Initial Exercises—Master Production Scheduling

Initial Exercises

Purpose: The purpose of these initial exercises is to introduce you to the basic functionality in Master Production Scheduling, which entails:

IMPORTANT
These Initial Exercises are intended for instructor use.

If you are a student, it is extremely important that you set up and work within your own site to maintain your data integrity. If you work within any other site, you will compromise your own exercise data as well as the data of other students.  Predictable exercise results require that your data be isolated in your own site. 

Setting Up Master Production Scheduling

Purpose: The purpose of this exercise is to introduce you to the basic functionality for setting up data for use in Master Production Scheduling.

Prerequisites:This data should already exist in the racing database.

Data Type Value Description
Import Inventory Part Information 240 Commodity Group 2 (MPS course)
Plan Structure 24-000 Engine Family Assembly
Intermediate Plan Structures 24-101 Formula Racing Engine
24-102 Stock Racing Engine
Product Structures 24-104 Engine—4-cylinder
24-106 Engine—6-cylinder
24-108 Engine—8-cylinder
24-313 Oil Pan
24-315 Oil Pan
MS Sets 0 Base Plan
1 Current Plan
2 S&OP
3 Aggregated Demand
4 Proposed Total Forecast
5 Eastern Region Forecast
6 Western Region Forecast
7 Customer Schedule–Imported Demand
8 Demand Planning–Imported Demand
MS Level 0 24-000 Engine Family Assembly
24-101 Formula Racing Engine
24-102 Stock Racing Engine
Family Set Data 24-000 Engine Family Assembly
MS Level 1 24-104 Engine–4-cylinder
24-106 Engine–6-cylinder
24-108 Engine–8-cylinder
Work Centers 370 General Assembly (RRP)
820 Inspection (RRP)
Product Families 200 Engines
Product Code 240 MPS Engine

Windows:
Copy Parts to Site
Plan Structure
Product Structure
MS Basic Data /Master Schedule Set

  1. Open the Copy Parts to Site window.
  2. Populate the window (F2).
  3. Copy all inventory parts with commodity code 240 from site 1 to your site.
  4. Update the inventory part planning information for all 10 imported parts (from the inventory part table in the Overview of Master Production Scheduling Planning Data exercise).
  5. Open the Plan Structure window.
  6. Query for the plan structure (24-000) and copy the structure to your site.
  7. Query for the intermediate plan structures (24-101 and 24-102) and copy the structures to your site. 
  8. Open the Product Structure window.
  9. Query for the product structures (24-104, 24-106, 24-108, 24-313, and 24-315) and copy the structures to your site.
  10. Open the MS Basic Data window and go to the Master Schedule Set tab.
  11. Verify that MS sets listed in the above table exist.

Performing Level 0

Purpose: The purpose of this exercise is to introduce you to the basic functionality for performing level 0 master production scheduling.

Prerequisites: Inventory parts must be created with planning methods O and T. A plan structure must also be created.

Windows:
MS Level 0 Part
Detailed Master Schedule Graph
Cumulative Master Schedule Graph
Calculate MS Level 1
MS Level 0 Part /Action Proposals
Disaggregate Level 0 to Level 1

  1. Open the MS Level 0 Part window.
  2. Create (F5) an MS level 0 part with a part number of 24-000.
  3. Open the Register Forecast window. 
  4. Register a level 0 forecast.
  5. Open the Disaggregate Level 0 to Level 1 window.
  6. Disaggregate level 0 to level 1.
  7. Open the Calculate MS Level 1 window.
  8. Aggregate level 1 to level 0.
  9. Open the Action Proposals tab.
  10. Query (F3) and review results.
  11. Open the Detailed Master Schedule Graph window.
  12. Query (F3) and review cumulative results.
  13. Open the Cumulative Master Schedule Graph window.
  14. Query (F3) and review cumulative results.

Performing Level 1

Purpose: The purpose of this exercise is to introduce you to the basic functionality for performing level 1 master production scheduling.

Prerequisites: Level 1 parts must be created by disaggregating a level 0 forecast.

Windows:
Calculate MS Level 1
MS Level 1 Part /Register Forecast
Detailed MS Graph
Cumulative MS Graph
MS Action Proposals

  1. Open the Register Forecast window.
  2. Query (F3) on part 24-104.
  3. Review the MS Set 1 field (Disaggregated Results).
  4. Open the Calculate MS Level 1 window.
  5. Calculate level 1.
  6. Open the Detailed MS Graph window.
  7. Query (F3) and review detailed results.
  8. Open the Cumulative MS Graph window.
  9. Query (F3) and review cumulative results.
  10. Open the MS Action Proposals window.
  11. Query (F3) and review action proposals  results.

Aggregating Level 1 to Level 0

Purpose: The purpose of this exercise is to introduce you to the basic functionality for aggregating lower level forecasts to level 0 and comparing them with the S&OP. This includes:

Windows:
Aggregate Level 1 to Level 0
Aggregate Inventory Transactions per Period
Sales and Operations Planning

  1. Open the Aggregate Level 1 to Level 0 window.
  2. In the Source MS field, enter 1.
  3. In the Target MS field, enter 0.
  4. Click OK.
  5. Open the Aggregate Inventory Transactions per Period window.
  6. Verify that your site is displayed, and then click OK.
  7. Open the Sales and Operations Planning window.
  8. In the Annual Base Plan field, enter 3. Note that 2 appears in the Proposed Sales Plan field.

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