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Just-In-Time Master Schedule Rollover - Calculations
Just-In-Time Master Schedule Rollover - Calculations
MS185E
A. Housekeeping
1. See the Common Processing Routines - Housekeeping section of this manual for a general discussion of this subroutine. Processing specific to this program is described below.
2. A parameter list is set up to receive parameters passed from another program.
3. Key lists are defined for each keyed file the program retrieves.
4. Work fields are defined and program constants are initialized.
5. The company name is retrieved from the company name record (COMNAM) on the System Control file (CT100M).
6. The following information is retrieved from the Reference file (REFERP):
a. The date format (category 049) is retrieved. If this record is not found, the date format defaults to MMDDYY, a message is sent to the system operator and the program aborts.
b. The order quantity decimal position is retrieved from the quantity field sizes record (category 446). If this record is not found, a message is sent to the system operator and the program aborts.
c. The Capacity Planning and Shop Floor Control installed flags are retrieved from the applications installed record (category 012) to determine whether the two applications are installed.
If the Capacity Planning module is installed, when manufacturing orders are changed or deleted their Capacity Planning labor requirements will also be changed or deleted. If the Shop Floor Control application is installed, the actual scrap on a manufacturing order may be used for converting yield to order units rather than the scrap factor.
d. The part status codes, decodes, and planning flags are retrieved from Reference File category D88. All part status data and corresponding information is loaded into corresponding arrays.
B. Mainline
1. If the last time flag (LASTTM) is set to Y, the last record indicator (*LR) is set on. The Master Schedule Rollover program (MS180E) will call this program after it is complete so that commitment control may be ended.
2. If this is the first time the program is called or if the plant has changed from a previous call, the plant information is loaded:
a. The manufacturing company and warehouse codes are retrieved from the Warehouse Description file (IC170ML2).
b. The next manufacturing order and requisition numbers are retrieved from the starting order numbers record (category 465) of the Reference file (REFERP). If no record is found, starting numbers of M000001 and R000001 are used, a message is sent to the system operator, and processing continues.
c. If the calendar code for the plant has been previously loaded, the occurrence of the calendar data structure (MPXCAL) is set. Otherwise, the following is performed:
(1) The last date in the calendar file is retrieved from the calendar file record (category C14) of the Reference file (REFERP).
(2) The arrays containing calendar dates (ACAL) and shop dates (ASHP) are loaded. These arrays are used for converting calendar dates to shop dates and vice versa.
(a) The starting date for each array is 50 shop days before the system date. The ending date of each array is 149 shop days after the system date.
(b) The logical Shop Calendar Date file (CT140ML) is read sequentially to retrieve the information from the arrays.
(3) The current week start date is determined from the logical Week Start Date file (CT140ML1). This will be used for determining the rollover request start date.
(4) The next week start date is determined from the logical Week Start Date file (CT140ML1). This will be used to determine the first week eligible for the rollover.
3. The part master record is retrieved for the part passed and all relevant data is saved. If the JIT MS Replan flag is 'Y' and the part is a JIT part, the net change flag for the item is changed to '2' (replan) so that the part will be replanned.
4. The revision level array is loaded. This information is needed to break flow authorizations and requirements.
5. The part is processed:
a. The Tentative Master Schedule file (MS160M) is prime read. If there is no tentative schedule for the part, control is passed back to MS180E so an error message can be written on the Action report (MS180).
b. The part status (IZACD) and part status planning flag (RD88PL) are validated.
(1) The part status array is searched for the current part status.
(a) If the part status is not found in the array, the part is written to the MS Part Status Exception Report file (RP100AP8) for processing at the end of the program, and the part is bypassed by the conversation.
(b) The part status found in the array is used to find the corresponding planning flag in the planning flag array.
(i) If the planning flag is N, the part is written to the MS Part Status Exception Report file and bypassed by the conversation.
(ii) If the planning flag is Y, the part is processed by the conversation.
c. The tentative master schedule quantities from the Tentative Master Schedule file (MS160M) are accumulated on a weekly basis for the period between the Rollover Request Start Date and Request Horizon Date and written to the MS Action Report Schedule file (MS180AP2).
d. The tentative master schedule, which is stored in yield units, is converted to order units by inflating by the scrap factor.
e. The current master schedule quantities (from flow authorizations, purchase requisitions, manufacturing orders, transfer orders, transfer requisitions, and purchase requisitions) from the Availability file (IC100L24) between the rollover request start date and request horizon date are accumulated on a weekly basis.
(1) Flow authorizations for the primary production center are accumulated in the actual supply array (ASA). All other supply, including flow authorizations for non-primary production centers, are accumulated in the point supply array (PSA).
(2) If a flow authorization is in process, the portion of the flow which is in the past is ended.
(3) For closed or Inventory Accounting closed manufacturing orders, the quantity received is used. If the order is not closed, the order quantity is used.
(4) Only purchase orders that are not direct ship and not phantom orders are accumulated. If closed, the quantity received is used. If not closed, the release quantity is used.
(5) Purchase requisitions are accumulated if they are not closed or canceled, and the Uncovered Quantity is greater than zero.
(6) For transfer orders that are fully shipped, the quantity received is used. If the order is not fully shipped, the quantity ordered is used.
(7) Only transfer requisitions that are not closed, canceled, or covered are accumulated.
f. For transfer parts, the rollover is analyzed and the relation between the tentative schedule accumulated weekly quantity (CSOQTY) and the current schedule accumulated weekly quantity (WKQTY and WKQTY1) is determined. Action is taken as follows:
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Tentative Schedule = Current Schedule
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No action.
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Tentative Schedule + Current Schedule
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No transfer orders;
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No transfer requisitions
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Add requisition.
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No transfer orders;
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Transfer requisitions
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Increase requisitions.
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Transfer orders;
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No transfer requisitions
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"Increase" action message.
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Transfer orders;
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Transfer requisitions
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Increase requisitions.
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Tentative Schedule - Current Schedule
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No transfer orders;
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No transfer requisitions
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End program.
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No transfer orders;
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Decrease requisitions.
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Transfer requisitions
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Delete requisitions if necessary.
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Transfer orders;
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"Decrease" action message.
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No transfer requisitions
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Transfer orders;
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Decrease requisition.
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Transfer requisitions
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Delete requisitions if necessary.
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g. For JIT parts:
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Tentative Schedule = Current Schedule
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No action.
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Tentative Schedule + Current Schedule
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Week fully within time fence
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"Add" or "Increase" action message.
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Week partially or fully outside
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Add or increase planned flow
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firm time fence
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authorizations.
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Tentative Schedule - Current Schedule
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Week fully within time fence
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"Delete" or "Decrease" action message.
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Week partially or fully outside
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Delete or decrease planned flow
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firm time fence
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authorizations.
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h. The output from the rollover processing is as follows:
(1) If an "increase" or "decrease" message is required for the period, the increase or decrease quantity and the period start date are written to the MS Action Report Message file (MS180AP3).
(2) If a planned supply record is to be added, deleted, increased or decreased, planned order maintenance is initiated and a message is written to the MS Action Report Planned Order Message file (MS180AP4). See Section "D. Planned Supply Record Maintenance" for a detailed description of this processing.
i. The remaining tentative master schedule quantities beyond the rollover request horizon date are accumulated for printing at the end of the Action report. This quantity (CSOREQ) is inflated by the scrap factor.
j. The remaining current schedule quantities beyond the rollover request horizon date are also accumulated and printed at the end of the Action report.
k. The details for the part are formatted and the MS Action Report Header file (MS180AP1) is written.
C. Wrapup
1. The net change flag and Master Scheduling change flag are reset and the Part Master file (DE100M) is updated.
2. Tentative schedule and supply quantities are accumulated beyond the horizon date.
3. The Master Scheduling Action Report header record is formatted and printed.
4. The next part is retrieved from the Part Master file (DE100M). If the part is not a JIT-manufactured, build-thru, or transfer part, control is returned to MS180E. Otherwise, the part is processed.