ALERE Manufacturing Plan Module

ManagerOrderRouteMachineScheduleBOMPlanCost

The Plan Module extends the capabilities of the MRP as follows:

Instead of calculating material requirements bill level at a time, the plan process looks at the material required for all levels from the sales order down to the raw materials in one single step. 

The list of required components are time-phased to determine when they need to be ordered or manufactured to fill that demand.

The net requirements are converted into planned work orders and purchase orders which can be included in the MRP report.

The plan process accomplishes this task in one single pass and does not require the multiple passes common in most MRP packages.

The planning can be done for

  • All locations.

  • Groups of locations.

  • A single location.

The scheduling information can be integrated with the planning.

A Grace Period can be entered that tells the process how many days to wait for orders already placed to arrive before generating a recommended order. This allows the system to overlook temporary stock out situations.

A Minimum Order Period can be entered that controls how often orders are to be released. This permits you to group orders thus minimizing constant reordering.

A Cushion can be set that adds to the lead time required for ordering items.

Order quantities can be calculated for exact quantities to reach the order criteria or for multiples of the standard reorder quantity.

On one screen you can review the complete list of recommended work orders.

The orders on the list may be automatically generated as work orders, individually or in groups.

The list of orders can be arranged by

  • Ascending planned order number.

  • Part number and within part number by the recommended starting date for the planned order.

  • Recommended starting date and within the start date by part number.

The list of orders can be filtered by

  • A location.

  • A from/to date range.

  • A matching part number.

The PO Requisitions report lists the items that need to be purchased based on the planning process.

The list of items to purchase can be filtered for

  • A specific item.

  • A location or group of locations.

  • A specific vendor.

The list can be ordered by

  • Vendor and within vendor by part number.

  • Vendor and within vendor by order date.

  • Part number.

  • Order date.

The date range of the list can also be set by beginning and ending order dates.

Materials Requirements Planning (MRP) is also done within the Plan Module.

The MRP process supports both bucketed and bucketless planning and can be run for any range of dates.

The bucketed process develops time-phased data and accumulates it in either weekly or monthly time periods.

The bucketless approach develops time-phased data and displays it using dated records instead of buckets. This method permits you to see the detail of the MRP process such as the purchase orders, sales orders and work orders.

MRP may be run for

  • All locations.

  • Groups of locations.

  • A single location.

MRP may be limited to

  • A single item.

  • A single order number.

  • A single product class.

  • Only manufactured items.

  • Only purchased items.

The MRP process can be used as a material shortage report by including only records that fall below safety stock levels or zero on hand stock.

The MRP report can integrate the recommended orders from the Plan Module to show their effect on the material planning process.

Synchronous Manufacturing is supported by including the production floor schedule in the MRP report.

 

Plan Screen

 

Generate Work Orders

 

Generate Purchase Orders

 

MRP Report

 

PO Requisitions Report

 

Recommended Orders Report

 

 

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Last modified November 07, 2008