How do I setup Stock for MRP?

This is probably one of the most complicated parts of the system. However, setup correctly, everything will run smoothly.

Job Card

Before we create the Stock Records, we need to understand how their settings contribute to the resulting Job Card, so first of all, we must understand the Job Card.

Header Details

• Job Card No
  • This field is nice and simple, it's the Numeric value given to the Job Card by the system.
• Tool No
  • This field is drawn from the "Tool" assigned to the Product being made in this Job Card.
• Tool Location
  • This field is drawn from the "Tool Stock Record", using the "Default Bin" for it.
• C/Insert Rqd
  • This field is drawn from the Product being made in this Job Card, Manufacturing tab -> "Change Insert/s Required" -> Yes/No
• C/Insert No
  • If the "C/Insert Rqd" field is "Yes", then the SKU is pulled from the Manufacturing tab -> "Change Insert/s Required" -> SKU.
• Machine
  • This field is drawn from the Machines assigned to the Stock Record from the Manufacturing tab -> "This Stock Record is assigned to the following Machines" section.
• Linked Job Cards
  • If the Product is also a "Pack", it grabs the associated Job Numbers from the rest of the items which make up a pack.
  • If the Product is part of a "Pack", it grabs the associated "Master Product" and displays that Job Number as well.
• Golden Sample Location
  • This field is drawn from the Product being made in this Job Card, Manufacturing tab -> "Golden Sample Location"
• Image
  • If there is an image uploaded to the stock record, this will be used here.

Job Details

• Customer
  • This field is pulled from the "Company Name" on the Customer Record.
• Customer PO Number
  • This field is pulled from the "Customers PO Reference" on the original Order under the "Payment" tab.
• Quantity Required
  • This field is pulled from the Job Card itself.
• Raised Date
  • This field is pulled from the Job Card itself.
• Raised By
  • This field is pulled from the original order, using the operator which placed the order.
• Required By Date
  • This field is pulled from the "Date Required" on the original order line.
• Our SKU
  • This field is pulled from the "Our SKU" field on the Stock Record, under the "Main" tab.
• Customer SKU
  • This field is pulled from the "Alternative SKU" field on the Stock Record, under the "Main" tab.
• Part Name
  • This field is pulled from the "Name" field on the Stock Record, under the "Main" tab.
• Impressions
  • This field is pulled from the "Impressions (whole numbers only)" field on the Stock Record, under the "Manufacturing" tab.
• Job Type
  • This field is pulled from the "Job Type" field on the Stock Record, under the "Manufacturing" tab.
• Production Time
  • This field is calculated by:
    1. Cycle Time multiplied by the Quantity Required.
    2. Scrap Percentage Added
    3. Divided by the Impressions (must be a whole number, larger than 0, otherwise the system will default to 1)
    4. Represented in Hours, Minutes and Seconds.
• Colour
  • This field is pulled from the "Colour" field on the Stock Record, under the "Manufacturing" tab.

• Cycle Time (seconds)
  • This field is pulled from the "Cycle Time (seconds)" field on the Stock Record, under the "Manufacturing" tab.
• Part Weight (g)
  • This field is pulled from the "Weight (g) (per single impression)" field on the Stock Record, under the "Main" tab.
  • The Job Cards converts this to a figure with 2 decimal places.
• Sprue Weight Per Cavity (g)
  • This field is pulled from the "Sprue Weight Per Cavity (grams)" field on the Stock Record, under the "Manufacturing" tab.
• Scrap Percentage
  • This field is pulled from the "Scrap Percentage (n.nn)" field on the Stock Record, under the "Manufacturing" tab.

Bill of Required Materials

First of all, this section is populated with any items made up from the "Packs" tab on the Stock Record. Now for each of the items in the pack

• BOM Type
  • This defaults to the type of "Pack Item".
• Our SKU
  • This is the "SKU" from the Stock Record under the "Main" tab.
• Description
  • This is the "Name" from the Stock Record under the "Main" tab.
• Required
  • This is calculated by:
    1. Multiplying the "Quantity Required" from the Job Card with the "Quantity" on the "Packs" tab of the Stock Record of the Product being made in this Job Card.
• Location
  • This is the "Reference" field from the "Default Bin" on the Pack Item Stock Record under the "Bins" tab.

Now for each Bill of Materials

• BOM Type
  • This field is from the "Type Name" field under "Stock" -> "Types" where the "Stock Type" is assigned to the Product under the "Main" tab.
• Our SKU
  • This is the "SKU" from the Stock Record under the "Main" tab.
• Description
  • This is the "Name" from the Stock Record under the "Main" tab.
• Required
  • First of all, the system calculates the "BOM Required Quantity" using the following method:
    1. If the BOM item "Stock Type" is a "Material" then it adds "Part Weight" to "Sprue Weight" and multiplies it by the Job Card "Quantity Required".
    2. For any other "Stock Type" it multiplies the BOM Quantity from the Stock Record by the Job Card "Quantity Required".
    3. The system then adds the Scrap Percentage.
    4. The system aggregates all items set as a "Material" together to form a "Material Required" quantity.
  • This is calculated depending on the "Type Quantity" associated with the Stock Record on the "Main" tab.
    1. If it is kg or g/kg and the "BOM Required Quantity" is greater than 1,000.
    • The system divides the value by 1,000, displays it to 2 decimal places and suffixes it with kg.
    1. If it is g or g/kg and the "BOM Required Quantity" is less than 1,000.
    • The system displays it to 2 decimal places and suffixes it with g.
    1. If it is setup as a "Box/Bag" and the BOM Quantity (Stock Record -> BOM tab) is greater than "zero":
    • The system uses the "BOM Required Quantity" to display.
    1. If it is setup as a "Box/Bag" and the BOM Quantity (Stock Record -> BOM tab) is less than or equal to "zero":
    • The system uses the "Box Required" quantity to display, calculated by:
    • Quantity Required on the Job Card divided by Box Quantity (Stock Record -> Manufacturing tab), rounded up to the nearest whole number.
    1. If it is setup as a "Percent" (Raw Material):
    • The system calculates the value the following way:
      1. Material Required multiplied by the Percentage.
      2. Displayed as either g/kg with the appropriate conversion calculation.
    1. For any other reason:
    • The system uses the "BOM Required Quantity" to display.
• Location
  • This is the "Reference" field from the "Default Bin" on the Bill of Material Item Stock Record under the "Bins" tab.

Workflow

This section is always blank for writing on.