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Material Requirements Planning Module Improvements

started a topic 7 months ago

The Material Requirements Planning module is aimed at addressing the needs of the production process. New production features will provide our current customers with powerful, logical manufacturing solutions to add to their inventory solution.


For more information, see Getting Started.


We would like to know your thoughts on how to further improve this module.


- DEAR Team


2 people like this idea
  • YES, this is DEFO something that I would use and actually require now!!

    Run MRP for selected build of product that clearly highlighting any shortages that require purchasing / expediting- one click order button,

    Minimum / multiple order qty for items (suppliers have MOQ)

    Would have to reports such as  supplier material on time or require to expedite.

    Would be great for supplier to have a portal or link where they can enter confirmed delivery dates for Open Po / lines.  (Auto update the PO delivery date in DEAR)


    Allow DEAR Po line to add a requested delivery date per line rather than just per PO



    1 person likes this
  • I can mirror Jonathan here in that being able to produce Purchase Orders of Production Orders would be fantastic.

    Especially if considerations such as MOQ can be considered.


    I would like to add some other recommendations:

    • Being able to do this on multiple PO's that are flagged as lacking materials, thereby ensuring that the purchase order raised for the supplier has the best opportunity of meeting and MOQ and reducing multiple PO's for the same supplier for similar goods.
    • I would also like to see the Stock Transfer option (Which is currently automatic) become an optional button that can be selected after the initial release of the production order.
    • The ability to Transfer stock to the Production Facility on a staged basis. Currently the automatic stock transfer transfers all materials needed for the entire production at once. This is fine for productions that may only take a day or so but not ideal for multi stage productions that run over months.


  • Be able to either:

    1. Transfer the Sale Order Line comment directly to the Production Comment so if there is something specific/custom for that production order it can be shown (preferred)
    2. use Mergefield Note from the Sales Order to be printed when using the Production Order doc templates - this would be another way to show something specific/custom for that production order (secondary option if 1 is not possible)

    Designate specific products to be produced in a specific warehouse location - If there is specialised equipment for production located in different warehouses then the 'Shop Floor' is driven off this field, rather than the Location of the Sale Order.

    'Bulk' print production orders from Production Order List screen and be able to see the SO number on this screen



  • Hello,


    Rhys, please let me add some details on Stock Transfer option for Production Orders processing. Now, you can set the creation of stock transfer automatically or manual in General Settings - > Production Process Customization:


    image


    This setting will be applied to all Production Orders which you create. If you set it to Automatic, then the workflow is as follows: when the Release button is pressed for the order (or the order is auto-released), the DEAR System checks the stock in a Shop floor location to define if there are available components for the Production Order. If there are components in the Shop floor, Transfer order is not created. If there are no components in the Shop floor, the DEAR system checks warehouse location which is connected to the Shop floor by the logistics path. If there are no components in the warehouse,  Purchase order is created. If there are components, then Transfer Order is created to deliver the components to the Shop floor.

    In case if you'd like to consider MOQ, you can use Smart Reordering functionality. Reorder suggestions consider the demand for the component and MOQ.


  •  Hello Jonathan Palliser,


    I'd like to let you know that we are considering the adding of reports for MRP and Production to facilitate the production process analyses, In connection with this, we will appreaciate if you send us some samples of the reports which you'd like to see in DEAR Inventory.


    Looking forward to hearing from you soon. 

  • Hi,


    I am playing around with the Production module and I am very impressed.  i think that this is going to be huge for us.


    I notice that the ability to consolidate orders is available but only when they are in Draft status - this creates an issue with Nested Production Orders as these can only be automatically generated in planned status and cannot therefore be consolidated - I have huge quantities of these where different completed parts share the same assembled raw material components.   


    My process is to add production orders for the finished parts so I can auto generate the required nested orders.  When I authorise these orders the Nested Component Production Orders get created automatically (This is great - exactly what we needed!).   However, because I have to Authorise the Production Orders to create the Nested parts, they are all in a Planned state.   I can only consolidate in a Draft state.  This means I have multiple Production Orders for the same parts that I can only consolidate by opening each one individually, clicking UNDO to return to draft and then consolidating before re-authorising.     


    Please can we allow consolidation fro draft orders - I think this is a big deal to allow Nested Orders to function as required.


    See pic - I create orders for 12086 and 12087 (Start).  These generate 3 Nested orders each,  The 2 orders I have marked 1 and 2 are for the same part though and need to be consolidated.   I can only do this if I revert these 4 orders back to draft status though.  


    image


    John Harley opened these articles before creating this ticket:

     Production Scheduler

  • Hello John,


    Thank you for your feedback and your suggestion. 

    We've added it to our development roadmap. 


    Please let me know if you have further suggestions.


    Best regards,

    Elena


    1 person likes this
  • Can you please re-consider the requirement for all resources to be specific. Specific resource cannot be in two places at one time. Notional resource can be shared provided total resource does not exceed available capacity for a given time frame. In a production environment, individual or pieces of kit tied to a line are specific. Pooled resources, usually people for costing purposes, are notional resource ie available for use by multiple lines up to available capacity. In our factory notional resource use to to supply materials across all the lines.


    2 people like this
  • Subcontract processing (like metal finishing) as a workstation that generates a PO and stock movements (without worrying about resource allocation) would be ace. 


    We purchase parts from a sheetmetal manufacturer, and then send them to anodisers or powder coaters to get them finished. At the moment it's fiddly to raise POs and manage where stock is at a given point in the process.


    It would be good to be able to log a delivery from one supplier to the finisher, raise a PO for the finishing process, and then handle the transfer of finished components to us for assembly in our factory.


    2 people like this
  • Hello Eddie Watson,


    Thank you for your feedback.


    Please let me explain the concept of resources in detail:


    The resource is a group of individual entities, individual resources, which are grouped based on some common feature  (for example, this can be costs or type of work the individual resources  complete). The resource is used to calculate the capacity of the group. The capacity is planned for the group and not for the individual resource.


    Let's review the process on example:


    My company produces furniture. I have 3 Wood Carving Machines, 2 Router Pneumatic Machines, 2 Wood Carvers who can work only on Wood Carving machines, 3 operators who can work on both: Wood Carving machines and Router Pneumatic Machine.


    My factory calendar is set to 8 working hours per day. To plan my production so that my resources were used effectively, I need to group them into groups. I group them as:


    Name: Wood Carving Machines Resource

    Type = Machine

    Individual resources: Wood Carving machine 1, Wood Carving machine 2, Wood Carving machine 3


    Name: Router Pneumatic Machines Resource

    Type = Machine

    Individual resources: Pneumatic Machine 1, Pneumatic Machine 2

     

    Name: Wood Carvers resource

    Type = Labour

    Individual resources: carver1@mycompany.com, carver2@mycompany.com


    Name: Operators

    Type = Labour

    Individual resources: operator1@mycompany.com, operator2@mycompany.com, operator3@mycompany.com


    So, I have resources:


    Wood Carving Machines Resource

    Router Pneumatic Machines Resource

    Wood Carvers resource

    Operators - this is my shared resource which capacity I can utilize with both Wood Carving Machines and Router Pneumatic Machines.


    In my Production BOM, I use a combination of these resources in operations. For example:


    Operation: Wood carving

    Cycle time: 4 hours

    Resource: Wood Carving Machines Resource

    Quantity: 2

    Resource: Wood Carvers resource

    Quantity: 1

    Resource: Operator resource

    Quantity: 1


    This means that capacity of 2 machines out of my 3 Wood Carving Machines and capacity of 1 carver out of my 2 carvers and 1 operator out of my 3 operators will be utilized in this operation. Note:  this can be any machine and any carver and any operator: carver1@mycompany.com or carver2@mycompany.com because capacity of the whole resource is planned. The system will plan the order as: 


    8 capacity (because 2 machines are needed for 4 hours each) is needed from Wood Carving Machines Resource

    4 capacity (1 carver is needed for 4 hours) is needed from Wood Carvers resource

    4 capacity (1 operator is needed for 4 hours) is needed from Operator resource

     

    I  use the following approach for grouping: I know that I have operators  who can work on any machines. Thus, in my production orders I'd like utilize their capacity as well. 


    In case if I try to group resources like:


    Name: Wood Carving Machines Resource

    Type = Other

    Individual resources: Wood Carving machine 1, Wood Carving machine 2, Wood Carving machine 3, carver1@mycompany.com, carver2@mycompany.com


    and 


    Name: Wood Carvers resource

    Type = Labour

    Individual resources: carver1@mycompany.com, carver2@mycompany.com


    And my Production BOM is:


    Operation: Wood carving

    Cycle time: 4 hours

    Resource: Wood Carving Machines Resource

    Quantity: 2

    Resource: Wood Carvers resource

    Quantity: 1


    The system will plan the order as: 


    8 capacity is needed from Wood Carving Machines Resource

    4 capacity is needed from Wood Carvers resource

     

    But in this case, I may face the situation when I may have duplicated capacity for my carvers because they are added to both resources, i.e. as you said, I will exceed available capacity for a given time frame. 

     

    Could you please describe your resources in more detail so that I could provide you with optimal grouping approach?


    Best regards,

    Elena


  • Hello Matt Batchelor


    Thank you for your feedback.


    Please let me inform you that at the moment we are in the process of development the co-manufacturing (sub-contract manufacturing) functionality. 

    We plan to cover the following scenarios:


    1. Full co-manufacturing - when manufacturer outsources the finished good for the full production cycle.
    2. Partial co-manufacturing - when when manufacturer outsources the parts of finished good for production.


    Both scenarios will allow to purchase components for co-manufacturing, send them to the co-manufacturer and create Purchase Orders for finished goods produced by co-manufacturer. 


    Please let me know if you have any questions.


    Best regards,

    Elena

     


    4 people like this
  • Hi Elena,

    Thanks for the update. Appreciate it's hard to get a concrete answer until the work is already done, but what kind of timeline are Dear targeting for the co-manufacturing functionality? Months? Quarters?

    Also regarding Eddie's question - could you make it more obvious in the documentation that defining a group of operators is a way to set up a pool? And can we set a 'notional' cost rate for that pool to help with cost estimation?

    Great to have regular updates and new features now that Dear's on the new platform.

    Matt

  • Hi Elena


    Our scenario is very simple. We have three lines: 


    Each line consists of a Filling/forming machine and a packing line.


    Each line require three operators, one for filling / forming one for packing. and one to supply the line with materials and to take away the packed product.


    We only ever run two lines at any one time. 


    The lines runs at different rates (Cycles / hour, throughput, mhpt however you wish to define it).


    The supply / take away role can support two lines lines, therefore their resource is allocated on a 50:50 basis.


    But because the lines run at different speeds the cost allocation for that person is variable depending on the line combination running that day.


    The combination of lines running often changes during the course of a day.


    Therefore I wish to allocate my resource as 2.5 people per line as that is the most realistic representation of what happens.


    Thank you.



  • Hello Matt Batchelor


    Hope you are doing great.


    We'll add more clarifications in documentation about resources. As for the costs for the pool, so, when you group individual resources into group - like I did with operatiors, I can set the cost for this resource in the Costs tab:



    You can define up as many components of the resource standard cost per the defined unit of time as you need. For example, when we speak about machine, the cost for 30 min of my machine consists of electricity costs, amortization, taxes, service manager contract costs, etc. So, I can add all these components into the cost of this Resource. Note: in my sample I have costs 100 per 30 min. This means that work of each individual resource will cost 100 per 30 min, not the whole group. Thus, if I have 3 individual resources, then 30 min work of the Resource is 300. 

    Please let me know if you'd like to see this total costs for the Resource?


    As for co-manufacturing functionality, if everything goes according to our plans, it will be available in a 1-2 months.


    Looking forward to hearing from you soon.


    Best regards,

    Elena

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