When generating planned MRP orders via the session "Generate Planned (MPS)/MRP Orders/Batches (timrp1210m000)", the following actions are carried out:

1. Delete planned MRP orders
2. Read in requirements
3. MRP orders for RPT-oriented MRP items
4. MRP orders for non-RPT-oriented MRP items
5. Generate rescheduling messages

1. DELETE PLANNED MRP ORDERS * First all existing planned MRP orders with the order status "Planned" will be deleted by the system.

2. READ IN REQUIREMENTS * Planned MRP production orders and planned MRP purchase orders are generated on the basis of the requirement per date. This requirement may originate from the following:

- Current purchase orders and purchase contracts from the module "Purchase Control (PUR)".

- Sales orders and sales contracts from the module "Sales Control (SLS)".

- Replenishment orders from the module "Replenishment Order Control (RPL)".

- Service orders from BAAN Service

- Production orders for MPS items and MRP items which have been planned and not yet reported completed. The planned order delivery date is determined with the aid of the production planning. A scheduled receipt is recorded on the computed delivery date, in which case account is taken of any subdeliveries that have already taken place.

- Allocations of materials for production orders are read from the actual data and recorded as scheduled issues per item. In the module "BOM Control (BOM)" materials have been assigned to an operation. The issue date is the planned start date of the operation in question, in which account is taken of previously issued materials and subsequential deliveries.

- All planned material requirements of projects that have the status "Active". Their calculation must be carried out in advance via the session "Generate Planned PRP Orders (tipcs5201m000)".

- The rough requirement for critical materials of MPS items.

- The sales quotations from the SLS module which have been selected for the MRP calculation.

- The MPS orders which are planned, confirmed and firm-planned.

- The MRP orders which are firm-planned and confirmed.

- The sales forecast for MRP items.

3. MRP ORDERS FOR RPT-ORIENTED MRP ITEMS *

When generating planned MRP production orders, a distinction must be made between RPT-oriented MRP items and non-RPT-oriented MRP items. When generating planned MRP production orders for RPT-oriented MRP items, account is taken of the following order parameters from the session "Maintain Item Data (tiitm0101m000)":

- MPS/MRP Order System RPT Items, to determine the operation route and the order quantity;

- RPT Item Order Per., to generate day or shift orders for the relevant MRP item;

- Min. Remaining Percentage, to determine whether the system must generate a new planned MRP production order or increase the order quantity for the last generated and planned MRP production order;

- Minimum Order Quantity, to determine the minimum order quantity;

- Safety Time, to determine the planned delivery date for the planned MRP order (based on the company calendar created in the session "Maintain Company Calendar (tirou4101m000)");

- Order Lead Time, to determine the planned start date for the planned MRP order on the basis of the company calendar (unless an (order quantity-dependent) operation has been defined for the MRP item in question).

When generating planned MRP production orders for RPT-oriented MRP items, account is taken of the available working time recorded for the relevant bottleneck work center in the session "Maintain Company Calendar (tirou4101m000)".

Next, the RPT schedule is updated. The following order parameters from the session "Maintain Item Data (tiitm0101m000)" are then checked, in which case exceptions are reported by the system: - Minimum Order Quantity - First Allowed Order Date

4. MRP ORDERS FOR NON-RPT-ORIENTED MRP ITEMS *

- Order Interval, to determine the total requirement during the order interval.

- Order Method, to determine the order quantity;

- Economic Order Quantity, if the order method is "Economic Order Quantity";

- Fixed Order Quantity, if the order method is "Fixed Order Quantity";

- Minimum Order Quantity, to determine the minimum order quantity;

- Maximum Order Quantity, to determine the maximum order quantity;

- Order Quantity Multiple of, to round off the order quantity. If the MRP item is a manufactured or generic item, the order quantity is rounded to an integer;

- Safety Time, to determine the planned delivery date for the planned MRP order (based on the company calendar defined in the session "Maintain Company Calendar (tirou4101m000)");

- Order Lead Time, to determine the planned order date for planned MRP orders (for purchased items this calculation is based on five working days per week, whereas for generic items the calculation is based on the company calendar as defined in the session "Maintain Company Calendar (tirou4101m000)"). Note: As to manufactured parts the start date for the planned MRP order is determined on the basis of the (possibly order quantity-dependent) operation route and the work center calendar or the company calendar.

When generating planned MRP production and purchase orders, account is also taken of the field "Maximum Number of MRP Orders per Day" from the session "Generate Planned (MPS)/MRP Orders/Batches (timrp1210m000)". If multiple MRP orders are generated per day, then the relevant MRP orders are optimized in such a way that the total order quantity is minimal.

After generating a planned MRP production order for a non-RPT-oriented MRP item and after generating a planned MRP purchase order, the following order parameters from the session "Maintain Item Data (tiitm0101m000)" are checked, whereby exceptions are reported by the system: - Minimum Order Quantity - Maximum Order Quantity - Order Quantity Multiple of - Fixed Order Quantity (if the MRP item's order method is "Fixed Order Quantity") - First Allowed Order Date

5. RESCHEDULING MESSAGES *

After the planned MRP orders have been generated for the relevant MRP item, the necessary rescheduling messages are generated. Account is then taken of the parameters "Display Item Foreground" and "Display Process Info Foreground" from the session "Maintain MRP Parameters (timrp0100m000)". If the expected inventory level falls below the lower margin or exceeds the upper margin of the planned inventory level, rescheduling messages will be generated by the system, if necessary.

SESSION OBJECTIVE To calculate the demand forecast by item for the short term by item. The system uses the demand forecast when calculating: - the safety stock - the reorder point

HOW TO USE THE SESSION 1) The safety stock:

+------------------------------------------------------------------+
|S = K x 1.25 x MAD Sqrt ((Oint x 5/7 + Oltm + Sftm)/Period Length)|
+------------------------------------------------------------------+

2) The reorder point

+-----------------------------------------------------------+
| Dem.forec. x (Oltm + Oint x 5/7 + Sftm) |
|Reorder Point = --------------------------------------- + S|
| Period Length |
+-----------------------------------------------------------+