Chapter 5: Additional Planning TopicsCHAPTER 5: ADDITIONAL PLANNING TOPICSObjectives                The objectives are:   ...
Manufacturing II in Microsoft Dynamics® NAV 2009Item Variants                  Item Variants in Microsoft Dynamics® NAV 20...
Chapter 5: Additional Planning Topics      Use the following steps to create variant codes for the touring bicycle:       ...
Manufacturing II in Microsoft Dynamics® NAV 2009                          11. Select variant code 25.                     ...
Chapter 5: Additional Planning Topics              18. Enter the following on the Options FastTab:                  Calcul...
Manufacturing II in Microsoft Dynamics® NAV 2009                          23. In the Planning Line FastTab, delete all fil...
Chapter 5: Additional Planning Topics              27. Select the production order for the 25-inch touring bicycle.       ...
Manufacturing II in Microsoft Dynamics® NAV 2009                          7. Select the production order for the 25-inch t...
Chapter 5: Additional Planning Topics                  The item ledger entry also includes the variant code. The process i...
Manufacturing II in Microsoft Dynamics® NAV 2009                          •   The consumption of the components is registe...
Chapter 5: Additional Planning Topics      Note that the Location Code field is automatically filled in.              17. ...
Manufacturing II in Microsoft Dynamics® NAV 2009                  The effect of which is that the component lines of produ...
Chapter 5: Additional Planning Topics      Because a production order states a need for component items besides the      r...
Manufacturing II in Microsoft Dynamics® NAV 2009                          10. Create a new sales order using the following...
Chapter 5: Additional Planning Topics      Return to the sales order to change the location code on the sales line. Howeve...
Manufacturing II in Microsoft Dynamics® NAV 2009                  Demonstration 5 - SKU Created for Both Parent Item and  ...
Chapter 5: Additional Planning Topics      Demonstration 6 - Transfer Replenishment      This demonstration continues from...
Manufacturing II in Microsoft Dynamics® NAV 2009                  In the navigation pane, click the Departments button.   ...
Chapter 5: Additional Planning TopicsBlanket Sales Orders                Many companies have stopped using forecasts. For ...
Manufacturing II in Microsoft Dynamics® NAV 2009                          10.   In the Location Filter field, select BLUE....
Chapter 5: Additional Planning Topics              27. On the Item FastTab, select item 1000 and BLUE as a location filter...
Manufacturing II in Microsoft Dynamics® NAV 2009                          43. Close the Planning Worksheet window.        ...
Chapter 5: Additional Planning Topics      Demonstration 8 - Multi-level Production Planning      To demonstrate multi-lev...
Manufacturing II in Microsoft Dynamics® NAV 2009                          4. Enter the following on the Options FastTab:  ...
Chapter 5: Additional Planning TopicsFiltering in the Planning Worksheet Objective                To run the planning work...
Manufacturing II in Microsoft Dynamics® NAV 2009                          8. Enter the following on the Options FastTab:  ...
Chapter 5: Additional Planning Topics                The report prints the columns on the Item Availability window and pro...
Manufacturing II in Microsoft Dynamics® NAV 2009Lab 5.1 - Additional Planning Topics                  Scenario            ...
Chapter 5: Additional Planning Topics              15. On the Item FastTab, select item 1001 and 23 as a variant filter.  ...
Manufacturing II in Microsoft Dynamics® NAV 2009Quick Interaction: Lessons Learned                  Take a moment and writ...
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Transcript of "Na2009 enus manii_05"

  1. 1. Chapter 5: Additional Planning TopicsCHAPTER 5: ADDITIONAL PLANNING TOPICSObjectives The objectives are: • Discuss Item Variants • Use Locations in Planning • Conduct Transfers between Locations • Use Blanket Sales Orders in Planning • Use Multi-level Production Orders • Provide an Overview of Planning Tools • Be able to filter the Planning Worksheet • Be able to refresh the planning line function • Use Planning ReportsIntroduction This course examines the use of additional planning concepts such as item variants, inventory locations, and transfers between warehouses. It also shows how to use blanket sales orders in planning and how to use multi-level production orders. Finally, the course provides an overview of additional planning tools and reports. Microsoft Official Training Materials for Microsoft Dynamics ® 5-1 Your use of this content is subject to your current services agreement
  2. 2. Manufacturing II in Microsoft Dynamics® NAV 2009Item Variants Item Variants in Microsoft Dynamics® NAV 2009 Manufacturing provide compatibility with standard Microsoft Dynamics NAV 2009 functionality. The purpose of the variant code feature is to provide a basis for customization. Variant codes in Microsoft Dynamics NAV 2009 are not specifically meant for product configuration or production forecasting. Item Variants allow an item to be defined in numerous ways in terms of its characteristics. This allows multiple characteristics to be assigned to an item without creating additional items. Item Variants in Planning It is now possible to plan with variant codes. When you calculate a plan, a variant code: • Is treated as a discrete item. • Can be specified in the Production BOM Line window, which is copied to the component line when the production order is created or refreshed. • Appears in the output journal when output is recorded. When the output journal is posted, the variant code also appears in the item ledger entry. An item variant only participates in the planning if there is demand (sales order or production forecast exists for the variant). Variant codes are helpful when you use a Master Production Schedule (MPS). A variant code carries text describing the particular variant, but there is no support for individual BOMs or routings for each variant. There is a maximum of one standard BOM and route for each item used across all variants of a particular item. The variant code functionality does not support individual cost for each variant. If a sales order is created with a variant code, the corresponding production order is filled in with the same variant code. Demonstration 1 - Planning with Item Variant The sales department sold a 25-inch touring bicycle. A Touring Bicycle item is created with a Production BOM and Routing. Since all touring bicycles of the company are the same, except for the tube length in the frame, the sales department decides to use the same item number and to sub-classify it by a variant code, which specifies three different models sold: • 23 inch • 25 inch • 27 inch5-2 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  3. 3. Chapter 5: Additional Planning Topics Use the following steps to create variant codes for the touring bicycle: 1. In the navigation pane, click the Items button. 2. Double-click item 1001 (Touring Bicycle). 3. Go to Related Information > Item > Variants. 4. Enter the following variant options: Code Description 23 Touring Bicycle 23" 25 Touring Bicycle 25" 27 Touring Bicycle 27" FIGURE 5.1 TOURING BICYCLE – ITEM VARIANTS 5. Click OK to close the window. Create a sales order for the 25-inch touring bicycle with the following data : 6. In the navigation pane, click the Sales Orders button. 7. Click New. 8. In the Sell-to Customer field, select 10000 (The Cannon Group PLC). 9. Enter a sales quantity of 1 for Item 1001 on the sales order lines. 10. Add the Variant Code field to the view on the sales line. Ignore any stock warnings, if any. Microsoft Official Training Materials for Microsoft Dynamics ® 5-3Your use of this content is subject to your current services agreement
  4. 4. Manufacturing II in Microsoft Dynamics® NAV 2009 11. Select variant code 25. 12. In the Shipping FastTab, in the Shipment Date field enter 1/28/2010. FIGURE 5.2 SALES ORDER WITH VARIANT ITEM 13. Click OK. The description changed based upon the variant code. To ship the 25-inch variant of the touring bicycle, it must be available in inventory, purchased, or produced. In this demonstration, it needs to be produced. 14. In the navigation pane, click the Departments button. 15. Go to Manufacturing > Planning > Tasks > Planning Worksheets. 16. Delete the lines in the planning worksheet, if any are displayed. 17. Click Calculate Regenerative Plan.5-4 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  5. 5. Chapter 5: Additional Planning Topics 18. Enter the following on the Options FastTab: Calculate MPS Starting Date 1/28/2010 Ending Date 2/5/2010 Use Forecast Blank Exclude Forecast Before Blank 19. On the Item FastTab, set a filter for item 1001. 20. Click OK. FIGURE 5.3 PLANNING WORKSHEET WITH VARIANT CODE The variant code is filled in automatically. (You may need to add this field if it does not appear.) Create the production order to build the 25-inch bicycle. 21. Under the Accept Action Message header, select the box. 22. Click Carry Out Action Message. Click the Options FastTab and use the following data: Production Order: Firm Planned Purchase Order: Make Purch. Orders Microsoft Official Training Materials for Microsoft Dynamics ® 5-5Your use of this content is subject to your current services agreement
  6. 6. Manufacturing II in Microsoft Dynamics® NAV 2009 23. In the Planning Line FastTab, delete all filters. FIGURE 5.4 CARRY OUT ACTION MESSAGES – PLAN 24. Click OK. 25. Close the Planning Worksheet. 26. In the navigation pane, click the Firm Planned Orders button.5-6 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  7. 7. Chapter 5: Additional Planning Topics 27. Select the production order for the 25-inch touring bicycle. 28. Add the Variant field to the Lines FastTab. FIGURE 5.5 FIRM PLANNED PRODUCTION ORDER If you do not see the production order, perform the following: 29. From the Planning Worksheet, go to Order > List. 30. Select the production order for the 25-inch touring bicycle from the list. Demonstration 2 - Variant Codes in Output Variant codes also appear in the output journal and are indicated on positive item ledger entries that were created as a result of output journal posting. To demonstrate variant codes in the output journal, conduct the following steps to change the status of the previous production order to Released. 1. From the production order, click Change Status. 2. Select Released as new status and 1/28/2010 as the Posting Date and then click Yes. Note the released production order number and record the output. 3. Click OK to close the Firm Planned order window. 4. In the navigation pane, click the Departments button. 5. Go to Manufacturing > Execution > Tasks > Output Journals. 6. Enter 1/28/2010 as the posting date on the first line of the output journal. Microsoft Official Training Materials for Microsoft Dynamics ® 5-7Your use of this content is subject to your current services agreement
  8. 8. Manufacturing II in Microsoft Dynamics® NAV 2009 7. Select the production order for the 25-inch touring bicycle, add the Variant Code and Setup Time fields to the output line column view, and then click Explode Routing. FIGURE 5.6 OUTPUT JOURNAL The Variant Code field is automatically inserted in the output journal. 8. Enter the process times (accepting the default output quantity), for example: Setup Time Run Time Operation 10 120 140 Operation 20 15 80 Operation 30 10 100 Operation 40 55 9. Click Post and Yes to post. 10. Close the Output Journal. The next step is to review the item and capacity ledger entries of the released order: 11. In the navigation pane, click the Released Production Order button. 12. Select the production order for the 25-inch touring bicycle. 13. Go to Related Information > Order > Entries > Capacity Ledger Entries, and add the Variant Code field to the capacity ledger. 14. Close the Capacity Ledger Entries window. 15. From the Released Production Order, go to Related Information > Order > Entries > Item Ledger Entries.5-8 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  9. 9. Chapter 5: Additional Planning Topics The item ledger entry also includes the variant code. The process is complete and the sales order can be shipped. 16. Locate the sales order number from Item Ledger Entries window by going to Actions > Functions > Order Tracking. 17. Note the sales order number and close all open windows. 18. In the navigation pane, click the Sales Orders button. . 19. Open the sales order for the touring bicycle variant. 20. Click Post and select Ship and Invoice. 21. Click OK. Item Variants in Production BOMs A variant code can be specified on the component lines of a Production BOM. However, a variant code cannot be specified on the BOM header. When you create a production order, the component lines reflect all variants indicated on the production BOM or BOM version. When you use BOM versions, you can structure variations on the base design of a product.Locations Microsoft Dynamics NAV 2009 Manufacturing can use an inventory location in one of two ways: • As an item modifier that is used and tracked from the demand for the particular item or item variant to the posted output • On a stockkeeping unit to facilitate a number of planning options (in addition to the above) For companies operating in a multi-site environment, they can assign a location to a stockkeeping unit, which allows the manufacturer to plan production in diverse locations. If locations are mandatory, SKUs must be set up for items.Inventory Locations in Production Demonstrations within this lesson illustrate the conventional use of locations and then introduce location usage with the SKU (stockkeeping unit) principle. Single Location in Planning If stocking and shipping finished production BOM items from one location (Location A), and the production of those items occur at a second location (Location B), then: • The planning of those finished production BOM items occurs at the stocking and shipping location (Location A). Microsoft Official Training Materials for Microsoft Dynamics ® 5-9 Your use of this content is subject to your current services agreement
  10. 10. Manufacturing II in Microsoft Dynamics® NAV 2009 • The consumption of the components is registered to the production location (Location B). • The output of the production orders is registered to the stocking and shipping location (Location A) that is entered on the original sales order to allow the sales order to ship. Demonstration 3 - Single Location in Planning This demonstration shows how a sales order is entered for the touring bicycle that is stocked and shipped in the Blue location. The production is occurring at the Blank location, and the output of the production order is registered to the Blue location. 1. In the navigation pane, click the Sales Orders button. 2. Click New. 3. In the Sell-to Customer field, select 10000 (The Cannon Group PLC). 4. In the Order Date field, enter 1/28/2010. 5. Enter a sales quantity of 5 for Item 1001 on the sales order lines. 6. Select location code BLUE. 7. In the Order Date field, enter 1/28/2010 8. In the Shipping FastTab, go to the Shipment Date field and enter 2/10/2010 and ignore any stock-out warnings. 9. Click OK. When you select location code Blue in the sales order line, the order is filled from that location. If the order cannot be filled with inventory, it must be purchased or produced. Since there is no available inventory in this example, the item needs to be produced. Use the planning worksheet to determine the requirements. 10. In the navigation pane, click the Departments button. 11. Go to Manufacturing > Planning > Tasks > Planning Worksheets. 12. Delete the lines in the planning worksheet, if any are displayed. 13. Click Calculate Regenerative Plan. 14. Enter the following on the Options FastTab: o Calculate MPS o Starting Date 1/28/2010 o Ending Date 2/10/2010 o Use Forecast: Blank o Exclude Forecast Before: Blank 15. On the Item FastTab, set a filter for item 1001. 16. Click OK.5-10 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  11. 11. Chapter 5: Additional Planning Topics Note that the Location Code field is automatically filled in. 17. Select your production order for the 5 Touring Bicycles and click Carry Out Action Message using the following options: Production Order: Firm Planned Purchase Order: Make Purch. Orders 18. Click OK and close the Planning Worksheet. 19. In the navigation pane, click the Firm Planned Production Orders button. 20. Click Execution > Firm Planned Prod. Orders and select the production order for the touring bicycle. 21. Double-click the production order for the 5 Touring Bicycles to open it. Note that when output is recorded, the location code appears in the output journal. When the output journal is posted, the location code also appears in the item ledger entry. As with the previous Item Variants example, the location codes in the output journal are automatically filled in with the Blue location when the route for the released production order is exploded. Once the output is posted, the loop is closed, the sales order can be shipped, and the status of the production order is changed to Finished. To save the user the effort of entering a location code on all component lines for consumption journal processing, a preferred location can be stated in the Components at Location field in Manufacturing Setup. Microsoft Official Training Materials for Microsoft Dynamics ® 5-11Your use of this content is subject to your current services agreement
  12. 12. Manufacturing II in Microsoft Dynamics® NAV 2009 The effect of which is that the component lines of production orders are automatically filled with the chosen location code. FIGURE 5.7 MANUFACTURING SETUP IN THE ROLETAILORED CLIENT. Multiple Locations in Planning Microsoft Dynamics NAV 2009 supports multiple location planning for companies operating in a multi-site environment. This enables individual planning at diverse locations that may plan: • Production orders • Purchase orders • Transfer orders (internal transfers from one location to another) • Service orders The stockkeeping unit (SKU), which is an extension of the item card, states the inventory and planning parameters for items and their variants for each location. By centralizing this information on the SKU, the program calculates plans on particular items at specific locations. The SKU does not state a BOM or a routing; therefore: • An item is produced at only one location. • There cannot be different BOMs for each SKU. • There cannot be different routings for each SKU. It is not mandatory to define an SKU for every combination of item, location, and variant stated in the demand. If no SKU is defined for the present combination, the system uses the basic information from the item card.5-12 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  13. 13. Chapter 5: Additional Planning Topics Because a production order states a need for component items besides the requested parent item, the Production Planner must decide which location the components are to be supplied from, in other words, the location where the demand for components appears. This is usually the same location where production takes place, and if the components are not available, planning suggests replenishment orders for the components at the same location. Using Stock Keeping Units in Planning Before illustrating the component planning on multiple locations, the following demonstration will explain how and when to use the SKU principle in planning. The second demonstration illustrates what happens when an SKU is defined for a component. One of six distribution centers sold ten bicycles and there is no stock of that bicycle in their local warehouse. To simulate a production environment where parent item inventory is planned for several locations: • SKUs must be created and set up for the parent item (Bicycle) for all distribution centers the bicycle is sold from (Blue, Green, Red, Silver, White, and Yellow). • A sales order is created to establish demand. • A regenerative plan is calculated for the distribution center (Blue location) in the planning worksheet, followed by the execution of that plan which results in the creation of production and purchase orders. First, create the SKU of the parent item (bicycle) that will be used in this demonstration: 1. In the navigation pane, click the Stockkeeping Units button. 2. Click New. 3. In the Item No.: field, select 1000 (Bicycle). 4. In the Location Code field, select BLUE. 5. Click the Planning FastTab. 6. In the Reordering Policy field, select Order. 7. Click the Replenishment FastTab and set the Components at Location field to Blank. 8. Click OK. 9. Create an SKU for this item for location Yellow with the following parameters: o Reordering Policy: Fixed Reorder Qty. o Reorder Cycle: 1W Microsoft Official Training Materials for Microsoft Dynamics ® 5-13Your use of this content is subject to your current services agreement
  14. 14. Manufacturing II in Microsoft Dynamics® NAV 2009 10. Create a new sales order using the following data: Sell-to Customer: 10000 (The Cannon Group PLC). Item: 1000 (Bicycle) Quantity: 10 Location: BLUE Shipment Date: 2/15/2010 Ignore any stock-out warning messages. 11. Click OK. 12. In the navigation pane, click the Departments button. 13. Go to Manufacturing > Planning > Tasks > Planning Worksheets. 14. Delete the lines in the planning worksheet, if any are displayed. 15. Click Calculate Regenerative Plan. 16. Enter the following on the Options FastTab: o Calculate MPS and MRP o Starting Date: 2/15/2010 o Ending Date 2/20/2010 o Use Forecast: Blank o Exclude Forecast Before: Blank 17. On the Item FastTab, set a filter for item 1000. 18. Click OK. 19. From the Planning Worksheet, Make sure that there is a check mark on the Accept Action Message header for this production order. 20. Click Carry Out Action Message using the following options: o Production Order: Firm Planned o Purchase Order: Make Purch. Orders 21. Click OK and close the Planning Worksheet. Adjusting for a Change in Demand of Parent Item Assume there is now a slight change in the demand for the parent item: The master planner decides to manufacture the 12 bicycles based on inventory at location YELLOW instead since this is closer to the customers address.5-14 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  15. 15. Chapter 5: Additional Planning Topics Return to the sales order to change the location code on the sales line. However, since the sales line is planned and a firm planned production order is created, a one-to-one reservation exists between the two. The reservation system does not allow the change of location unless the reservation is cancelled. 1. Open your sales order and on the sales line, click the arrow beside the Reserved Quantity field to get to the Reservation Entries window. 2. In the Reservation Entries window, select Actions > Functions > Cancel Reservation. 3. Click Yes and close the Reservation Entries window. The reservation created by the planning system is now removed and the location on the sales line can be changed. 4. Return to the sales order and change the Location Code field in the sales order line to YELLOW. 5. Click OK to close the sales order. Please note that if you get a warning message ("Reserved quantity must be 0 in the sales line"), you need to: • Select discard changes • Open the sales order again and select YELLOW in the location field. • Close the sales order. Replan the demand. 6. In the navigation pane, click the Departments button. 7. Go to Manufacturing > Planning > Tasks > Planning Worksheets. 8. Delete the lines in the planning worksheet, if any are displayed. 9. Select Actions > Functions > Calculate Net Change Plan. 10. Enter the following on the Options FastTab: o Calculate MPS and MRP o Starting Date: 2/15/2010 o Ending Date: 2/20/2010 o Use Forecast: Blank o Exclude Forecast Before: Blank 11. On the Item FastTab, set a filter for item 1000. 12. Click OK. 13. Close the Planning Worksheet window. Microsoft Official Training Materials for Microsoft Dynamics ® 5-15Your use of this content is subject to your current services agreement
  16. 16. Manufacturing II in Microsoft Dynamics® NAV 2009 Demonstration 5 - SKU Created for Both Parent Item and Component In this demonstration, a component item (bell) of the parent item (bicycle) in the previous example has an SKU of its own. The net change plan can therefore plan for that component (bell) at a selected location, using that locations unique parameters, with a fixed reorder quantity of 50. 1. From the navigation pane, click the Stockkeeping Units button. Create an SKU for item 1600 (Bell) with the following parameters: 2. In the Location Code field, select YELLOW. 3. Click the Planning FastTab. 4. In the Reordering Policy field, select Fixed Reorder Qty. 5. In the Reorder Quantity field, enter 50. 6. Click the Replenishment FastTab and set the Components at Location field to Blank. 7. Click OK. 8. Return to the planning worksheets and delete the existing lines. 9. Click Actions > Functions > Calculate Net Change Plan. 10. Enter the following on the Options FastTab: o Calculate MPS and MRP o Starting Date: 2/15/2010 o Ending Date 2/20/2010 o Use Forecast: Blank o Exclude Forecast Before: Blank 11. On the Item FastTab, set a filter for item 1600. 12. Click OK. 13. Close the Planning Worksheet.Inventory Transfers in Planning If a component is produced at another plant, the need for a component can be redirected to another location. This can be stated either by: • Using the Components at Location field on the SKU. • Setting up the component SKU to be replenished through transfer order from a particular location using the Replenishment System field on the SKU.5-16 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  17. 17. Chapter 5: Additional Planning Topics Demonstration 6 - Transfer Replenishment This demonstration continues from the previous demonstration, where the parent item (bicycle) is produced in the Yellow location. In this demonstration, the component SKU (bell) is produced in the Blue location, and the Yellow location replenishes the bell component by means of a transfer order from the Blue location. 1. Select the SKU for item 1600 (Bell). 2. Select Actions > Edit. 3. Click on the Replenishment FastTab and in Replenishment System field, select Transfer. 4. In the Transfer-from-Code field, select BLUE. 5. Click OK. Check if a transfer route from location BLUE to location YELLOW exists. 6. In the navigation pane, click the Departments button. 7. Go to Warehouse > Administration > Inventory > Transfer Routes. 8. Click Show Matrix. An in-transit code already exists for items being transferred from location BLUE to locations RED and YELLOW. 9. Close all open windows. FIGURE 5.8 TRANSFER ROUTES MATRIX Return to the planning worksheet, delete the existing lines, and generate a new net change plan. Microsoft Official Training Materials for Microsoft Dynamics ® 5-17Your use of this content is subject to your current services agreement
  18. 18. Manufacturing II in Microsoft Dynamics® NAV 2009 In the navigation pane, click the Departments button. 10. Go to Manufacturing > Planning > Tasks > Planning Worksheets. 11. Delete the lines in the planning worksheet, if any are displayed. 12. Go to Actions > Functions > Calculate Net Change Plan. 13. Enter the following on the Options FastTab: o Calculate MPS and MRP o Starting Date: 2/15/2010 o Ending Date: 2/20/2010 o Use Forecast: Blank o Exclude Forecast Before: Blank 14. On the Item FastTab, set a filter for item 1600. 15. Click OK. This time, the system shows that the reorder quantity for the component item will be replenished by transfer to location YELLOW. 16. Select the boxes under Accept Action Message and click Carry Out Action Message. 17. In the Purchase Order field, select Make Purch. Orders. In the Transfer Order field, select Make Trans. Orders. Ignore any error messages, if any. 18. Click OK. 19. Close the Planning Worksheet. Planning with Manual Transfer Orders Similar to purchase orders and production orders, transfer orders contain a Planning Flexibility field to define if items on the transfer order need to be included or excluded from the planning run. This is useful when, in addition to automatic transfer orders, a planner needs to perform a general move of inventory quantities to another location, regardless of existing demand. For this purpose, a transfer order is manually created to move the quantity. To ensure that the planning system does not try to manipulate this manual transfer order, the Planning Flexibility field on the transfer line(s) is set to None. Conversely, for the planning system to adjust the transfer order quantities and dates to existing demand, the Planning Flexibility field is set to the default value of Unlimited.5-18 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  19. 19. Chapter 5: Additional Planning TopicsBlanket Sales Orders Many companies have stopped using forecasts. For these manufacturers, the program provides the option to plan on the basis of long-term blanket orders instead of individual forecasts. In a Just in Time environment, for example, where there is a strong customer and vendor relationship, blanket order contracts usually improve the precision of production plans and the Production Planner does not have to supervise and control forecasts and abnormal demand. A blanket order is a sales agreement that covers: • Fixed item quantities • Fixed price or discounted price • Fixed shipment (delivery) dates When using blanket orders in production planning, the following characteristics exist: • A blanket order is a source of independent demand. • The system does not track blanket orders. • A sales order connected to a blanket order consumes the blanket order. • A sales order connected to a blanket order does not consume forecast. When the program calculates blanket order consumption, the shipment date of the connected sales order is irrelevant. Demonstration 7 - Planning with Blanket Orders Demonstration 7 shows how the planning engine suggests replenishment plans for a blanket order. To illustrate blanket orders that do not consume forecast, a forecast is activated that lies before the blanket sales order. 1. In the navigation pane, click the Departments button. 2. Go to Administration > Setup > Manufacturing Setup. 3. In the Planning FastTab, go to the Current Production Forecast field and select 2010. 4. Select the Use Forecast on Locations check box. 5. Clear the Combined MPS/MRP Calculation check box. 6. Click OK. 7. In the navigation pane, click the Departments button. 8. Go to Manufacturing > Planning > Lists > Production Forecasts. 9. Select 2010 Forecast and click Edit Production Forecast. Microsoft Official Training Materials for Microsoft Dynamics ® 5-19 Your use of this content is subject to your current services agreement
  20. 20. Manufacturing II in Microsoft Dynamics® NAV 2009 10. In the Location Filter field, select BLUE. 11. In the View by field, select Month. 12. Click Show Matrix. 13. Define a forecast of 300 pieces for item 1000 (Bicycle) in February 2010. FIGURE 5.9 PRODUCTION FORECAST 14. Click OK and close all open windows. 15. In the navigation pane, click the Blanket Sales Orders button. 16. Click New. 17. In the Sell-to Customer field, select 10000 (The Cannon Group PLC). 18. Enter a sales quantity of 500 for Item 1000 on the sales order lines. 19. Select location code BLUE. 20. In the Shipping FastTab, go to the Shipment Date field and enter 2/10/2010. 21. Click OK. 22. In the navigation pane, click the Departments button. 23. Go to Manufacturing > Planning > Tasks > Planning Worksheets. 24. Delete the lines in the planning worksheet, if any are displayed. 25. Click Calculate Regenerative Plan. 26. Enter the following on the Options FastTab: o Calculate MPS o Starting Date: 2/10/2010 o Ending Date: 2/20/2010 o Use Forecast: 20105-20 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  21. 21. Chapter 5: Additional Planning Topics 27. On the Item FastTab, select item 1000 and BLUE as a location filter. 28. Click OK. There are two planning lines. 29. Close the Planning Worksheet window. Create two sales orders that are attached to the present blanket order. • One due before the blanket order shipment date. • One due after the blanket order shipment date. 30. Open the blanket order and in the Qty. to Ship field, enter 100. 31. Click Make Order and click Yes. Ignore any stock-out warnings. 32. Note the sales order number. 33. Click OK. 34. On the Shipping tab, change the date in the Shipment Date field to 02/01/2010. 35. Click OK. Go to the planning worksheet and generate a new regenerative MPS with the same planning options as shown previously. 36. In the navigation pane, click the Departments button. 37. Go to Manufacturing > Planning > Tasks > Planning Worksheets. 38. Delete the lines in the planning worksheet, if any are displayed. 39. Click Calculate Regenerative Plan. 40. Enter the following on the Options FastTab: o Calculate MPS o Starting Date: 02/01/2010 o Ending Date: 2/20/2010 o Use Forecast: 2010 41. On the Item FastTab, select item 1000 and BLUE as a location filter. 42. Click OK. The planning line shows the 100 pieces for the sales order. Microsoft Official Training Materials for Microsoft Dynamics ® 5-21Your use of this content is subject to your current services agreement
  22. 22. Manufacturing II in Microsoft Dynamics® NAV 2009 43. Close the Planning Worksheet window. 44. Create an additional sales order with the following data: o Sell-to Customer 1000 (The Cannon Group PLC) o Shipping date 02/25/2010 o Item 1000 o Quantity 100 o Location BLUE 45. Make the Blanket Order No. field available on the sales order line using the Show Column function. 46. Click the drop-down button from the Blanket Order No. field and select the blanket order from the Sales Lines window. 47. Click OK. Ignore any stock-out warnings. Return to the planning worksheet and generate a new regenerative MPS. 48. In the navigation pane, click the Departments button. 49. Go to Manufacturing > Planning > Tasks > Planning Worksheets. 50. Delete the lines in the planning worksheet, if any are displayed. 51. Click Calculate Regenerative Plan. 52. Enter the following on the Options FastTab: o Calculate MPS o Starting Date: 02/01/2010 o Ending Date: 02/28/2010 o Use Forecast: 2010 53. On the Item FastTab, select item 1000 and BLUE as a location filter. 54. Click OK. In this MPS, the last sales order for 100 pieces is also shown.Multi-level Production Orders Users have the ability to create multi-line and multi-level production orders. This order methodology is often used in the Make-To-Order (MTO) environment, where all items are built in response to sales orders.5-22 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  23. 23. Chapter 5: Additional Planning Topics Demonstration 8 - Multi-level Production Planning To demonstrate multi-level production orders, perform the following: • Change the manufacturing policy to MTO for items 1100 (front wheel) and 1200 (back wheel), which are some of the subassembly items for the touring bicycle. • To deactivate the current forecast, make the following planning setup in the Manufacturing Setup window. 1. Use the following parameters on the Planning FastTab: o Current Production Forecast: <blank> o Use Forecast on Locations: <cleared> o Combined MPS/MRP Calculation: ticked FIGURE 5.10 MANUFACTURING SETUP 2. Create a new sales order with the following data: Sell-to Customer: 10000 (The Cannon Group PLC) Item: 1001 (Touring Bicycle) Quantity: 10 Shipment Date: 02/05/2010 3. Open a planning worksheet. Delete any existing lines and prepare to calculate a regenerative plan with certain filters. Microsoft Official Training Materials for Microsoft Dynamics ® 5-23Your use of this content is subject to your current services agreement
  24. 24. Manufacturing II in Microsoft Dynamics® NAV 2009 4. Enter the following on the Options FastTab: o Calculate MPS and MRP o Starting Date: 1/28/2010 o Ending Date: 2/10/2010 o Use Forecast: Blank o Exclude Forecast Before: Blank 5. On the Item FastTab, set a filter for item 1001. 6. Click OK. If it is only the production order line that appears, click Refresh Planning Line and use the following parameters: Scheduling Direction: Backward Routing: <ticked> Component Need: <ticked> The program suggested orders for the subassemblies (front and back wheels). If these orders are released, the production orders for the front and back wheels assembly are included on the production order for the bicycle. This option lets users become more efficient by combining all items produced from a sale on a single production order. 7. Close the Planning Worksheet window.Planning Tools Change Replenishment System Microsoft Dynamics NAV 2009 offers the flexibility of changing an item from Production Order to Purchase (Make-to-Buy) on the planning worksheet. This is accomplished by changing the Replenishment System field on the planning line. For instance, the first order can be changed for the front wheel from Production Order to Purchase from the previous lesson. This functionality is applicable when a company may want to subcontract a normally produced item because of capacity constraints or machine downtime. Once the Replenishment System field on the planning line is changed for the Front Wheel assembly to Purchase, delete all other lines in the planning worksheet. This requirement can now be forwarded to the Purchasing Department with the Carry Out Action Message function.5-24 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  25. 25. Chapter 5: Additional Planning TopicsFiltering in the Planning Worksheet Objective To run the planning worksheet for a particular item or group of items, the program offers the capability of filtering on any Item Card field. Demonstration 9 - Filter Planning Worksheet This demonstration shows you how to filter on a particular item number. 1. Create a new sales order with the following data: Sell-to Customer: 10000 (The Cannon Group PLC) Item: 1001 (Touring Bicycle) Quantity: 23 Location: SILVER Shipment Date: 02/12/2010 2. Go to a planning worksheet and delete any existing lines. 3. Go to Actions > Functions > Calculate Net Change Plan. 4. Enter the following on the Options FastTab: o Calculate MPS o Starting Date: 2/5/2010 o Ending Date: 2/12/2010 o Use Forecast: Blank o Exclude Forecast Before: Blank 5. On the Location Filter, select SILVER. 6. Click OK. The planning worksheet is filled in with the net requirements for the Touring Bicycle item only. Since the planning line for the Touring Bicycle has the MPS Order field selected, run MRP to generate the dependent requirements. 7. Select the production order for the touring bicycle. Select Actions > Functions > Calculate Net Change Plan. Microsoft Official Training Materials for Microsoft Dynamics ® 5-25 Your use of this content is subject to your current services agreement
  26. 26. Manufacturing II in Microsoft Dynamics® NAV 2009 8. Enter the following on the Options FastTab: o Calculate MRP o Starting Date: 2/5/2010 o Ending Date: 2/12/2010 o Use Forecast: Blank o Exclude Forecast Before: Blank 9. On the Location Filter, select SILVER. 10. Click OK.Refresh Planning Line Function To update the planning worksheet for any changes in the bill of material or routings (including a change in active versions), you can use the Refresh Planning Line function to refresh the planning line to account for the new BOM or routing. This function works similar to the Refresh function on a production orderPlanning Reports The Planning Availability report can be printed in summary or detail and is similar to the Item Availability-By window that is reviewed for each line on the planning worksheet. To view the Planning Availability Report, go to Related Information > Item > Item Availability by > Period or Variant or Location from the Planning Worksheet. Use the Planning Availability report to filter on selected fields on the planning line, such as Item No. To print the report: 1. In the navigation pane, click the Departments button. 2. Go to Manufacturing > Planning > Reports > Planning Availability. 3. On the Options FastTab, select Yes in the Detailed field. 4. In the Planning Buffer FastTab, select a filter. For example, item 1000 (Bicycle). 5. Click Preview and preview the report.5-26 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  27. 27. Chapter 5: Additional Planning Topics The report prints the columns on the Item Availability window and provides multi-level tracking information for each line on the planning worksheet. To review a report summary, perform the previous steps with the only exception that in the Detailed field, select No preview for the report.Summary As a supplement to the two planning courses Master Production Scheduling (MPS) and Materials Requirements Planning (MRP), this course examines a variety of additional planning topics such as planning with item variants, using locations and transfer orders in a multi-site environment, and using blanket orders in planning. The course also describes some additional tools and reports. Microsoft Official Training Materials for Microsoft Dynamics ® 5-27 Your use of this content is subject to your current services agreement
  28. 28. Manufacturing II in Microsoft Dynamics® NAV 2009Lab 5.1 - Additional Planning Topics Scenario As a Production Planner, you will: 1. Use the variants created in this courses examples to complete this exercise. 2. Create a sales order for five 23-inch bicycle 1000 for 01//24/08. 3. Calculate a regenerative plan. 4. Create a firm planned production order based on the plan. 5. Change the sales order to reflect a 30-inch bicycle. 6. Rerun a regenerative plan. 7. Record the results. Step by Step 1. In the navigation pane, click the Sales Orders button. 2. Click New. 3. In the Sell-to Customer field, select 10000 (The Cannon Group PLC). 4. Enter a sales quantity of 5 for Item 1001 on the sales order lines. 5. Add the Variant Code field to the view on the sales line. Ignore any stock warnings that display. 6. Check that the location code is blank. 7. Select variant code 23. 8. In the Shipping FastTab, go to the Shipment Date field and enter 2/10/2010. 9. Note the sales order number and click OK. 10. In the navigation pane, click the Departments button. 11. Go to Manufacturing > Planning > Tasks > Planning Worksheets. 12. Delete the lines in the planning worksheet, if any are displayed. 13. Click Calculate Regenerative Plan. 14. Enter the following on the Options FastTab: o Calculate MPS and MRP o Starting Date: 1/28/2010 o Ending Date: 2/10/2010 o Use Forecast: BLANK5-28 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement
  29. 29. Chapter 5: Additional Planning Topics 15. On the Item FastTab, select item 1001 and 23 as a variant filter. 16. Click OK. 17. Add the Variant Code column to the planning worksheet if it is not visible. 18. Make sure that the Accept Action Message check box is selected. 19. Click Carry Out Action Message. Click the Options FastTab and use the following data: Production Order: Firm Planned Purchase Order: Make Purch. Orders 20. In the Planning Line FastTab, delete all filters. 21. Click OK. 22. Close the Planning Worksheet. 23. In the navigation pane, click the Sales Orders button. 24. Open your sales order and change the variant code from 23 to 25. 25. In the Reserved Quantity field, click the quantity to open the Reservation Entries window. 26. Go to Actions > Functions > Cancel Reservation. 27. Cancel the reservation. 28. Click OK and ignore any stock-out warnings. 29. In the navigation pane, click the Departments button. 30. Go to Manufacturing > Planning > Tasks > Planning Worksheets. 31. Delete the lines in the planning worksheet, if any are displayed. 32. Click Calculate Regenerative Plan. 33. Enter the following on the Options FastTab: o Calculate MPS and MRP o Starting Date: 1/28/2010 o Ending Date: 2/10/2010 o Use Forecast: BLANK 34. On the Item FastTab, select item 1001. 35. Click OK. There will be planning lines: one is to cancel the production order for 5 23-inch bicycles; the other is to create a production order for 5 of the 25-inch bicycles. 36. Close the Planning Worksheet. Microsoft Official Training Materials for Microsoft Dynamics ® 5-29Your use of this content is subject to your current services agreement
  30. 30. Manufacturing II in Microsoft Dynamics® NAV 2009Quick Interaction: Lessons Learned Take a moment and write down three key points you have learned from this chapter 1. 2. 3.5-30 Microsoft Official Training Materials for Microsoft Dynamics ® Your use of this content is subject to your current services agreement

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