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Materials Management for Rootstock

Materials Management Module

Cloud MRP

Rootstock Material Requirements Planning (MRP) is the software engine that will use the sales order and forecast demands in conjunction with the effective production bill of material and by reviewing item inventory balances will generate planned supplies in a time phase manner to offset the outstanding demands for end items and sub assemblies.

Specifically, MRP generates what are termed planned work orders for manufactured items and planned purchase requisitions for purchase or subcontract items. For firmed (or greater supplies) it generates reschedule or excess messages when, and if, appropriate.

Rootstock Material Requirements Planning (MRP) uses information from Sales Order Management to drive the top level demands. Forecast demands, or not only end items but any item can be entered as well. A forecast demand for an item denotes the start period date and the end period date and the quantity forecasted for that period. MRP will perform the traditional netting’ and plan to the greater of the Sales Order Demand and Forecast demand (by period).

The MRP Engine uses the typical algorithms in the industry and will proceed level by level through the Bill of Material starting with the top level (i.e. end item) of the BOM and review the demands and safety stock requirements, netting out the inventory and firmed (or greater) supplies and first suggest reschedules for firmed (or greater) supplies and then create planned supplies as appropriate.

The MRP Engine will always use the effective’ Bill of Material in its plan. It accomplishes this by reviewing the scheduled pick dates of the planned work order supplies or planned subcontract requisition supplies and using that date to extract the components that are effective’ and implemented’ as of that date in the generation of the work order and subcontract requisition demands.

MRP can be planned by division and by site as well as by project (in those divisions where project control is applicable). It uses planning policies such as lot for lot’ or days cover. Since many lead times can be stipulated at the item (or commodity code) level, the MRP Engine also determines for the work order supply the scheduled firm date, scheduled release date, scheduled pick date as well as the scheduled start date on the shop floor and the scheduled due date. For a requisition, it will determine the scheduled firm date, purchase order place date, date it is due on the receiving dock as well as the due date it is to be stocked. For those parts identified as items to be planned using re-order’ point, the MRP Engine can also perform re-order point computations.

Cloud Scheduling and Capacity Planning

Rootstock Scheduling & Capacity Planning provides the management and monitoring of the work order operations’ scheduled dates that are required to meet the Material Requirements Planning Work Order’s Scheduled Due Date into Stock.

The Rootstock Scheduler develops a schedule for all firmed, release and in process’ work orders based on the due date, standard times extended by the work order quantity, priority (as derived from compressed float), move and queue times and the work center’s standard for the hours in a production day.

The Capacity Requirements Planning will allow one to view a work center’s available capacity on a day by day basis (in terms of labor hours or machine hours) in a colorful graphical format. The drag and drop’ feature supports moving the schedule for a given work order within a work center from one day to another. If moving up the priority (and display) of a work order within a work center is required, this drag and drop’ feature allows the altering of the priority. The schedule is adjusted automatically when the work order’ is moved from one day to another.


The work order scheduling logic is performed for each work order, in a stepped method, establishing certain criteria at the end of each step before ultimately determining each work order operation’s scheduled start date and scheduled complete date. The determination of the operation standard time is influenced by a number of factors.

The first step in the scheduling algorithm is to establish the first work order’s operation’s schedule start date. If the work order has as not yet been started and the Work Order Production Release Dates is later than today’s date, then first operation’s schedule start date is the Work Order Production Release Date. If the Work Order Production Release Date is less than (or equal to) today’s date, then the first work order’s operation schedule start date is set to today’s date. If the work order has been started, then the first work order operation’s scheduled start date, not as yet completed, will be set to today’s date.

The next step is to determine the subsequent work order operations’ scheduled start and scheduled complete dates. This is accomplished by computing the scheduled quantity at the operation and then using that quantity in conjunction with labor and machine standards to determine the expected time to be expended in a work center for this operation. Considering the length of the standard production day will determine if this expended time (assuming infinite capacity) can be completed on the current scheduled date or a later date. The algorithm, when establishing dates for the next operation, will use the scheduled complete date of this operation that was previously scheduled and then add move and queue times to determine the present operation’s scheduled start date. The quantity to be scheduled will be adjusted based upon actual or expected scrap of the prior operation.

Given that this is a forward scheduling method, the next step in the process will determine the priority using a comparison between the standard (or natural) move and queue time and the compressed move and queue time required to meet the Work Order Scheduled Due Date into Stock. If a compression can be done, then the work order operations’ scheduled start and scheduled complete dates will be readjusted to meet the Material Requirements Planning Work Order Scheduled Due Date.

Capacity Planning

The Capacity Planning Work Bench is launched from the Manufacturing Menu. In the capacity planning work bench, the user, using the easy to use drag and drop’ capability, can move the work order operation start date’ forward or backward and the scheduling algorithm described above will be executed.

The work order operation’s start date (and scheduled complete date) will determine which work center day slots the work order will occupy. The priority will determine the order of the listing within the work center. Those work orders in green are expected to be started within the available capacity’ and those in red exceed capacity’. It is expected that the user may change the position of the work order within a work center by altering the priority and for those work orders in red, it is expected that the user, via a drag and drop’ capability, will move them to another day.

Lot & Serial Control

Rootstock Lot & Serial Control provides for an item’s lot or serial number to be registered through Purchasing Receipts, Inventory, Shop Floor Control and Sales Order Fulfillment functions.

The Purchasing Receipt function will note the Item Number classification and if lot controlled’, then the lot number must be assigned to the entire Purchase Receipt for the items being received prior to their acceptance’ into stock. There is an option that allows the user to assign the receiver number’ as the lot number which provides for an easy but practical application for the lot identification.

Rootstock Modules

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