If you use QAD MRP, here’s help so you get the most out of it and use it to its full potential! MRP expert Don Lindsey explains:
• MRP’s role in QAD
• Ways to calculate time-phased material requirements
• Where important data elements are within the QAD menu structure
• Optimization of MRP data planning elements
• And, more!
Don shares ways to simplify your process, tricks of the trade, and secrets to superb material requirements planning that will enable you to ensure timely customer delivery, a smooth-running production operation, and healthy cash flow.
What does the “Discrete Lot for Lot” order policy do?
The Lot for Lot order policy tells MRP to create a planned order for each and every net requirement.
Is there a way to use the FOQ (Fixed Order Quantity) but have it not drive for more than the overall total requirements?
Not in the current version of MRP. FOQ tells MRP to always order the FOQ quantity, whether the net requirement is 1 or 1000. For example, if the FOQ is 500 and the net requirement is 1000, MRP will plan two orders of 500 Each. MRP net requirement causes the planned order quantity to be based on the order policy, not the gross requirement. You may want to consider some combination of multiple, max, and minimum Order quantities. Just remember that any non-blank value other than FOQ, POQ, ONO or LFL are processed as lot for lot.
How far out should you firm up work orders?
In menu 23.24, you will find the value for the field called “Order Release Horizon.” This tells MRP how far out in the future to tell the planner to take action on planned orders. The value of that field should be equal to the amount of time it takes the planner to evaluate the recommendation + the amount of time necessary to gather the work order pack and documents together + the amount of time to send to the stock room/warehouse and get picked. Typically it is 7 calendar days. If you run MRP once a week, the release horizon should be at least 7 days.
What problems does it cause to change the release date of a work order after it has been released?
If your order release horizon is shorter that it should be, then work orders will not be in the system [i.e. at the work center or at the supplier] at the right time. This can cause the plan to be out of phase and give incorrect information. Remember, MRP assumes you told it the truth. If you told MRP it would take X days to complete the order, then it uses that to plan.
If a work order needs to be rescheduled, and it is already released, does rescheduling change the release date (meaning the parts are coming in now but work isn’t needed until later)?
This depends on the order status of the work order. If the order has a status value of F [firm planned], then a change to the due date will automatically change the due date of the components to the release date of the parent. If the work order has a status value of R [Released Status], a change to the due date of the parent will not change the due date of the components. However, you can change the due date of the components in menu 16.13.10 – Work Order Bill Maintenance.
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