2135.34

v 13.0 Third Party 7
Required Apps Inventory (stock)
Manufacturing (mrp)
Purchase (purchase)
Sales (sale_management)
Invoicing (account)
Included Dependencies
Openvalue Warehouse Calendar (19 lines of code)
Work Center Capacity (95 lines of code)
Lines of code 2635
Technical Name mrp_master_production_plan
LicenseSee License tab
Websitehttp://linkedin.com/in/openvalue-consulting-472448176
Also available in version
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Required Apps Inventory (stock)
Manufacturing (mrp)
Purchase (purchase)
Sales (sale_management)
Invoicing (account)
Included Dependencies
Openvalue Warehouse Calendar (19 lines of code)
Work Center Capacity (95 lines of code)
Lines of code 2635
Technical Name mrp_master_production_plan
LicenseSee License tab
Websitehttp://linkedin.com/in/openvalue-consulting-472448176
Also available in version

MASTER PRODUCTION PLAN

 

Planning your production plants in MTS scenario with feasible plans as result of capacity checks and financial impacts evaluations. A planning tool with several planning techniques is provided for determining production plans in balancing the demand in Sales and Operations Plan phase.

 

Process Overview

The Master Production Plan Management consists of the following process steps:

Demand Management: evaluate the forecast demand by entering Planned Independent Requirements

Sales and Operation Planning: determine master production plan by balancing the released forecast demand, the current stock, sales and supply quantities. The master production plan can be generated through the support of a planning tool. Before releasing the SOP plan, its feasibility can be evaluated through capacity checks and financial evaluation

Master Production Plan: consolidate the master production plan by evaluating capacity loading and financial figures; master production plan can be used stand alone for production planning

 

 

The following picture provides an overall process overview:


Remarks:

       this model is to manage the master plan in MTS logistic model: therefore, MTO indicator in product master data should not be set for all the involved products

       working calendar has to be assigned to every warehouse for production dates determination

       all the calculation in SOP management are to be propagated from the concerned line to the whole table; for this reason, a massive update feature is available in the action button

       make or buy” decision can be taken at SOP level by defining “normal” BOM or subcontracting BOM and subcontractor either

       Master Production Plan can be used stand-alone (without planning any demand) for planning production process

       two process roles are involved, i.e. SOP manager and SOP user, throughout the overall process

 

 

Planning Parameters


Planning parameters are to be defined for each product at warehouse level. A planning parameters is necessary for planning a product in a warehouse; therefore, it is not possible to plan a product in a warehouse without creating its planning parameters record. Checks are implemented in all the subsequent process steps.


The following planning parameters are implemented:

·       Total Replenishment Lead Time in working days for the determination of start pivot date in production items

·       Planned Sales Delivery Lead Time in calendar days for achieving the availability date from the requested date in Demand Management

·       Safety Stock taken into account in SOP planning tool

·       Safety Time in working days for the determination of planned date in SOP planning tool; the planned date is backwards in working days

·       Reorder Quantity Method: the following planning techniques are provided for the lot determination in SOP planning tool:

o   Lot for Lot

o   Fixed Order Quantity

o   Supply Coverage Days

·       Fixed quantity for “Fixed Order Quantity” method

·       Days of Coverage for “Supply Coverage Days” method

·       Multiple Qty for rounding the determined lot quantity

 

All the Planning Parameters records are reported in the product master data in a proper tab.

 

 

Work Center master data


Available capacity determination by entering

       working days per week,

       working hours per shift,

       number of shifts per working day.

 

 

Planning Version


Demand is managed by planning version; all PIR items are grouped and identified by their planning version. A Planning version can be closed, so no further PIR items can be entered with reference to it.

The following features are provided also:

·       Planning validity dates to be checked in Demand Planning

·       determination of revenues and costs figures for PIRs belonging to the concerned planning version

·       link to the concerned Demand, i.e. PIR items assignment to the concerned planning version

·       Planner assignment, as responsible of a Demand Version

·       report for comparing costs and revenues for several planning versions

·       document attachment feature

·       Odoo standard activity feature has been activated

 

 

Demand Management


Independent demand is entered as planned requirements with reference to a planning version. Several planning versions can be used at the same time in the Demand Management.

The following features are provided also:

       Quick entering of Planned Independent Requirement Items specifying planning version, product code, warehouse, requested quantity, requested date and requestor

       demand record can be entered only if the corresponding planning parameters record exists for its product and warehouse

       availability date is determined according to the sales lead time in product master data in calendar days

       check availability date lies within planning version validity period

       check availability date is not lying before the date calculated starting from to the start date of the planning version backward to the Overall Replenishment Lead Time; this is for guarantying the master plan feasibility, i.e. the requested quantity can be produced; the backward scheduling is performed according the working calendar assigned to the warehouse

       check only material with real BOM can be taken into account (i.e. BOM exists as manufacturing or subcontracting one either)

       check only manufacturing warehouse can be entered

       check only one PIR for the same warehouse (and product code) can be entered for the same date

       Release Planned Independent Requirement for moving them to the next planning level, i.e. SOP

       Reset Planned Independent Requirement for evaluating a new planning scenario

       Odoo standard activity feature has been activated

 

The following tools are provided also for massive item processing:

·       PIRs massive creation copying them from existing ones; the selection is performed by current planning version, current warehouse and current product code

·       PIRs massive release: selection is performed by current planning version and current warehouse

·       PIRs massive reset: selection is performed by current planning version and current warehouse

·       massive reset for selected PIR items

·       massive cancel for selected PIR items

 

The following picture explains the relationship between Demand and SOP by the status flow:


 

Sales and Operations Planning


In Sales and Operations Plan process the demand is balanced by feasible master production plans. A planning tool supports the master production plan generation; three lot quantity techniques set in planning parameters, i.e. “lot for lot”, “fixed lot quantity” and “supply coverage days”, are implemented.

 


The following features are provided to manage the SOP process:

·       PIR approval creates SOP items, as Demand item; for each warehouse and product, two fictitious items are created automatically for defining the overall planning horizon: the first at 01/01/1900 as planned date and the second one at 31/12/2999

·       Manual quick entering of SOP items, as Supply items, specifying product code, warehouse, planned quantity, planned date and BOM (for subcontracting BOM, subcontractor also)

·       the planned quantity for each SOP supply item adjusts the “projected inventory quantity” calculated through the “stock on hand quantity”, the “cumulated sales quantity”, the “cumulated supply quantity” (purchase orders and manufacturing order) and the “requested PIR quantity”.

·       Multiple planning versions can be taken into account

·       for each SOP item the following figures are available:

·       stock on hand quantity (mainly for the first item at 01/01/1900)

·       cumulated current demand (sales order) at the planned date

·       cumulated forecasted demand (PIR coming from Demand Management) at the planned date

·       cumulated supply quantity (open purchase orders and open manufacturing orders) at the planned date

·       cumulated supply quantity for Manufacturing Orders in draft status at the planned date

·       cumulated supply quantity for Purchase Orders in draft status at the planned date

·       cumulated planned quantity at the planned date

·       projected inventory quantity at the planned date

·       massive update action to reevaluate computed fields

·       massive SOP item processing tool (Supply items only) for:

·       Reset from Rough Cut Capacity status to Draft status

·       Cancel from Draft status to Cancel Status

·       Capacity Check from Draft status to Rough Cut Capacity status

·       Release from Rough Cut Capacity status to Done status

·       Odoo standard activity feature has been activated

 

 


Rough Cut Capacity


Capacity work centre loading evaluation at SOP level can be done through the Rough Cut Capacity tool. The capacity requirements per WC in a time period are compared with the available capacity. The Capacity records generated by SOP are pointed out from those coming from MPP.

 

Financial Evaluation


Financial evaluation can be achieved by checking Costs and Revenues over the time.

 

 

Master Production Plan


 

The following features are provided to manage the MPP process:

·       Manual entering of MMP items specifying product code, warehouse, planned quantity, planned date and BOM (for subcontracting BOM, subcontractor also)

·       check whether planned date is not lying before the date calculated starting from today backwards to the Overall Replenishment Lead Time in working days according to the working calendar at warehouse level; this is for guaranteeing the master plan feasibility, i.e. the requested quantity can be produced

·       check only production material can be taken into account (i.e. BOM exists, normal or subcontracting one either)

·       check only manufacturing warehouses can be entered

·       workflow for managing Master Production Plan item through the following states:

o   draft (MPP creation),

o   capacity check performed,

o   done (MPP release by creation a Manufacturing Order or Subcontracting Purchase Order) and

o   Cancelled (MPP rejected)

·       reports for evaluating planned quantity and costs over the time (week period) for financial evaluation

·       massive MPP item processing tool for:

o   Reset from Capacity Check status to Draft status

o   Cancel from Draft status to Cancel Status

o   Capacity Check from Draft status to Capacity Check status

o   Release from Rough Cut Capacity status to Done status

·       Odoo standard activity feature has been activated

 

 

The following picture details the relationship between SOP and MPP status flow:


 

Financial Evaluation


MPP Costs over the time are provided to evaluate financial impacts.

 

 

MPP Capacity


Capacity Check for consolidation of a Master Production Plan Version evaluating capacity load per time period for involved work centers and comparing it with theoretical capacity available. The SOP capacity requirement are not taken into account.

The capacity requirements are cancelled when the corresponding MO is cancelled or closed either.

 

In the following picture provides the relationship between capacity requirements in the two capacity checking tools:


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