VPi Advanced Topics

Rick Pollman

VPi Support Team, October 3, 2011

AGENDA

Maximize planning using VPi features

 Managing forecasts
 Quick review of last year’s enhancements
 Waterfall – Material Shortages
 Managing multiple resources within a work center
 Individual Operation Overlap
 Shipping Buffer by Item
 Planned Order Time Fence
 Operation Delay Time – Group Mode

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Forecast Consumption Overview

Consumes Forecast within a Calendar Month

 This period, Backwards in the same month & then Forward

Forecast is generated and consumed in 4 ways

 Individual Item
 Component Item
 Planning Bill
 Product Family

Forecast split
 Split monthly number into weekly numbers

Forecast demand time fence

 Global setting
 Individual Item
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FORECAST SPLITTING

 Host ERP forecast managed in monthly buckets and VPi

will split the monthly number into daily or weekly buckets

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VPi Engine Process Flow

Host ERP System

Extract

Data Files Format

Files Upload Plan

Transfer Data VPi

VPi
Configuration Cancel
DbUtility Settings
VPi Planning
Engine
Load data and
Map Data and split forecast
perform forecast
Write Schedule Pass consumption

VPi Database
Microsoft Access / SQL Server database

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VPi Engine Process Flow

ERP Monthly forecast

Host ERP System

Extract

Data Files Format

Files Upload Plan

Transfer Data VPi

VPi
Configuration Cancel
DbUtility Settings
VPi Planning
Engine
Load data and
Map Data and split forecast
perform forecast
Write Schedule Pass consumption

VPi Database
Microsoft Access / SQL Server database

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VPi Engine Process Flow

ERP Monthly forecast

Host ERP System

Extract

Data Files Format

Forecast Splitting
Files andUpload
Time PlanFence
parameters
Transfer Data VPi

VPi
Configuration Cancel
DbUtility Settings
VPi Planning
Engine
Load data and
Map Data and split forecast
perform forecast
Write Schedule Pass consumption

VPi Database
Microsoft Access / SQL Server database

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Forecast Demand Fence by Item
Forecast Demand Fence by Item

Monthly Forecast split into Weekly Buckets

Forecast is not dropped but pushed out beyond Demand Fence
MANAGING FORECAST DEMAND

Component Level
CMPOC10 BOM Where Used

CMPOC10RED CMPOC10RBLUE CMPOC10GREEN

Customer Order will be for CMPOC10

end items

Forecast will be for

component

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Component forecast setup in PPITEM

Component Forecast setup details in the ERP file

PPITEM
Warehouse Item number Family Forecast Plan
ID Family ID Bill
IPFMID IPPRTF Item
1 COMPOC10 FULL 0
===============================================================

Forecast the component

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MANAGING FORECAST DEMAND

Planning Bill
PBCOLOR Planning Bill

Forecast will be for the PBCOLOR

Planning Item in the host DBUTIL will create
ERP using standard individual end item
planning bill structure forecasts based on the
planning bill

CMPOC10RED CMPOC10RBLUE CMPOC10GREEN

50 % 30% 20%

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Planning Bill Forecast setup in PPITEM

Planning Bill Forecast setup details in the ERP file PPITEM

Warehouse Item number Family Forecast Plan
ID Family ID Bill
IPFMID IPPRTF Item
1 PBCOLOR PBCOLOR 1
1 COMPOC10RED PBCOLOR 0
1 COMPOC10BLUE PBCOLOR 0
1 COMPOC10GREEN PBCOLOR 0
===============================================================

Forecast the Planning Bill

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MANAGING FORECAST DEMAND

Product Family
PFCOLOR Product Family

Forecast will be for the

PFCOLOR
Product Family Item in the Forecast remains as the
host ERP using a BOM Product Family Item and
and Routing common to its BOM and Routing
the end items initially drives the load in
VPi

CMPOC10RED CMPOC10RBLUE CMPOC10GREEN

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Product Family Forecast setup in PPITEM

Product Family Forecast setup details in the ERP file PPITEM

Warehouse Item number Family
Forecast Plan
ID
Family ID Bill
IPFMID
IPPRTF Item
1 PFCOLOR PFCOLOR
PFCOLOR 0
1 COMPOC10RED PFCOLOR 0
1 COMPOC10BLUE PFCOLOR 0
1 COMPOC10GREEN PFCOLOR 0
===============================================================

Forecast the Product Family

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Splitting the Item forecast – 400 per month

Customer order Qty 375 for week 3

Action Week 1 Week 2 Week 3 Week 4
Forecast 100 100 100 100
FC consumption 100 100 100 75

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Forecast Summary viewed from the Engine

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Features introduced in 2010
Vendor Multi-sourcing

 Multiple vendor planning

 Split
 Rotate

 Mirrors current XA MRP functionality

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Which Customer Orders to Push Out

 Quickly identify customer orders in trouble

 work with Production to expedite
 work with Sales to notify customer

 Option to print
 Option to export to Excel spreadsheet

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WriteSchedule Pass Waterfall Chart
Waterfall – Feeding Supplies
Waterfall – Material Shortages
 Managing Capacity

Multiple Resource Units per Work Center

Multiple Resource Units per Work Center

 What is a Resource Unit?

One or more like

One or more people machines

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Managing Multiple Resource Units per Work Center

WKCTR Eighteen hour

WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID
LTH1NC 3 1 18_HOUR
calendar

MACHINE
WORKCENTER_ID START_DATE END_DATE UNITS
LTH1NC 5/10/2010 5/10/2010 1 Override WKCTR fixed
LTH1NC 5/12/2010 5/13/2010 6 Units utilizing the
LTH1NC 5/14/2010 5/17/2010 1
MACHINE table

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Managing Multiple Resource Units per Work Center

WKCTR
WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID
LTH1NC 3 1 18_HOUR

MACHINE
WORKCENTER_ID START_DATE END_DATE UNITS
LTH1NC 5/10/2010 5/10/2010 1 Standard Capacity
LTH1NC 5/12/2010 5/13/2010 6 3(units) * 18(hours) = 54
LTH1NC 5/14/2010 5/17/2010 1
hours

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Managing Multiple Resource Units per Work Center

WKCTR
WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID
LTH1NC 3 1 18_HOUR Manage the
capacity by
MACHINE changing the
WORKCENTER_ID START_DATE END_DATE UNITS number of units
LTH1NC 5/10/2010 5/10/2010 1
LTH1NC 5/12/2010 5/13/2010 6 available for
LTH1NC 5/14/2010 5/17/2010 1 specific time
frames.

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Managing Multiple Resource Units per Work Center

WKCTR
WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID
LTH1NC 3 1 18_HOUR

MACHINE
WORKCENTER_ID START_DATE END_DATE UNITS 1(unit) * 18(hours) = 18 Hours
LTH1NC 5/10/2010 5/10/2010 1
LTH1NC 5/12/2010 5/13/2010 6
LTH1NC 5/14/2010 5/17/2010 1

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Managing Multiple Resource Units per Work Center

WKCTR
WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID
LTH1NC 3 1 18_HOUR

MACHINE
WORKCENTER_ID START_DATE END_DATE UNITS 6(units) * 18(hours) = 108 Hours
LTH1NC 5/10/2010 5/10/2010 1
LTH1NC 5/12/2010 5/13/2010 6
LTH1NC 5/14/2010 5/17/2010 1

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Managing Multiple Resource Units per Work Center

WKCTR
WORKCENTER_ID UNITS UTILIZATION CALENDAR_ID
LTH1NC 3 1 18_HOUR

MACHINE
WORKCENTER_ID START_DATE END_DATE UNITS 1(unit)
1(unit)**18(hours)
18(hours)==18
18Hours
Hours
LTH1NC 5/10/2010 5/10/2010 1
LTH1NC 5/12/2010 5/13/2010 6
LTH1NC 5/14/2010 5/17/2010 1

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Split Order Qty across multiple Units

Traditional Global Setting (SplitQtyAcrossUnitsForNonDrums)

has been to split the order quantity for all work centers or
none
 New Config setting: SplitQtyAcrossUnitsForNonDrums= -1

 drops the global setting and becomes work center dependent

using values (0, 1 or 2) in WKCTR field ATTRIBUTE5
Individual Operation Overlap

Traditional Global Setting (TransferEntireBatch=) has been:

- all operations set to overlap
or
- all operations are sequential

TransferEntireBatch=0 combined with

the value in the field Transfer_Size in ROUTE and WOROUTE
provides the ability to plan sequential and overlapped operations
Shipping Buffer by Item
Planned Order Time Fence

Horizon Start Date + PART table MinMRPLeadTime

establishes a Planned Order Time Fence
the logic pushes the planned order to the Order Time Fence
or the released Order’s Due Date if later than the fence
Operation Delay Time

Original Design
Required you to know the work center capacity (i.e.: 8, 16, 24 hrs)
and multiply by 3,600 seconds times the number of days
Operation Delay Time cont.

Group Mode combined with Operation Delay Time

 select multiple operations
 enter the desired Operation Scheduled Start Date and VPi handles
the calculations!
Fixed Yield

 Fixed Yield is stored in the field YIELD in the PART table

 values .01 to 1.00 are reserved for Part Yield
(XA defines it as Shrinkage)
 any whole value greater than 1.00 represents Fixed Yield
Examples of how different part yields would be interpreted.
 .95 0 fixed quantity and 95 percentage yield
 1.00 0 fixed quantity and 100 percentage yield
 1.85 1 fixed quantity and 85 percentage yield
 2.00 1 fixed quantity and 100 percentage yield
Replenishment Item

Replenished Manufactured and Purchased Items

(Lean Manufacturing - Red, Yellow, Green tag)

 Replenishment logic: three tier reorder point system

decoupling customer orders or forecast demand. This
can be used to maintain an inventory level without
requiring independent demand to drive the planning.
 Review the Budget

Timephased Resource Load Summary

Timephased Resource Load Summary

By Work Center

Weekly or Monthly
buckets

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 The VPi value

Replaces and Extends functionality of MRP, CRP and PCC

VPi extended functionality

 Real time graphical plan management

 Maintains the manufacturing order start and due date
 Component requirement dates are re-synced when the
order start date is changed
 VPi calculated dates are updated in MOROUT
 Unique calendars for each work center
 Create/Manage multiple units within a work center
 Spread a manufacturing order across multiple units within a
work center
 ability to plan concurrent or overlapped operations
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 The VPi value

for the experienced MRP

customers considering a move to
VPi
Routings based on MRP Lead Time

For customers who are confident in their MRP Lead Times

but lack precision with routing run times
VPi will generate an internal routing using MRP Lead Time
when the standard routing is not downloaded for an item
 works only with planned and firm planned orders
 manufacturing orders use the live routing

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 VPi Training – Chicago
November 29, 30 and December 1st

http://knowledgezone.infor.com/live.cgi?Branch=discrete&ID=8309