has a Replenishment Horizon specified on the Stock Record MRP tab, that value will override the value entered in this field. This field only comes into consideration if the Stock Record MRP Replenishment Horizon is set to 0.

Aggregate Demand: This option determines whether the system will take individual stock record aggregation settings into account or not. With this option enabled, demand will be aggregated based on the aggregation settings defined on each item. Otherwise the system will process each demand individually, without any aggregation.

Replenishments: You can choose which replenishment sources you would like to include by ticking/unticking the appropriate options:

Note: When the ‘All Replenishment Sources’ option is selected the individual options are greyed out. To enable the individual options, uncheck the ‘All Replenishment Sources’ option.

Target Items: You can choose to run MRP against all items, or specific targeted items:

All Items: MRP will process all stock records.

Specific Stock Records: Selecting this option will allow you to build a filter to determine which specific stock items MRP should process.

Note: If any manufactured items are returned by the filter, those items will be exploded and any component or sub-assembly items will be added to the MRP run. This is to ensure the system has considered those components/sub-assemblies when calculating whether you can satisfy the demands for the top-level item.

Specific Sales Orders: Selecting this option will allow you to select one or more sales orders. The selection screen is like other selection screens throughout the system.

Tick the box in the left-hand column for the sales orders you wish to include, and press Select.

Warning: You must ensure the selected sales orders are all included in the demand schedule, otherwise no recommendations or results will be returned by MRP.

Note: All outstanding items from those orders will be included in the MRP run. If any manufactured items are included, those items will be exploded, and any component or sub-assembly items will be added to the MRP run. This is to ensure the system has considered those components/sub-assemblies when calculating whether you can satisfy the demands for the top-level item.

Specific Works Orders:  Selecting this option will allow you to select one or more works orders. The selection screen is like other selection screens throughout the system.

Tick the box in the left-hand column for the works orders you wish to include, and press Select.

Warning: You must ensure the selected works orders are all included in the demand schedule, otherwise no recommendations or results will be returned by MRP.

Note: All component items from those Works Orders will be included in the MRP run. This is to ensure the system has considered those components/sub-assemblies when calculating whether you can satisfy the demands for the works order items.

Once you have confirmed which replenishment sources you wish to include, and specified which items you want MRP to process, press the OK button in the bottom left corner of the screen to begin the MRP run.

The system will process the MRP run. As it processes through the tasks, a status indicator will display the progress of the run.

Note: Depending on the size of the dataset and number of items to be processed, an MRP run can take anywhere from a few minutes to over an hour.

MRP Run

Whilst MRP is running it will go through the following steps:

 

Getting Available Stock

This process goes through every stock record that will be included in the MRP run, as determined by the selection options in the ‘Target Items’ section. This process determines free stock quantities along with the planning settings defined on each item.

 

Calculating Usage Levels

Usage levels are a key element of the MRP process. The system will process items in Usage Level Order. This is to ensure all items are processed in an order such that no demand gets missed.

In a scenario where a top-level item is processed by MRP, and that process generates a works order recommendation, there will also be additional component demand generated because of that works order recommendation. If we were not processing items in usage level order, there is a risk that we would have already processed the component item and subsequently this new demand would not be processed.

The system calculates Usage Levels every time a BOM is saved. This is a time intensive process as any change to a BOM can have a knock-on effect across any other commonly affected items. As such, this calculation is carried out on the server by the ‘CIMi’ service.

At the time MRP is run it gathers and validates the usage levels and calculates any that have not currently been set.

 

Getting Linked Items

This process goes through all existing firm links between Sales Orders and Works Orders, then validates them to ensure SO/WOs have not been cancelled and are still outstanding.

 

Getting PO Replenishments

This process reads through all outstanding Purchase Orders to determine what stock is due to be available from PO receipts and when it will be received.

 

Getting WO Replenishments

This process reads through all outstanding Works Orders to determine what stock is due to be available from WO receipts and when it will be completed.

Reading Demand Schedule

This process gathers all the demands included in the Demand Schedule ready for processing by MRP.

 

Processing Items

This process of the MRP run is where the system processes each item individually. Reading through the demands, offsetting stock and replenishments against those demands and raising recommendations where appropriate.

This process is generally the longest part of the MRP run and displays the current item that is being processed.

 

Rescheduling

The rescheduling process re-evaluates all the replenishments in the system. Determines if/when they are needed and whether they need to be cancelled or rescheduled.

If a replenishment is not required to satisfy any demand, and the stock record is configured to allow rescheduling/cancellations, it will be recommended to be cancelled unless it falls within the firm planning period.

If a replenishment is required by a demand but the demand date is later than the replenishment receipt date it will recommend rescheduling the replenishment so that it is received just in time for the demand.

 

Validating

Lastly the system will validate the run, report any errors that were encountered and commit the MRP output log to the Cim50 share.

The screen will then close and return you to the MRP list view.