Perform Project MRP

Explanation

This activity is used to perform project material requirements planning with a single project (project MRP) or with multiple projects (multiproject MRP). The application creates project MRP planned orders and offers suggestions for planning orders for optimal manufacturing, considering material availability.

PMRP can be performed per activity by considering one activity at a time, when calculating net requirements. This means that excess supply of a part from other activities which are under consideration in the same process, will not be used to meet shortages in the current activity, and excess supply belonging to the current activity will not be used to satisfy shortages in other activities.

PMRP can be performed per project by considering all the activities belonging to a single project at a time, when calculating net requirements. This means that any excess supply of a part from one activity in the project can be used to satisfy the demand for that part in other activities through MTR’s. However, excess supply in one activity cannot be used to fulfill demand from another activity which belongs to a different project

PMRP can be performed per PNG by considering all the activities belonging to a planned netting group (PNG) at a time, when calculating net requirements. This means that any excess supply of a part from one activity can be used to satisfy the demand for that part in other activities included in the PNG, through MTR’s.

Part requirements can be ascertained based on the sources of supply and demand such as shop orders or customer orders. If project MRP was performed previously, then all the planned supplies and action messages generated in the previous process will be removed first. The results of project MRP suggest a process for fulfilling the demands using, for example, purchase or shop order requisitions. These results also suggest how to plan orders for optimal manufacturing in view of material availability. Project MRP plans the supply for all the parts with a dependent demand. The product or recipe structures of the parts must have been entered. After the structures are entered, you can run project MRP for all the parts with a dependent demand. Project MRP considers only company-owned stock and activity specific requirements. Planning methods B, C, N, O, and T are excluded by project MRP.

Project MRP can be performed by integrating with CRP. When performing PMRP alone, it considers site manufacturing calendar and the registered manufacturing lead time for the part. When project MRP is performed integrating with CRP, shop order requisitions generated by PMRP will be backward scheduled and the start date of shop order requisitions are calculated considering the relevant work centers/resources and work center connected calendar availability. In this way more accurate results can be achieved.

After performing project MRP, a succeeding site MRP process can be started. This will allow the system to plan for standard planned items right away after demands of project controlled parts get calculated during the project MRP process. The values of Stop PMRP on Error, MRP Horizon, and Phantom Part Dependent Demand Message flags will also apply to the succeeding MRP run. Here, options are available to control MRP input parameters considering, Plan Safety Stock Receipt considering MRP Run Date and Plan Alternate Component.

Prerequisites

• Project MRP identifies supply and demand for project MRP parts generated in the following IFS modules: IFS/Customer Order, IFS/Purchasing, IFS/Project Master Scheduling, IFS/Shop Order and IFS/Work Order only if those demands are tagged with PPSA.
• To perform multiproject MRP, a planned netting group must have been defined in IFS/Project.

Project MRP requires the following general prerequisites:

• Bill of Materials (BOM) must have been defined for the parts, and lead times for both purchased and manufactured parts must have been established. The product structures must be in the Plannable or Buildable status, otherwise the BOM explosion will stop. Project MRP only uses the existing product structure with the alternate indicated by an asterisk (*).
• Project MRP calculation will consider inventory parts that have the MRP Control option enabled on the Inventory Part/Manufacturing tab.
• Before you run project MRP, you must go through an extensive setup in the IFS/Inventory and IFS/Purchasing modules in IFS Distribution. You must create calendars and attach them to the sites. You must have entered basic data in IFS Manufacturing and the IFS/Shop Order. Since project MRP is based on the quantity on hand and planned orders, data must be available in these components.
• In addition to the basic requirements for project MRP as discussed above, customer orders, shop orders, and purchase orders for these parts need to exist. There is much additional information that affects project MRP, and it is important that you verify this information and its accuracy before running any calculations.
• Inventory parts with the DOP supply code are managed within DOP.
• Project MRP calculation will consider inventory parts with a part that allows demand and supply.
• PPSA must be in the Released status.

System Effects

• A new background job for the project MRP process will be started, and it can be queried on the Background Jobs page.
• After the process is executed, it can get the Error, Warning, or Ready status.

Status	Significance
Error	Some critical errors have occurred. Project MRP stops the process.
Warning	A message posted for this process has to be reviewed by the user. This can be done by right-clicking and then clicking View Detail in the Background Jobs window, which displays the posted message in the status information table. If the user decides to continue the project MRP process when an error occurs, the system will post a message containing a warning.
Ready	The process is completed successfully without any errors.

• The project MRP will generate shop order requisitions for parts that need to be manufactured and purchase requisitions for parts that need to be purchased. Shop order requisition type and purchase requisition IDs are project MRP. Shop order  requisitions that are not converted to shop orders will be deleted in the next project MRP process.
• The project MRP will calculate the lowest level code parts and update the Low Level on the Inventory Part/Manufacturing tab.
• In the multiproject MRP process, when a user specifies a planned netting group (PNG), the system creates a project MRP planned material transfer requisition (MTR). The multiproject MRP process creates material transfer requisitions in addition to shop requisitions and purchase requisitions. MTRs created by the multiproject MRP will have the Manually Created value set to no.
• When creating MTR, the Generate MTR for Planning Only option in the Planned Netting Group page determines the type of MTR that will be created by project MRP. If the option is enabled, project MRP will create MTR with the Planning type. If it is disabled, possible MTR types that will be created are: Transfer, Borrow and Payback.
• If the Generate Safety Stock option is enabled on the Activity Setup Parameters page, and if the part has safety stock specified on the Inventory Part Planning Data page, then safety stock will be generated for this part and activity when running project MRP.

Pages

Perform PMRP per Project PNG
Perform Project MRP per Activity
Perform Project MRP per Planned Netting Group

Activity Diagrams

Perform Project MRP