MRP Master Production Plan

by
Odoo

2363.60

v 14.0 Third Party 7
Required Apps Sales (sale_management)
Manufacturing (mrp)
Inventory (stock)
Purchase (purchase)
Invoicing (account)
Included Dependencies
Lines of code 4385
Technical Name mrp_master_production_plan
LicenseSee License tab
Websitehttp://www.openvalue.cloud
Also available in version v 13.0
You bought this module and need support? Click here!
Required Apps Sales (sale_management)
Manufacturing (mrp)
Inventory (stock)
Purchase (purchase)
Invoicing (account)
Included Dependencies
Lines of code 4385
Technical Name mrp_master_production_plan
LicenseSee License tab
Websitehttp://www.openvalue.cloud
Also available in version v 13.0

MASTER PRODUCTION PLAN

 

The “Master Production Plan” Module supports the supply chain planning process in Make to Stock scenario with feasible plans as result of capacity checks and financial impacts evaluations. The replenishment of complex supply chains made of several Distribution Warehouses and Manufacturing Warehouses can be managed. A planning tool with several planning techniques is provided for determining production plans balancing the demand in Sales and Operations Plan phase.

 

Process Overview

The Master Production Plan Management consists of the following functional parts:

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

·       Distribution Deployment Planning for managing stock requests to replenish distribution warehouses from manufacturing warehouse

·       Sales and Operation Planning: to determine production plans by balancing the released forecast demand, the current stock and supply quantities. Production plans 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: to consolidate the master production plan by evaluating capacity loading and financial figures; master production plan can be used stand alone for production planning

·       Procurement Deployment Planning to manage purchase requests from the Demand for the procurement of buy products and consumables

 

The following business processes are managed:

·       Production Planning of Manufacturing Warehouses (classical scenario)

·       Inter-plant internal procurement scenario between Distribution warehouses and Manufacturing Warehouses in a complex supply chain (internal procurement scenario)

·       External procurement scenario for both Distribution and Manufacturing Warehouses

 

 

The following pictures provide an overall process overview of the above business scenarios:

 

·       Production Planning scenario


Classical business scenario where the planned demand is uploaded as planned independent requirements which are taken in charge by the SOP planning to be satisfied. The results are feasible plans (loops are possible after evaluating production capacity constraints and financial impacts over the time).

 

·       Inter-plant procurement scenario


It is possible to address Planned Independent Requirements in the Demand Management from a Distribution Warehouse to a Supply Warehouse (which should be a manufacturing one) as stock transfer request (dependent demand). A stock transfer is created in draft status for moving the requested products from the supply warehouse to the distribution one. All stock transfer moves are collected into the Deployment Plan where their confirmation can be performed; the confirmed goods transfer can be taken in charge by the Production Warehouse dpt.

 

·       External Procurement scenario


It is possible to define external independent demand over the time for Consumables and Spare Parts (buy products). In this business scenario, the requested warehouse is the same of the supply one. All the purchase requirements are collected in the Procurement Plan where purchase orders (with multiple items) can be created, so the purchase dpt is activated for performing the follow-on process steps.

 

 

Remarks:

·       working calendar has to be assigned to each warehouse for production dates determination;

·       “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 new process roles have been created: Master Production Plan Manager and Master Production Plan User for managing permissions along the overall planning process;

·       Several system checks have been implemented for user support and avoiding mistakes.

 

 

Settings


The following parameters can be set in manufacturing configuration:

·       Default source warehouse in Demand Planning

·       Default (destination) warehouse in Demand Planning

·       Maximum number of replenishment proposal in SOP planning when fixed lot method has been chosen (in case that the maximum number is exceed, an exception message is issued and addressed to the responsible planner without interrupting the SOP planning run)

 

 

MPP Planning Parameters


Planning parameters are to be defined at warehouse level for each manufactured product, i.e. produced internally or subcontracted externally; therefore, a planning parameters record is necessary for planning a manufactured product in a warehouse.

Only manufacturing warehouses and storable products with BOM can be entered. A check guarantees only one MPP parameters master data can be created for a product in a warehouse.

 

 


 

The following planning parameters have been implemented:

·       MPP Planner to identify the planner responsible to set properly MPP master data

·       Bill of Materials (normal or subcontracting ones are allowed only)

·       Subcontractor, in case of subcontracting BoM to be suggested in the follow-on process steps and changed if necessary

·       Planned Sales Delivery Lead Time in calendar days for achieving the planned date from the requested date in Demand Management in classical scenario; in the other two business scenarios the corresponding lead time at product level is taken into account; in both cases the planned date is achieved in backward mode in working days

·       Total Replenishment Lead Time in working days for checking the lead time feasibility for manufactured items in overall planning process, i.e, in Demand Management, SOP planning and Master Production Plan

·       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

Weekly available capacity determination by entering

·       working days per week,

·       working hours per shift,

·       number of shifts per working day.

The available capacity is compared with the capacity requirements in the Rough Cut Capacity check at SOP level and in the MPP Capacity check at Master Production level.

 

 

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:

·       Planner Responsible to address all exception issues in SOP planning

·       Planning validity period: planned dates in Demand Planning are to be within the planning validity period

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

·       link to the PIR items assigned 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, source warehouse, requested quantity, requested date and planning responsible

·       Planned date is determined according to the sales lead time in MPP parameters record, if it has been created, or in the product master data

·       check planned date is within planning version validity period

·       check whether the date calculated from to the planned date going backward to the Overall Replenishment Lead Time is after the version start date

·       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

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

 

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


The integration between Demand Management and Distribution Deployment Plan and Procurement Plan is detailed afterwards.

 

 

Sales and Operations Plan


In Sales and Operations Plan process the demand is balanced by supply items. A planning tool supports the automatic supply items generation; three lot quantity techniques set in planning parameters, i.e. “lot for lot”, “fixed lot quantity” and “supply coverage days”, have been implemented. The planning results can be checked from both financial and capacity constrains perspective; therefore, only feasible plans are released as result of SOP planning process.

The sales orders are not relevant for SOP planning (MTS scenario).

 


 

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 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

·       For subcontracting items, the suggested subcontractor can be changed (only subcontractor with supplier-info record are possible)

·       check whether the date calculated from to the planned date going backward to the Overall Replenishment Lead Time is not in the past; this is for guaranteeing its feasibility from the lead time perspective, i.e. the requested quantity can be produced; the backward scheduling is performed according the working calendar assigned to the warehouse

·       the planned quantity for each SOP supply item adjusts the “projected inventory quantity” calculated by taking into account the “stock on hand quantity”, the “cumulated demand quantity”, the “cumulated supply quantity”, purchase orders and manufacturing order in draft status and the “requested PIR quantity”.

·       Multiple planning versions can be taken into account at the same time

·       for each SOP item the following figures are available:

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

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

·       cumulated current demand 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

 

 

the following picture provides an overview of SOP process:


 

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 (weekly basis) 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 (monthly basis).

 

 

Master Production Plan


The following features are provided to manage the Master Production Plan process:

·       Manual entering of MMP items specifying product code, warehouse, planned quantity, planned date

·       For a manufacturing warehouse, only products with MPP parameters record can be entered

·       For subcontracting items, the suggested subcontractor can be changed (only subcontractor with supplier-info record are possible)

·       check whether the date calculated from to the planned date going backward to the Overall Replenishment Lead Time is not in the past; this is for guaranteeing its feasibility from the lead time perspective, i.e. the requested quantity can be produced; the backward scheduling is performed according the working calendar assigned to the warehouse

·       workflow for managing Master Production Plan item through the following states (as shown below):

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 for financial evaluation

·       Odoo standard activity feature has been activated

·       Wizard for creating a subcontracting purchase order with multiple items is available.

 


 

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 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:


 

Distribution Deployment Plan


The following picture shows the relationship between statuses involved in deployment management:


The release action in Demand Management for internal procurement items (MPP planning parameters record exists) involves the creation of SOP demand record (dependent demand on source warehouse to be processed).

When approving a Distribution Deployment Item, the reference number of stock transfer document is reported.

It is possible to reset PIR in Demand Management; this action performs the check whether the stock transfer has not been processed yet.

Wizard for creating a stock transfer document with multiple items is available.

 

 

Procurement Plan


The following picture shows the relationship between statuses involved in procurement plan management:


The release action in Demand Management for external procurement items (no MPP planning parameters record exists) determines a procurement plan item creation.

When approving a Procurement Item, the reference number of purchase order document is reported.

It is possible to reset PIR in Demand Management; this action performs the check whether the purchase order has not been confirmed yet.

Wizard for creating a purchase document with multiple items is available.

 

This software and associated files (the "Software") may only be used (executed,
modified, executed after modifications) if you have purchased a valid license
from the authors, typically via Odoo Apps, or if you have received a written
agreement from the authors of the Software.
You may develop Odoo modules that use the Software as a library (typically
by depending on it, importing it and using its resources), but without copying
any source code or material from the Software. You may distribute those
modules under the license of your choice, provided that this license is
compatible with the terms of the Odoo Proprietary License (For example:
LGPL, MIT, or proprietary licenses similar to this one).
It is forbidden to publish, distribute, sublicense, or sell copies of the Software
or modified copies of the Software.
The above copyright notice and this permission notice must be included in all
copies or substantial portions of the Software.
THE SOFTWARE IS PROVIDED "AS IS", WITHOUT WARRANTY OF ANY KIND, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO THE WARRANTIES OF MERCHANTABILITY,
FITNESS FOR A PARTICULAR PURPOSE AND NONINFRINGEMENT.
IN NO EVENT SHALL THE AUTHORS OR COPYRIGHT HOLDERS BE LIABLE FOR ANY CLAIM,
DAMAGES OR OTHER LIABILITY, WHETHER IN AN ACTION OF CONTRACT, TORT OR OTHERWISE,
ARISING FROM, OUT OF OR IN CONNECTION WITH THE SOFTWARE OR THE USE OR OTHER
DEALINGS IN THE SOFTWARE.

Please log in to comment on this module

  • The author can leave a single reply to each comment.
  • This section is meant to ask simple questions or leave a rating. Every report of a problem experienced while using the module should be addressed to the author directly (refer to the following point).
  • If you want to start a discussion with the author or have a question related to your purchase, please use the support page.