RRP and CRP in App 10

RRP

Resource Requirements Planning (RRP) is a capacity planning process where planned capacity, based on demonstrated output, is balanced with required capacity. This enables you to:

• Calculate capacity to meet the master schedule
• Calculate capacity to meet the output (new forecast, new operations plan and planned inventory or backlog) of the sales and operations plan
• Test end-item production plans, using different MS sets and capacity scenarios
• Compare and modify required and planned capacity
• Analyze load on key resources by user defined time periods
• Isolate and resolve potential problems

RRP lets you work with both machine capacity and other resources. This enables you to define different types of key resources and calculate the need for storage space, personnel, transport capacity, supplier capacity and so on.

RRP evaluates the effect of load from either demand plans, master production schedules or sales and operations plans against planned capacity over a mid to long term time frame.

Before working with RRP you must first enter certain basic data in IFS Manufacturing. For example, you must enter work centers where the constraining resources are located. You can use previously defined work centers and/or create unique ones solely to be used by RRP. If you create an RRP unique work center you can specify any unit of measure, for instance pieces, square meter, liter or kilo. You must also specify the work center’s capacity and load source. Load source decides whether to use unconsumed forecast and demand or supplies created by master scheduling or sales and operations planning to consume capacity. You can also select projected on hand as the load source, then RRP will present the projected on hand development versus a defined max capacity.

In addition, you must define the resource requirements by creating RRP resource routings. Here you have the possibility to time phase the requirements. This can be useful if the planned resource is a supplier for a critical component and you need to offset the requirements to match the lead time of that supplier.

Once the details of a simulation have been defined you can calculate load. The load can then be analyzed through a graphical user interface. The data shown can be restricted to specific time periods of your choice.

CRP

Capacity requirements planning (CRP) is a technique used to calculate the workload for different machines and production groups based on an existing manufacturing plan from material requirements planning (MRP). CRP is a total capacity requirements calculation, meaning that it includes all records and all shop order requisitions that have been generated. Ultimately, the goal of CRP is to help you verify that the manufacturing plan is feasible, i.e., whether there is enough capacity to fill all shop orders. This allows you to determine when production orders should be implemented. With CRP, you can analyze resource requirements for a shorter period than is possible with resource planning.

CRP considers all existing shop order requisitions, regardless of their origin. They can be entered manually, generated from order point proposals, generated from KANBAN, created in connection with MRP/PMRP, or generated from the MS/PMS. The system generates shop order requisitions originating from the master schedule when it performs Level 1 calculations. These calculations consider demand up to the planning time fence. CRP also considers the fixed and variable master schedule proposals that are located outside the planning time fence. Furthermore, it considers unreleased dynamic order processing (DOP) orders that are entered or generated manually. When DOP orders are created, they use specific routings revision and alternate numbers. When the system calculates the CRP load per work center, it verifies the DOP revision routings and alternate numbers. If these numbers are valid, they are either considered as CRP load on the work center or not considered at all.

Using the resource requirements and information about the capacity of various work centers, the system performs a detailed CRP calculation. This calculation does not consider maximum capacity. The calculation begins with a current operation list for the standard part and works backward. The system verifies that the workload is planned only for days that are included in the shop calendar. Only workdays should exist in the shop calendar. Weekends and holidays are not counted in MRP. CRP also considers CBS overlap values either in units or as a percentage entered in operation level for CBS sites and Advance Planning Board enabled sites.

Once you have confirmed the capacity requirements calculation, the system copies all the information needed for the calculation from the MRP results. The needs that arise from master schedule proposals lying outside the planning time fence are also included in the calculation. Because the information is copied, you can continue working while the system performs CRP. If any basic data changes, such as operations for a part or capacity of work centers, you must redo the calculation. Otherwise, the results will be incorrect.

CRP Status Classification

At any time, the CRP process will have one of three statuses shown below.