COMPUTE MATERIAL REQUIREMENTS

Use this screen to generate material requirement reports, as well as purchase requisitions, manufacturing orders, and inventory reservations. You can also determine material availability for potential future jobs, plan new jobs, and check the status of existing jobs. Costpoint can check the current inventory availability for one project, a number of projects linked in a netting group, or all inventory projects. If an MO ID and project ID are the same during the creation process, the system will use the next MO ID in the sequence to ensure data integrity.

During requisition generation, the preferred vendor must not be flagged as a payroll vendor, and its Approval Code must not be "Not Approved" or "Pending". The vendor's Vendor Status for PO must not be "On Hold".

Print this report whenever current inventory availability is required.

For more information, see the Production Control Special Topic PC-1, "Compute Material Requirements".

Location

Report Types and Sort Options

If a part exists in an Engineering Change Notice (on the Manage Engineering Change Notices screen in Costpoint Engineering Change Notices), and the ECN's Status is P (Pending), I (In-Approval), A (Approved), or D (Documents Updated), and you have selected the Provide Warning for Parts and Documents with Open ECNs check box on the Configure Engineering Change Notice Settings screen, a warning message displays the ECN ID and status code when the part (and/or its MBOM components) is loaded.

Options

Reports

Buy Part List

Select this check box to generate a summarized list of all parts in the designated Bills of Material (BOMs) that are considered buy parts (according to the Manufacturing BOMs selected). The availability and requirement information is summarized for each buy component across the entered BOMs.

Make Part List

Select this check box to generate a summarized list of all make parts (end parts and their subassemblies according to the Manufacturing BOMs selected), along with their requirements and material availability.

Indented BOM Explosion

Select this check box to generate an indented BOM report for each end part selected, with the availability and requirement information for each of its subassembly and component.

Inventory Project Selection

Use the selections in this group box to check material requirements against a specific project's inventory availability. Inactive inventory abbreviations are excluded.

Project Option

Select from the drop-down list the criteria for checking material requirements. Valid options are:

• All Inventory Projects — Select this option to check material requirements against all projects' inventory availability.

• Inventory Project — Select this option to check material requirements against an inventory project's availability. This option allows you to use the Inventory Project field.

• Netting Group — Select this option to check material requirements against a netting group of projects' inventory availability. This option allows you to use the Netting Group field.

Inventory Project

If you select  Inventory Project from Project Option drop-down list, enter, or click to select a project against which the material requirements is checked. The field following displays the Project Planning Option (MRP) code for the entered project from the Manage Inventory Projects screen in Costpoint Inventory. This code determines which other projects besides the one selected are included in the calculation of inventory availability. Available codes are:

• Project-No CS: This code indicates inventory availability calculations are based only on the selected project.

• Project-CS: This code indicates inventory availability calculations depend on whether each part is a common stock part. If it is not a common stock part, inventory availability is based only on the selected project. If it is a common stock part, inventory availability also includes common inventory projects along with the selected project.

• Top-level Project-No CS: This code indicates inventory availability calculations are based on the selected project, along with other projects that belong to the same top-level project as the selected project (and have a Planning Option Code (MRP) of "Top-level Project-No CS" or "Top-level Project-CS").

• Top-level Project-CS: This code indicates inventory availability calculations are based on the selected project, along with other projects that belong to the same top-level project as the selected project (and have a Planning Option Code (MRP) of "Top-level Project-No CS" or "Top-level Project-CS"). Also, if the part is a common stock part, inventory availability calculations include common inventory projects.

• Netting Group-CS: This code indicates inventory availability calculations are based on the selected project, along with other projects that belong to the same netting group as the selected project. Also, if the part is a common stock part, inventory availability calculations include common inventory projects.

• Netting Group-No CS: This code indicates inventory availability calculations are based on the selected project, along with other projects that belong to the same netting group as the selected project.

• All Projects: This code indicates inventory availability calculations are based on the selected project, along with all other projects that have a Planning Option Code (MRP) of "All Projects".

Netting Group

If you select Netting Group from the Project Option drop-down list, enter, or click to select, the netting group against which the material requirements is checked. If the check box for Use Common Inventory is selected on the Manage Netting Groups screen and the part is a common stock part, inventory availability calculations also include common inventory projects.

Include Common Inventory Projects

Select this check box to include all common inventory projects' inventory availability. If this check box is selected (along with the Netting Group or Inventory Project options in the Project Option drop-down list), inventory availability calculations include common inventory projects for all parts.

Add Safety Stock to Requirements

Select this check box to include part or project safety stock quantities when calculating requirements. The net available quantity is reduced by the sum of the safety stock quantities for the included projects. This applies to both Plan New and Review Existing requirements selected in the Requirements group box.

Break Out Supply/Requirements by Project

Select this check box to break out all requirements and supplies by project in the make part list, buy part list, and indented explosion report. If you select this option, each part's net availability by included project is listed separately, along with the summarized net availability. This option is unavailable if you select Impromptu Reports Table in the Output Format group box.

Add Pending Inventory Requests to Requirements

Select this check box to include any inventory reservations with a status of Pending on the Manage Inventory Requests screen in Costpoint Inventory when calculating requirements. Net available quantities are increased by planned owed quantity and reduced by planned reserved quantity. This applies to both Plan New and Review Existing requirements, selected in the Requirements group box.

Plan Against Selected Warehouse

Select this check box to calculate available inventory only for the selected warehouse.

Order BOM Requirements Only

Select this check box to order only the quantities required for this bills of material explosion. If you select this check box, the system ignores negative net available quantities when calculating net requirements and order/requirement quantities.

Include MPS Forecast Demand

Select this check box to include MPS forecast as demand for availability calculations.

Requirements Type

From the drop-down list, select the requirement type format. Valid options are:

• Plan New — Select this option if these requirements are considered previously unplanned. This plans the end parts with new requirements. All requirements are added to any existing reservations; and requisitions, manufacturing orders, and reservations are planned accordingly.

• Review Existing —Select this option if these end part requirements have already been planned and reserved in inventory. It is assumed that the listed end parts have already been reserved by a sales order or inventory reservation. This option is used to ensure that all the required parts are still available. It can be used to generate further requisitions and manufacturing orders if net availability has been made negative by modifications in requirements since the date the report was last run.

Last Planned Date

Enter, or click to select, the date the update process was last run for these end parts. This is used to determine if any BOM modifications have occurred since the last run. Such modifications are printed in the Materials Requirements Indented Report under the Reports menu in Costpoint Bills of Material.

Output Format

From the drop-down list, select the format of the report. Valid options are:

• Report

• Report Table

Sort By

Buy Part List - 1st Sort

From the drop-down list, select how the buy part list is to be sorted. Valid options are:

• Part

• Commodity/Part

• Planner/Part

• Buyer/Commodity Part

• Lead Time/Part

Planner/Part is disabled if the Planner Assignment on the Configure Production Control Settings screen is not by Part.

Make Part List - 1st Sort

From the drop-down list, select the option on how the Make Part List is to be sorted. Valid options are:

• Part

• Commodity/Part

• Planner/Part

Planner/Part is disabled if the Planner Assignment on the Configure Production Control Settings screen is not by Part.

Generate

Use this group box to view or modify various process options for generating requisitions and Manufacturing Orders (MOs). Generate purchase requisitions for all buy parts determined to be under-supplied and manufacturing orders for all assemblies and subassemblies, along with associated inventory reservations. Instead of generating MOs, use this subtask to generate inventory reservations for end parts; this enters requirements in Costpoint for the lowest-level components, or buy parts with components (no manufactured subassemblies), without creating individual MOs.

Select Order/Reservation Types

Purchase Requisitions

Select this check box to generate purchase requisitions for the needed buy parts. Requisitions are processed in these way:

• Requisition ID and Requisition Grouping — A starting requisition number is required to create requisitions and requisition ID auto-assign is not on (that is, the System option is unselected in the Req Numbering Method group box on the Configure Purchase Requisition Settings screen in Costpoint Procurement Planning). Within a requisition, lines are sorted and numbered by part number, revision, project. The Requisition Grouping selected on the Configure Purchase Requisition Settings screen determines the grouping of requisition lines.

• Warehouse/Ship ID — Generated requisitions use the ship ID of the Warehouse selected on this screen.

• Inventory Abbreviation — Generated requisitions use inventory abbreviations selected in the Inv Abbrevs for New Reqs/MOs group box - Buy Parts inventory abbreviation (for raw materials) or Common Stock inventory abbreviation (for common stock parts, if not excluded in the main screen selection criteria). It is also possible to check inventory against one inventory project and generate requisitions for another project's inventory abbreviation.

• Preferred Vendor — Generated requisition lines have a default preferred vendor, if you have established one for the requisitioned parts on the Assign Vendors to Items screen in Costpoint Product Definition.

• Buyer Assignment for requisition line — The buyer assignment is determined on the Configure Purchase Requisition Settings screen in Costpoint Procurement Planning. If buyers are assigned by Proj/Acct/Org, the default buyer for the project associated with the Buy Parts inventory abbreviation or Common Stock inventory abbreviation is used in the generated requisition line, as designated in the Link Project subtask of the Manage Buyers screen in Costpoint Purchasing. If such a default buyer does not exist, the default buyer for the top-level project is used. If neither exists, the default buyer is taken from the Link Acct/Org subtask of the Manage Buyers screen. If buyers are assigned by Commodity, the default buyer for the commodity code of the part (as established on the Manage Commodity Codes screen in Product Definition) is used in the requisition line. If buyer is assigned by Item/Misc Type, the default is taken from the Manage Parts screen in Costpoint Product Definition. If buyer is assigned by Preferred Vendor, it is taken from the Link Default Vendor subtask of the Manage Buyers screen in Costpoint Purchasing.

• Buyer Assignment for requisition header — This is the same as for the requisition lines if all the generated requisition lines have the same buyer ID, or if Buyer Assignments and Requisition Grouping (Configure Purchase Requisition Settings screen in Costpoint Procurement Planning) are by the same criteria (Commodity, Item/Misc Type, Preferred Vendor), or if the Configure Purchase Requisition Settings screen has the approval process assigned by Proj/Acct/Org. If none of these are true, a buyer is not assigned to the requisition header.

• Unit of Measure (U/M) — The quantity in the requisition lines is expressed in the part's order unit of measure. Order/requisition quantities (in inventory u/m) from the requirements processing are converted to quantities (in order u/m) using the conversion tables in the Units of Measure Conversion subtask of the Manage Parts screen in Costpoint Product Definition. If such a conversion does not exist, Costpoint uses the Conversion subtask of the Manage Units of Measure screen in Costpoint Product Definition).

• Minimum/Multiple Order Policy — If the requisitioned part has an order policy with a minimum lot size (in inventory u/m) that is greater than zero (as designated on the Manage Parts screen in Costpoint Production Definition), the required quantity from requirement processing (if less than minimum lot size) is adjusted to the minimum lot size. Similarly, if the requisitioned part has an order policy with a multiple lot size (in inventory u/m) that is greater than zero (as designated on the Manage Parts screen in Costpoint Production Definition), the required quantity from requirement processing is adjusted upwards to meet the policy requirement.

• Estimated Unit Price, Tax, and Costs — The system uses the cost type with the lowest sequence number, excluding zero (as defined on the Manage Purchase Requisition Cost Types screen in Costpoint Procurement Planning). Possible types are: "IL" (Item Last), "IS" (Item Standard), "IR" (Item Reference), "PL" (Project/Item Last), "PS" (Project/Item Standard), and "PR" (Project/Item Reference). The corresponding unit cost (as set up on the Manage Item Costs or the Manage Project Item Costs screens in Costpoint Product Definition) is defaulted into the Estimated Unit Cost field. If the cost is zero or non-existent, the cost value and cost type with the next lowest sequence number is used. An estimated unit cost of zero is loaded if no cost types apply. If the order u/m is different from the inventory u/m, unit costs are adjusted to account for the conversion factor. Whether the requisition line is taxable or not depends upon the Default Taxable Status group box settings on the Configure Purchasing Settings screen in Costpoint Purchasing. (If the Use Item Type Default option has been selected, it will depend upon whether parts are set up as taxable on the Configure Product Definition Settings screen in Costpoint Product Definition). If the Auto Calculate Sales/VAT Tax check box has been selected in the on the Configure Purchasing Settings screen, the tax (for taxable parts) is calculated using the requisition line ship ID's sales tax code of the warehouse.

• Approval Process Assignment — This depends upon the settings in the Requisition Approval group box on the Configure Purcahse Requisition Settings screen in Costpoint Procurement Planning. The Approval Level determines whether the approval processes is to be assigned at the requisition header or line level. The Process Assignments group box determines the default settings for the approval:

• No Approval Required — There is no default approval process.

• Global — The default is the Approval Process code from the Configure Purchase Requisition Settings screen in Costpoint Procurement Planning.

• Manual — The default is the Req Approval Process Code from the Manage Inventory Projects screen in Costpoint Inventory. If that does not exist, the Approval Process code from the Configure Purchase Requisition Settings screen in Costpoint Procurement Planning is used. If there is no code, you can create a requisition, but the status will always be "Pending", forcing you to add an approval process for each requisition and submit it for approval.

• Proj/Acct/Org — The default is the requisition approval process that is linked to the project associated with the inventory abbreviation that is used for the generated requisitions. Set up these links in the Link Project subtask of the Manage Purchase Requisition Approval Processes screen in Costpoint Procurement Planning. If such a project link does not exist, the default is the requisition approval process that is linked to the account/organization associated with the inventory abbreviation that is used for the generated requisitions. You can set up such a link in the Link Acct/Org subtask of the Manage Purchase Requisition Approval Processes screen in Costpoint Procurement Planning.

• Item Type — The default is the requisition approval process that is linked to an Item Type of Part. Set this link up in the Manage Purchase Requisition Approval Processes screen in Costpoint Procurement Planning.

• Initial Status — The initial status of the requisitions or requisition lines depends upon the status selected and the approval process assigned by the system. The initial status will be Pending if an approval process is required but could not be assigned or Approved if the assigned approval process does not have any approval titles that have an Approval Type of Electronic or Both as selected on the Manage Purchase Requisition Approval Titles screen in Costpoint Procurement Planning. The initial status will also be Approved if you select In Approval in the Requisition Information group box and the No Approval Required option is selected on the Configure Purchase Requisition Settings screen in Costpoint Procurement Planning.

This application populates new RQ_LN_PO fields with the PO Type, Completed Work Retention Percent and Stored Materials Retention Percent if the row is inserted by the process for purchase agreement logic using suggested blanket orders.

When creating purchase requisitions from this application, transaction amounts in both transactional and functional currencies will be populated for the appropriate fields in the purchase requisition header, purchase requisition line, purchase requisition line account, and purchase requisition line PO tables. Transactional and functional currencies are assumed to be the same for the generated purchase requisitions unless a purchase requisition line PO is generated using an existing purchase order, in which case the PO's transaction currency and exchange rate information will be loaded. Otherwise, all currency related fields will be populated with default values and the exchange rate will be 1. Amount fields will therefore have the same values for transactional and functional currencies. You cannot enter a different transaction currency or exchange rate after generating requisitions.

Requirements

Select this check box to generate MOs or inventory reservations for needed parts.

Requirement Type

From the drop-down list, select a requirement type to generate inventory reservations. This field is not accessible if the Requirements check box is not selected.

• Manufacturing Orders — Select this option to generate manufacturing orders for the needed make parts. During the MO generation process, Costpoint calculates total requirements by exploding through all applicable BOM levels of the end part. A generated MO will have material requirements based on only one level of explosion, except in the case of a phantom part where explosion is done for an additional step.

• Reservations — Select this option to generate inventory reservations for buy parts, buy with component parts, and any lowest-level make components without generating MOs. Such inventory reservations ignore any subassemblies or any make part that has a BOM below it. To generate an inventory reservation, you must enter an expense inventory abbreviation in the Make Parts field or a valid Project, Acct, Org, or Acct, Org.

Inventory Abbreviations

Make Parts

Enter, or click to select, the finished goods inventory abbreviation to be used for all manufacturing orders.

Buy Parts

Enter, or click to select, the inventory abbreviation to be used for all purchase requisitions and buy part requirements.

Common Stock

Enter, or click to select, the inventory abbreviation (that must belong to a common inventory project) to be used for all common stock part purchase requisitions and requirements.

Requisition Information

This group box is accessible and required only if you selected the Purchase Requisitions check box in the Select Order/Reservation Types group box.

Starting Requisition

Enter the beginning requisition number for the generation process, if requisitions are not auto-assigned. (To turn on auto-assignment, select the System option in the Requisition Numbering Method group box on the Configure Purchase Requisition Settings screen in Costpoint Procurement Planning.)

Requisitioner

Enter, or click to select, the employee ID of the requisitioner for generated requisitions.

Status

Use this drop-down list to select the initial status of generated requisitions. Valid options are:

• In Approval

• Pending

Warehouse

From the drop-down list, select the warehouse to be loaded on all generated requisitions, MOs, and reservations, and to determine the ship ID for all requisition lines generated.

Order Reference

Enter the order reference number to load on all generated requisitions and MOs.

Manufacturing Order/Reservation Information

This group box is accessible only if the Requirements check box is selected in the Select Order/Reservation Types group box.

Starting MO

Enter the beginning MO number for the generation process, if MOs are not auto-assigned. (Auto-assignment is enabled in the MO Numbering Method group box on the Configure Production Control Settings screen.) If auto-assign is enabled, leave this field blank for a default MO number to be loaded (after selecting OK) based on the selected MO Numbering Method on the Configure Production Control Settings screen. The MO number can be modified. This field is enabled only if you selected the Manufacturing Orders option in the Requirement Type drop-down list.

Status

Use this drop-down list to select the initial status of generated MOs. Valid options are:

• Planned

• Firm Planned

• Released

This drop-down list is enabled and required only if you selected Requirements in the Select Order/Reservation Types group box, then Manufacturing Orders in the Requirement Type drop-down list. If you are using Costpoint Material Requirements Planning, the Planned option is not available.

Priority

Enter a number between 1 and 10 to indicate the priority (where 1 is the highest priority and 10 is the lowest priority) of the created manufacturing orders for capacity planning purposes. After you execute this application, the Priority field in the Additional Info tab of the Manage Manufacturing Orders screen will populate with this value for MOs related to the Part. The Priority field defaults with the value from the Default MO Priority field on the Configure Advanced Planning and Scheduling Parameters screen in Product Control Interfaces.

Reservation

Use this group box to enter reservation data. This group box is accessible and required only if you selected the Reservations option as a requirement type in the Select Order/Reservation Types group box. These fields are not required if you chose a make part inventory abbreviation with an expense account type.

Starting Reservation

Enter the beginning reservation number for the generation process, if reservation numbers are not auto-assigned. (Auto-assignment is enabled in the Auto-Assign field in the Transaction IDs subtask of the Manage Warehouses screen in Costpoint Inventory). If auto-assign is enabled, a default reservation number is loaded based on the Last Inv Trans ID in the Transaction IDs subtask of the Manage Warehouses screen. The starting reservation number can be modified. This field is enabled only if you selected Reservations in the Requirement Type drop-down list.

Project

Enter, or click to select, the ID of the project that the reservation will charge.

Project Abbrev

This field displays the abbreviation associated to the selected project.

Organization

Enter, or click to select, the ID of the organization that the reservation will charge.

Org Abbrev

This field displays the abbreviation associated with the organization.

Account

Enter, or click to select, the account ID that the reservation will charge.

Planner

Use System Assignment

Select this check box to have Costpoint load planners based on user settings criteria (set in the Planner Assignment group box on the Configure Production Control Settings screen) for all generated items.

• If you selected Part in the Planner Assignment group box, the default planner is pulled from the Manage Parts screen in Costpoint Product Definition.

• If you selected Inventory Project in the Planner Assignment group box, the default planner is pulled from the Manage Inventory Projects screen in Costpoint Inventory.

• If you selected Netting Group in the Planner Assignment group box, the default planner is pulled from the Manage Inventory Projects screen in Costpoint Inventory.

• If you selected Commodity in the Planner Assignment group box, the default planner is pulled from the Manage Commodity Codes screen in Costpoint Product Definition.

• If a system assigned planner is not available, or if this check box is not selected, use the drop-down list on the right to select a planner. This planner is used for all MOs, but not for requisitions and reservations.

Planner

Enter, or click to select, the ID of the planner to be assigned to all MOs, requisitions, and reservations

Subtasks

• Table Information

  Changes on this screen update the following tables:

  • W_FUNC_PARM_CATLG

  • PARMS_PCPMRR