Production Planning and Control, MPS

MASTER PRODUCTION SCHEDULE (MPS) WORKFLOW SCENARIO

MASTER PRODUCTION SCHEDULE (MPS) WORKFLOW SCENARIO

Release 2.8

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Copyright
Copyright 2010 ERESOURCE. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of eresource Infotech P. Ltd. The information contained herein may be changed without prior notice. Microsoft, WINDOWS, NT, EXCEL, Word, PowerPoint and SQL Server are registered trademarks of Microsoft Corporation. HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C, World Wide Web Consortium, eresource, eresource Logo. Eresourceerp.com are trademarks or registered trademarks of eresource Infotech in India and several other countries all over the world. All other products mentioned are trademarks or registered trademarks of their respective companies

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Table of Contents
Master Production Schedule ........................................................................................................................ 5 The Production Process definition in eresource. .......................................................................................... 6 Product and Material Definition in eresource .............................................................................................. 7 Forecasts Consumed by orders ..................................................................................................................... 8 Linkage to other Company Activities .......................................................................................................... 10 Master Production Scheduling in MPC system ........................................................................................... 10 Capacity Planning and Daily Route Availability ........................................................................................... 11

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Master Production Schedule

Interaction between demand management and master production scheduling (MPS) are frequent and detailed. As customer orders are received and entered into MPS, the detailed order information should be provided to the master production scheduler as the orders occur. An effective master production schedule in eresource ERP provides the basis for making good use of manufacturing resources, making customer delivery promises, resolving trade-off between sales and manufacturing, and attaining the firms strategic objectives as reflected in the sales and operations plan. Similarly, in eresource ERP demand management needs information on the status of orders, capacity consumed, and capacity available so customer can be kept information. Details vary significantly between make-to-order, assemble-to-order, and make make-to-stock. In all conditions, the underlying concept is that forecasts are consumed over time by actual customer orders. Eresource ERP Master Production Scheduling system is used in conjunction with Material Requirements Planning (MRP) to schedule finished goods production and raw materials requirements when and where they are required.

Make-to-order Assembleto-order Customer orders Forecast order

Make-to-stock

Capacity

Time in future Current date

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The Production Process definition in eresource.

In eresource, the Production process starts from setting up the Production process parameters. Eresource ERP is scalable enabling users to configure the production process for any Item as required. The lead time of an production operation for a product is defined; The executing time is the linear sum of the following segment times; Start Time End Time Process Time

On the basis of the parameters defined here, the system computes the duration of individual operation of the product.

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Product and Material Definition in eresource

Product Defination is an integral part of the ERP Production process and Material Requirement management, and thus requires a detailed explanation in the setup process, not only from the master data point of view but also for transactional processes. We will therefore describe how eresource handles finished product Management The product Defination in eresource can be extended and described in the following manner Basic Product Information : Basic product information includes search key values, Description, Product Categorizaion, Unit of measurement, EAN Production Process : This refers to the process that takes to manufacture the product and time taken in each of the processes

Product BOM (Bill of Material) : More advanced products would include BOM kits that are made up of other products (referred to as BOM components) IPQC and FGQC process : IPQC refers to In-process-Quality-Check and FGQC to Finished Quality Check. Here the parameters of IPQC and FGQC is defined with the acceptable tolerance.

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Product Business Partner: This describes additional information used when product Is manufactured and purchased. Product Replenishment: This describes the rules of how a product would be replenished. This would, for instance, include minimum and maximum quantities to hold in stock.

Forecasts Consumed by orders

Observe in above figure that the lines for three different environments are quite different in eresource ERP. For the Make-to-order environment, there are very few actual customer orders, thus demand is generally satisfied from inventory. This reflects the need to manage the finished goods inventory. For the assemble-to-order environment, there are customer orders already booked for several periods into the future. This reflects the need to provide accurate delivery promise dates the customers. Still different demand management problems confront the firm with a make-to-order environment, even though theres a larger backlog of customer orders. Communication between the firm and the customer first involves engineering, as orders become completely specified, and then project management status and delivery date promising.

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eresource ERP provides you the provision to create Master Production scheduling on the bases of Sales order, Forecast or Both. For a particular time period you are allow to do Production Scheduling. All finish material requirement get filtered out on the click of Consolidated Requirement Item Name Wise. A Mfg Order No. which is system generated gets populated which is customer specific and its sales order no. In eresource ERP you have provision to schedule a plan Qty and system will auto generate the pending Qty. System will tell the start and end date of each and every particular Mfg Order No.

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Linkage to other Company Activities

Resource Planning

Rough-cut capacity planning

Master Production Scheduling ( MPS ) Front end Engine Detailed Material planning ( MRP )

Master Production Scheduling in MPC system

The above figure presents a partial schematic for the complete manufacturing planning and control system which is showing the linkages to master production scheduling. The detailed schedule produced by the MPS which drives the entire engine and back-end system, as well as the rough-cut capacity planning activity. The linkage to the eresource ERP system of the firms is shown as indirect, but they are important. The role of MPS in eresource ERP system is the same as we have described here: disaggregating the sales and operations plan, creating a statement of the output from the factory, and providing the information for coordinating sales and manufacturing. The demand management block in above figure represents a companys forecasting, order entry, order promising and physical distribution activities. Demand management collects data on all sources of demand for manufacturing capacity: customer orders, forecasts of future customer orders, warehouse replenishments, interplant transfer, spare parts requirements and so forth. These forecasts in eresource ERP are summarized and provided to sales and operations planning.

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Enterprise Resource Planning ( ERP )

Sales and operations planning

Demand Management

In eresource ERP sales and operations planning the forecasts from demand management will be consolidated and incorporated into sales and operations plan.

Capacity Planning and Daily Route Availability

Capacity planning involves an analysis of the master production schedule to discover the existence of any manufacturing resources that represent potential bottlenecks in the production flow. This is a eresource Linkage that provides a rough evaluation of potential capacity problems with a particular MPS. The disaggregation of the operations plan into production plans for specific product defines the product minx that will be produced. These plans in eresource ERP also provide the basic demand forecast for each MPS production unit. The eresource MPS, in turn, provides the input data to the material requirements planning system. The MPS, then, is the driver of all the detailed manufacturing activities needed to meet the output objectives of the firm.

Eresource ERP Master Production Scheduling system quickly and accurately schedules all item requirements for each manufacturing facility.

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Some of the benefits of using Master Production Schedule module are it helps last minute scheduling, shortage avoidance, efficient allocations of resources and cost control. It gives the customer timely information on what they need and when they need. Eresource ERP's MPS module organizes what the customer need to do and when efficiently. The schedule can be re-calculated easily when a process fails, for example, the situations like a material shortage or manpower absence.

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