Performing Project Master Scheduling—Key Exercise

Basic Data Setup

Overview of Project Master Scheduling Data

Purpose: The purpose of this exercise is to create the required data that is used in the main exercises below. This sets up data for your site that only needs to be done once for project master product scheduling.

If you have already set up the project master scheduling data on your site, use that data instead.

  1. Set up your site with project master scheduling basic data for racing engines.

General exercise for project master scheduling data

Main Exercises

Purpose: The purpose of this lesson is to enter forecasts for the project MS part, perform project MS, and analyze the results of performing project MS.

Enter Project Master Schedule

Purpose: The purpose of this lesson is to enter forecasted demand for the project MS parts.

Prerequisites: The parts used in this exercise must have been registered as project MS parts.

Windows:
Project MS Part
Project MS Part /Register Forecast
Project Navigator

  1. Open the Project MS Part window and query for your project MS parts 20-110 and 20-120 in your site and PNG.
  2. In the Part No list, select part 20-110 for which you want to register a forecast.
  3. Click the Register Forecast tab and create a new record.
  4. In the Forecast Date field, enter the date on which the forecast becomes valid. Enter a date just outside of the planning time fence (PTF), i.e. check the PTF date and add one day in the Forecast Date field. The system shows whether the date lies within or outside of the time limits.
  5. Enter a forecast of 10 pcs in the Forecast field.
  6. Create another record in the Register Forecast tab and enter another forecast of 15 pcs about one month later than the first forecast row.
  7. Save the information.
  8. Open the Project Navigator window and query for your project.
  9. Select the forecast activity (A11 Acquisition) and verify in the Activity/Cost tab that the planned costs have been updated for the forecast activity according to the cost of the part and quantity that has been added as the forecast.
  10. Repeat step 3-9 for the other PMPS part. In this case the forecasts are 20 pcs respective 30 pcs.

Perform Project Master Schedule Calculation

Purpose: The purpose of this exercise is to manually calculate a Project Master Schedule for a part.

Prerequisites: Forecasts need to have been entered for the project MS parts.

Windows:
Calculate Project MS
Background Jobs
Project MS Part
Project MS Part /Register Forecast

  1. Open the Calculate Project Master Scheduling dialog box.
  2. Enter your site in the Site field.
  3. Enter the project PNG for your project in the PNG field.
  4. Verify that the run date is the current date (i.e., the system date).
  5. Click OK.
  6. Open the Background Jobs window and populate it.
  7. Verify that the state for the Project Master Scheduling background job is Ready.
  8. Open the Project MS Part window and query for the parts 20-110 and 20-120 in your site and PNG.
  9. Verify that the value in the Last Run Date field is the current date.
  10. Click the Register Forecast tab and verify that the following values appear in the Master Schedule field for the parts.
    Part Number Description Forecast Date Master Schedule Proposed
    20-110 Engine Block 1600 PTF + 1 work day 10 Proposed
    20-110 Engine Block 1600 One month later 15 Proposed
    20-120 Cylinder Head 1600 PTF + 1 work day 20 Proposed
    20-120 Cylinder Head 1600 One month later 30 Proposed

As the proposals are created just outside the PTF they are only proposals, i.e. no requisitions are created yet.

Calculating Project MS When Proposals Fall Within the PTF

Purpose: The purpose of this exercise is to simulate what happens when project master schedules are calculated for parts and the proposals fall within the planning time fence.

Prerequisites: Master schedule proposals from the previous exercise need to exist for the parts and the first proposal of each part needs to have a date just outside the PTF.

Windows:
Calculate Project MS
Background Jobs
Project MS Part
Project MS Part /Register Forecast
Project MS Part /Supplies and Demands

  1. Open the Project MS Part window and query for the parts 20-110 and 20-120 in your site and PNG.
  2. Add 1 day to the PTF for each part (this will, in this exercise, help us to simulate that the first proposals of each part falls inside the PTF without us having to wait for a working day to pass).
  3. Save the information. The Within PTF check box should now be automatically selected for the row with the proposal when you save the changes.
  4. Open the Calculate Project Master Product Scheduling dialog box.
  5. Enter your site in the Site field.
  6. Enter the project PNG for your project in the PNG field.
  7. Verify that the run date is the current date.
  8. Select the check boxes to start Project Material Requirements Planning (PMRP) and Material Requirements Planning (MRP) once the project MS calculation is completed.
  9. Click OK.
  10. Open the Background Jobs window and populate it.
  11. Verify that the state for the Project Master Scheduling, Project Material Requirements Planning and Material Requirements Planning background jobs is in Ready status.
  12. Open the Project MS Part window and query for the parts 20-110 and 20-120 in your site and PNG.
  13. Verify that the value in the Last Run Date field is the current date.
  14. Click the Register Forecast tab and verify that the following values appear for the parts.
    Part Number Description Forecast Date Master Schedule Proposed
    20-110 Engine Block 1600 PTF 10 Fixed
    20-110 Engine Block 1600 One month later 15 Proposed
    20-120 Cylinder Head 1600 PTF 20 Fixed
    20-120 Cylinder Head 1600 One month later 30 Proposed
  15. Click Supplies and Demands tab and verify that a purchase requisition has been created for the first proposal which has become fixed for the part 20-110 and a shop order requisition is created for the part 20-120.

Check Availability Planning After Project MS Calculation is Run

Purpose: The purpose of this exercise is to check the availability planning for the project MS parts and their components after you have performed project MS, PMRP and MRP.

Prerequisites: Master schedule proposals and requisitions from the previous exercise need to exist for the project MS parts and PMRP and MRP need to have been performed after completing project MS.

Windows:
Project MS Part /Register Forecast
Inventory Part Availability Planning

  1. Open the Inventory Part Availability Planning window and query for the purchase part 20-110 in your site and your project.
  2. Verify that both the requisition and proposal created by project MS are displayed according to the table below.
    Part Number Description Supply Type Status Supply Activity
    20-110 Engine Block 1600 Purchase Requisition Planned 10 A11
    20-110 Engine Block 1600 Project MS Supply Proposed MS Receipt 15 A11
  3. Query for the manufactured part 20-120 at your site and your project ID.
  4. Verify that both the requisition and proposal created by project MS are displayed according to the table below.
    Part Number Description Supply Type Status Supply Activity
    20-120 Cylinder Head 1600 Shop Order Requisition Proposal Created 20 A11
    20-120 Cylinder Head 1600 Project MS Supply Proposed MS Receipt 30 A11
  5. Query for the components 20-121 and 20-122 of the parent part 20-120. Select the records belonging to your site and your project.
  6. Verify that the demand for the parent part 20-120 is broken down to demands of its components and that the components 20-121 and 20-122 are handled by PMRP. Demand and supply are displayed according to the table below.
    Part Number Description Supply Type Status Supply Demand Activity
    20-121 Cylinder Head Cover 1600 Purchase Requisition Planned 20   A11
    20-121 Cylinder Head Cover 1600 Project MS Demand     20 A11
    20-121 Cylinder Head Cover 1600 Purchase Requisition Planned 30   A11
    20-121 Cylinder Head Cover 1600 Project MS Demand     30 A11
    20-122 Camshaft 1600 Purchase Requisition Planned 40   A11
    20-122 Camshaft 1600 Project MS Demand     40 A11
    20-122 Camshaft 1600 Purchase Requisition Planned 60   A11
    20-122 Camshaft 1600 Project MS Demand     60 A11
  7. Query for the component 20-123 which is a standard planned component of the parent part 20-120. Select the records belonging to your site and in this case the project ID should be *.
  8. Verify that the demand for the parent part 20-120 is broken down to demands of the standard planned component 20-123 and that this component is handled by MRP. Demand and supply are displayed according to the table below.
    Part Number Description Supply Type Status Supply Demand Activity
    20-123 Valve 1600 Purchase Requisition Planned 320   A11
    20-123 Valve 1600 Project MS Demand     320 A11
    20-123 Valve 1600 Purchase Requisition Planned 480   A11
    20-123 Valve 1600 Project MS Demand     480 A11

Note that as the part 20-123 is standard planned, the demand for this part may come from different projects. In this example we have assumed that the demand only comes from your project.

Evaluate Result Using Table - Forecast Consumption When Customer Order Has Been Entered

Purpose: The purpose of this exercise is to show how a customer order for a project MS part consumes the forecast.

Prerequisites: Master schedule proposals and requisitions from the previous exercise need to exist for the project MS parts. A sales part needs to have been entered for the project MS part 20-110. A customer order needs to have been created with two order lines against the part 20-110. The first order line must have a quantity of 3 pieces and a wanted delivery date which is the same as (or later than) your first forecast date for the part 20-110. The second order line must have a quantity of 4 pieces and a wanted delivery date which is the same as (or later than) your second forecast date for the part 20-110. Both order lines are connected to another activity than the forecast activity for your project.

Windows:
Project MS Part /Register Forecast
Customer Order
Customer Order lines
Inventory Part Availability Planning

  1. Open the Calculate Project Master Scheduling dialog box.
  2. Enter your site in the Site field.
  3. Enter the project PNG for your project in PNG field.
  4. Verify that the run date is the current date.
  5. Click OK.
  6. Open the Background Jobs window and populate it.
  7. Verify that the state for the Project Master Scheduling background job is in Ready status.
  8. Open the Project MS Part window and query for the part 20-110 in your site and PNG.
  9. Verify that the value in the Last Run Date field is the current date.
  10. Click the Register Forecast tab.
  11. Verify that the following values appear for the parts.
    Part Number Description Forecast Date Forecast Consumed Forecast Unconsumed Forecast
    20-110 Engine Block 1600 PTF or later 10 3 7
    20-110 Engine Block 1600 One month later than above 15 4 11

    There are also rows for actual demands and supplies added in this tab.

Trace Supplies and Demands - Trace Which Orders Have Consumed the Forecast

Purpose: The purpose of this exercise is to trace which demands have consumed forecast.

Prerequisites: A customer order needs to have consumed the forecast for a project MS part.

Windows:
Project MS Part /Register Forecast
Inventory Part Availability Planning

  1. Open the Project MS Part window and query for the part 20-110 in your site and PNG.
  2. Click the Supplies and Demands tab and verify that your customer order lines as well as requisitions and orders created by project MS are displayed. In addition to that, material transfer requisitions should have been created from the project MS supply activity (A11) to the actual demand activity (A21) to which the customer order was connected.
  3. Right-click anywhere in the header and then click Inventory Part Availability Planning to open the Inventory Part Availability Planning window for the selected part.
  4. Select one of the first two rows with material transfer requisitions, right-click and then click Supply/Demand Details.
  5. In the Material Transfer Requisition window that appears, verify that the material transfer requisition (MTR) is of type Netting and that the supply source is Requisition and that it is from the supply activity A11 to the actual demand activity A21.
  6. Select one of the last two rows with material transfer requisitions, right-click and then click Supply/Demand Details.
  7. In the Material Transfer Requisition window that appears, verify that the MTR is of type Netting and that the supply source is Forecast and that it is from the supply activity A11 to the actual demand activity A21.

Note: As all supplies of project MS parts are created against the project MS supply activity (the forecast activity), project MS creates an MTR to plan for this supply to be transferred to the actual demand activity (if the actual demand activity is different from the supply activity). It should, however, not be possible to execute the transfer of the quantity or used cost from the forecast activity to the actual demand activity. Therefore an MTR of type Netting is created.

Trace Supply and Demand - Trace Which Misc Demand Has Consumed the Forecast

Purpose: The purpose of this exercise is to trace which miscellaneous part demands and other types of demands have consumed a forecast.

Prerequisites: Forecasts need to have been entered for the project MS parts.

Windows:
Project MS Part /Register Forecast
Inventory Part Availability Planning

  1. Open the Project Navigator window and query for your project.
  2. Select the actual demand activity (an activity other than the forecast activity) from the graphical object structure in the left pane.
  3. Click the Demand tab and then the Misc Part tab.
  4. Enter a misc part demand for your manufactured project MS part 20-120. Enter a required date which is later than the date for your first forecast and set the supply option to Project MRP.
  5. Save the information.
  6. Verify that the planned cost for the miscellaneous part demand is 0 as this is a project MS part which has the planned costs against the forecast activity instead.
  7. Open the Calculate Project Master Scheduling dialog box.
  8. Enter your site in the Site field.
  9. Enter the project PNG for your project in the PNG field.
  10. Verify that the run date is the current date.
  11. Click OK.
  12. Open the Background Jobs window and populate it.
  13. Verify that the state for the Project Master Scheduling background job is in Ready status.
  14. Open the Project MS Part window and query for the part 20-120 in your site and PNG.
  15. Click the Register Forecast tab and verify that your miscellaneous part demand has consumed the forecast.
  16. Click the Supplies and Demands tab and verify that your miscellaneous part demand as well as the requisitions and orders created by project MS are displayed. In addition to that, material transfer requisitions should have been created from the project MS supply activity (A11) to the actual demand activity (A21) to which the misc part demand was connected.

Note In step 4, if you had entered a part other than a project MS part as a miscellaneous demand, you would have gotten planned costs for that demand. If this was a parent part which included components which were project MS parts, the planned cost would have been deducted with the costs for the project MS parts. You can add a miscellaneous part demand for 20-100 with the supply option Project MRP to verify this.

If you enter a miscellaneous part demand against 20-100 with the supply option Project MRP, PMRP will create a shop order requisition against the part 20-100. The demand on the components which are project MS parts, i.e. 20-110 and 20-120 will not be taken into consideration in the project MS calculation until this shop order requisition is released to a shop order.

Pick and Deliver a Customer Order that has Consumed the Forecast

Purpose: The purpose of this exercise is to show what happens if we deliver a customer order that has consumed the forecast.

Prerequisites: A customer order with two order lines and having consumed the forecast for a project MS part must exist. There needs to be sufficient project inventory of the project MS part to deliver the customer order..

Windows:
Project MS Part /Register Forecast
Inventory Part Availability Planning
Quick Order Flow Handling

  1. Open the Quick Order Flow Handling window and query for your customer order.
  2. Reserve, pick and deliver your customer order.
  3. Query for your order again and verify that your customer order is delivered.
  4. Open the Project MS Part window and query for the part 20-110 in your site and PNG.
  5. Right-click anywhere in the header and then click Run Project MS. Click OK in the dialog box that appears.
  6. Click the Register Forecast tab and verify that the Forecast After Issues field has been updated with the delivered quantity and that the Unconsumed Forecast field is the same as it was before the customer order was delivered.

Evaluate Action Messages and Project Exceptions

Purpose: The purpose of this exercise is to show that an action message and a project exception are created if a customer order exceeds the unconsumed forecast for a project part.

Prerequisites: A customer order needs to have been created against the project MS part 20-110 with a quantity that exceeds the unconsumed forecast (the accumulated unconsumed forecast for the forecast dates that are earlier or equal to the wanted delivery date on the customer order line).

Windows:
Calculate Project MS
Background Jobs
Project MS Part /Action Messages
Project MS Action Proposals
Project Exceptions

  1. Open the Calculate Project MS dialog box.
  2. Enter your site in the Site field.
    Enter the project PNG for your project in the PNG field.
  3. Verify that the run date is the current date.
  4. Click OK.
  5. Open the Background Jobs window and populate it.
  6. Verify that the state for the Project Master Scheduling job is in Ready status.
  7. Open the Project MS Part window and query for the part 20-110 in your site and PNG.
  8. Click the Action Messages tab and verify that you have gotten the action message Insufficient unconsumed Forecast to satisfy Actual Demand.
    Note: The action messages can also be followed up per planner using the Project MS Action Proposals.
  9. Open the Project Exceptions window and query for your project.
  10. Click the Forecast Exceeded tab and verify that you have gotten a project exception displaying the quantity by which the demand has exceeded the unconsumed forecast and against which activity this demand was raised.

Scheduling Project Master Scheduling Jobs

Purpose: The purpose of this exercise is to schedule a project master scheduling batch job.

Windows:
Calculate Project MS
New Database Task Schedule

  1. Open the Calculate Project MS dialog box.
  2. Click Schedule to open the New Database Task Schedule.
  3. Enter scheduling parameter to schedule project MS to be performed at intervals you specify. In the Parameters area, enter your site in the Site field and your project PNG in the PNG field.

Note: You can view the project MS tasks that have been scheduled by opening the Scheduled  Database Task  window and by searching for task name or schedule Name as Calculate Project Master Scheduling.