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MR-G  Print Material Requirements

Purpose of Program

Use the program to get a listing of the material requirements for each inventory item.

The report is sorted in date order and shows a projected on-hand quantity opposite each transaction.  Each transaction is either an existing sales order, forecast, work order, work order allocation, purchase order, or a suggested (planned) work order or purchase order.

Sales orders, forecasts, and work order allocations reduce inventory; work orders, purchase orders, and suggested work orders and purchase orders increase inventory.

Action messages are given that suggest when to make or buy items, and when to expedite or delay existing orders.

Column Heading Explanations

Req Date

The date column shows the required date of each transaction and uses the following dates for each transaction type: sales orders - the estimated ship date; purchase orders - the receiving due date; work orders - the scheduled finish date; work order allocations - the start date of the work order; forecasts - the forecast due date.

Fin Date

This column contains the estimated Finish Date of the work order for lines showing work order activity.

Quantity

The quantity of each transaction.  In the case of sales orders, this would be the combination ship and backorder quantity.  Otherwise, it would be the work order quantity-to-make, the purchase order quantity, the forecast quantity, the quantity allocated for a work order, or the suggested (planned) buy or make quantity.

On-Hand

The projected running on-hand quantity accompanying each transaction.  It begins with the current actual on-hand quantity and gets reduced by sales orders, forecasts, and work order allocations, and gets increased by work orders, purchase orders, and suggested (planned) work orders and purchase orders.

Pegged to

This column is used to identify transactions that produce requirements for material.  A Pegged to value always accompanies a negative (bracketed) amount in the Quantity column.  If it is a work order number (easily identified by the fact that it has a prefix and a suffix) then it means that there is a work order for which this item is allocated in the work order's bill of material.  If it is a single number without a suffix, it is a sales order number.  If the word FORECAST is printed, it is a forecasted requirement.  If PL and a number appears, it means the item is allocated to a suggested (planned) work order that does not yet exist.  If you have a great many items pegged to planned orders, it means you have not generated suggested work orders.  Once planned work orders get generated, the number of items pegged to PLANNED work orders will be reduced.

Prod Code

This column contains the Item Code of the parent part in the Pegged to column to make it easier to identify what assembly is driving the demand for an item.

Cust/Vend Name

The name of the customer or vendor associated with the requirement

Cust Order

This column contains the customer PO for the Sales Order driving the requirement.

Order No

This column is used to identify work orders and purchase orders that satisfy material requirements.  If it is a work order number (easily identified by the fact that it has a prefix and a suffix), it means that it is an existing work order.  If it is a single number without a suffix, it is an existing purchase order number.

Planned (suggested) purchase orders are identified with the word BUY.

Planned (suggested) work orders are identified with a number that consists of the prefix "PL" followed by an up to five digit number.  These numbers are sequential beginning with "PL    1" and are regenerated from scratch each time MR-F  Generate Material Requirements is run.  The assignment of these planning numbers assists you in tracking requirements back to particular planned orders.

St Date

In the case of existing work orders, this is the scheduled start date.  For planned (suggested) work orders, this is the suggested start date.  For existing purchase orders, this is the order date.  For suggested purchase orders, this is the suggested purchase order date.

Action

This column is for displaying action messages.

•MAKE identifies a suggested (planned) work order.
•BUY identifies a suggested purchase order.
•EXPEDITE identifies a work order or purchase order that is sufficient in quantity to fill a requirement, but arrives late and therefore needs to be moved up in the schedule.  The work order finish date or purchase order due date must fall within the item's EXPEDITE buffer for the order quantity to be considered a fulfillment of the current requirement, albeit late, as opposed to fulfilling some future requirement.  If the finish date or due date falls outside the item's EXPEDITE buffer, the program assumes the order quantity is for some future requirement and will therefore issue a MAKE or BUY message to fulfill the current requirement.
•DELAY identifies a work order or purchase order that is arriving earlier than needed, unnecessarily increasing inventory and tying up capital.  For an order quantity to be considered as arriving too early, the work order finish date or purchase order due date must fall within the item's DELAY buffer.
•REVIEW means that an item is due to arrive earlier than a requirement's DELAY buffer, and thus is not pegged to any requirement and should be reviewed.  This can be triggered by several things.  One, your DELAY buffer is set too small and items are arriving earlier than the buffer period.  A common reason for a REVIEW message is that an order is arriving so late, new MAKE or BUY actions have been suggested in its place and now the order is no longer tied to any requirement.  The solution is to disregard the MAKE or BUY recommendation and to reschedule the order to arrive when needed.  Another reason for getting a REVIEW message is that you've simply ordered some material for which there is no requirement.
•NONE is a message given when an order quantity and its requirement fall on the same date.

General Program Operation

This report is often used as an inquiry for a single item, viewed on the screen.  If printed for the entire inventory, it can be an extremely long report.  If you wish to identify MAKE, BUY, EXPEDITE, and DELAY actions to be performed, an alternative to this report is MR-H  Print Order Action Report, which is limited strictly to MRP transactions with action messages.

You can list the Material requirements for all components at all levels through the BOM of an assembly by answering Y to Print BOM Components in which case you only enter the top assembly item number.  Otherwise, Enter a from/thru range of item numbers or select item numbers from a  lookup window by pressing the F2 key (or clicking on the Lookup button).

Enter a date range to limit the report to a specific time period or press <Enter> through both fields to look at all MRP records.  

You can further limit the report by inventory type (F=Finished Goods, A=Subassemblies, M=Make Froms, R=Purchased Parts), inventory category, item class or primary vendor.

Finally you are asked New page for each Item number?  If you answer yes, each item number's report will start at the top of a page.  If no, each item number's report will print in succession without any page breaks.