smartplant materials a-z training - material reservation...

SmartPlant Materials A-Z Training - Material Reservation/Forecast

Version 2011 SP8 (7.0.8)

April 2013

DMAR1-TE-100015A

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2 SmartPlant Materials A-Z Training - Material Reservation/Forecast

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SmartPlant Materials A-Z Training - Material Reservation/Forecast 3

Contents Objectives .................................................................................................................................................... 7

Prerequisites ........................................................................................................................................... 7 Overview ................................................................................................................................................. 7

Explanation .................................................................................................................................................. 9

Workflow Diagram ................................................................................................................................. 10 Setup ..................................................................................................................................................... 10

Project Defaults .............................................................................................................................. 10 DBA Settings .................................................................................................................................. 12 Work Packages .............................................................................................................................. 13 Site BOM Setup Nodes .................................................................................................................. 17

Forecast Run Setup .............................................................................................................................. 17 Forecast Run Header ..................................................................................................................... 18 Run Options .................................................................................................................................... 19 Shipment Options ........................................................................................................................... 22 BOM Options .................................................................................................................................. 22 Calculate Options ........................................................................................................................... 22 Job Execution Statistics.................................................................................................................. 23 Job Control ..................................................................................................................................... 23 Split Results .................................................................................................................................... 25 Assigned Warehouses.................................................................................................................... 25 Assigned Work Packages .............................................................................................................. 25 Run Limitations ............................................................................................................................... 26

Forecast Run ......................................................................................................................................... 28 Reserved Nodes ............................................................................................................................. 30 Reserved Positions ......................................................................................................................... 33

Reservation Run ................................................................................................................................... 37 Forecast/Reservation Overview ............................................................................................................ 42

Tutorial........................................................................................................................................................ 45

Define a Work Package ........................................................................................................................ 45 Define a Forecast Run .......................................................................................................................... 48 Run Materials Forecast ......................................................................................................................... 51 Reserve Materials ................................................................................................................................. 54 Check Reservations .............................................................................................................................. 57

Summary .................................................................................................................................................... 61

Helpful References ............................................................................................................................... 61 Comments and Questions .................................................................................................................... 61

Index ........................................................................................................................................................... 63


Contents


S E C T I O N 1

In this lesson you will learn how to perform forecast and reservation runs in SmartPlant Materials to simulate materials availability.

In detail, you will learn how to:

Define work packages

Define forecast runs

Run material forecasts

Reserve materials

Check reservations

Prerequisites For this session, you must know how to log in to the software with the appropriate access rights from your administrator. You also need to have a consolidated knowledge about SmartPlant Materials and SmartPlant Reference Data basic functionality, which means you should be familiar with general screen handling in the software.

Additionally, you need a basic knowledge of Bill of Materials (BOM) handling and material receiving in SmartPlant Materials.

Sessions BASICS – General Screen Handling

SPMAT – How to Manage BOM

SPMAT – Material Receiving on Site

Overview This session explains how to handle material forecast and reservation runs in SmartPlant Materials. During the tutorial, you will define a work package, a forecast run, and a reservation run.

Objectives


Objectives


S E C T I O N 2

A forecast run is a tool to simulate material availability. That is, it is used to verify whether the material required for construction or fabrication is -- or will be -- available for use. It is also a ‘look-ahead’ function used to plan subcontractor staffing.

A forecast run will NOT change on-hand quantities in the inventory or BOM expected quantities.

A typical question the material controller may have to answer is:

How many and which BOMs could be pre-fabricated or installed at a specific date in the future, if all material that has already been received, plus all material that is currently on purchase orders and on approved requisitions, will be delivered on that specified date?

The result of a forecast run will answer such a question. Forecast runs require the following aspects to be defined:

Header - General information about the forecast run.

Options - Analysis options defined for each forecast run or calculation.

Assigned Warehouses - The warehouses to be queried for material.

Assigned Work Packages - The scope of material to be included in the forecast.

Run Limitations - Limiting factors affecting the material.

Explanation


Explanation

Workflow Diagram The following workflow diagram illustrates how to define a forecast run.

Setup When starting a new project in SmartPlant Materials, you must define the Site-related project defaults and perform the setup of the Site module.

Project Defaults You can find a detailed description of how to set project defaults and the purpose and usage of each project default in the Site section of the SmartPlant Materials Project Defaults documentation, available from the Printable Guides page in the software.

Some of the project defaults must be set before any forecast/reservation run is defined. Others are optional depending on the detailed workflow established by the project.

Project Default Comment

ZC_ATTR_CH This project default controls whether the comparison in the forecast run is performed against the group by attributes.

ZC_BESTQTY This project default controls whether the BOM Best Qty uses only Site Status option is selected when you create a new forecast/reservation run. You can change the setting of the check box on the screen.


Explanation ZC_BIN_LOC This project default controls whether warehouse logic (Warehouses like

C.10.03 and Locations like C.10.01) is used (ZC_BIN_LOC=WHTU, default), or whether bin location logic is used (ZC_BIN_LOC=BLOC).

ZC_EXC_MIR This project default controls whether the exclude MIR Qtys check box is selected when you create a new forecast/reservation run. You can change the setting of the check box on the screen.

ZC_FC_ALVL This parameter controls what kind of attribute matching is to be performed by forecast runs. The following options are available:

NONE: This option completely disables the attribute matching logic.

IVI: This option specifies that inventory item attribute values must match BOM position values.

WH: This option specifies that warehouse attribute values must match BOM position values.

ZC_FC_AMTC This parameter controls how the attribute matching logic selected by the project default ZC_FC_ALVL is to be applied during a forecast run. The following options are available:

EXACT: Attribute values must always exactly match in order to be considered by the forecast/reservation procedure. If there are empty attribute values on either the BOM position or on the attribute of the selected comparison attribute source (ZC_FC_ALVL), these attribute values would not match.

NULL_MATCHES_ANY: An empty attribute on either level is regarded as a wildcard.

ZC_FC_HIST This parameter controls the handling of the forecast job history. If unset or set to -1, all job runs and run results are kept. If set to a non-negative integer value, this number specifies how many old job runs and run results are to be kept, implying that older ones of the same type are deleted automatically when the forecast program is started again for a new run of that type.

ZC_RR_ALVL This parameter controls what kind of attribute matching is to be performed by reservation runs. The following options are available:

NONE: This option completely disables the attribute matching logic.

IVI: This option specifies that inventory item attribute values must match BOM position values.

WH: This option specifies that warehouse attribute values must match BOM position values.


Explanation ZC_RR_AMTC This parameter controls how the attribute matching logic selected by the

project default ZC_RR_ALVL is to be applied during a reservation run. The following options are available:

EXACT: Attribute values must always exactly match in order to be considered by the forecast/reservation procedure. If there are empty attribute values on either the BOM position or on the attribute of the selected comparison attribute source (ZC_FC_ALVL), these attribute values would not match.

NULL_MATCHES_ANY: An empty attribute on either level is regarded as a wildcard.

DBA Settings You can find a detailed description of how to set DBA settings and the purpose and usage of each DBA setting in the SmartPlant Materials DBA Settings documentation, available from the Printable Guides page in the software.

C30_JOB_STATUS When this DBA setting is set to N, no job status is created on A.60.85. This setting might be switched off for performance reasons.

C30_OPTIMIZER_MODE Optimizer mode that forecast/reservation runs should use. Choose among:

CHOOSE,

RULE,

FIRST_ROWS

ALL_ROWS

Once the forecast/reservation job is finished, this session parameter is reset to the value that was in effect before the job started.

C30_SORT_AREA_SIZE Sort area size that C3001/11 should use. Specify a value between 64K (this is the default) and 256M. Once the forecast/reservation job is finished, this session parameter is reset to the value that was in effect before the job started.


Explanation

Work Packages A work package is a user-defined selection of BOM nodes and materials that allows you to define specific where conditions for the ident and list position selection (scope of material).

Using these work packages, the forecast/reservation runs determine the material that is required to perform scheduled construction tasks. Work packages must be predefined before a forecast/reservation run can be performed.

Work packages are defined and maintained on the C.10.05 Work Packages screen.

To create a new work package, enter the work package name in the Name field and the descriptions in the Short Desc and Description fields.

To assign a ROS (Required On Site) date to the work package, select the date from the LOV in the ROS Date field.

The next fields can be used to assign where conditions to the selected work package. For more information about where conditions, refer to Where Conditions in the SmartPlant Materials Administrator‘s Guide, available from the Printable Guides page in the software.

In the Where Condition for Ident field, you can select a pre-defined where condition from the LOV. The LOV shows all where conditions defined on A.60.06 for the ‘C1005_1’module. Double-click in the field to open the A.60.06 screen. With this where condition, you can limit the idents (material) to be selected from the BOM by the forecast/reservation run.

In the Where Condition for List Pos field, you can select a pre-defined where condition from the LOV. The LOV shows all where conditions defined on A.60.06 for the ‘C1005_2’module. Double-click in the field to open the A.60.06 screen. With this where condition, you can limit the WBS nodes and BOM list positions to be selected from the BOM by the forecast/reservation run.


Explanation In the Where Condition for Mandatory LP field, you can select a pre-defined where condition from the LOV. The LOV shows all where conditions defined on A.60.06 for the ‘C1005_3’ module. Double-click in the field to open the A.60.06 screen. With this where condition, you can define a set of specific material (mandatory list positions; LP=list positions) that is absolutely necessary for starting the installation, and depending on this material issue. For example, pipes are essential for the installation of a pipeline. This where condition is used by the forecast/reservation run shortage option. For more information, see Forecast Run (on page 28).

In the Where condition for CIP (List Pos) field, you can select a pre-defined where condition from the LOV. The LOV shows all where conditions defined on A.60.06 for the ‘C1005_4’ module. Double-click in the field to open the A.60.06 screen. This optional where condition is used by the forecast/reservation run for the shortage option ‘2-Pass CIP’.

In the Where condition for CIP (Ident) field, you can select a pre-defined where condition from the LOV. The LOV shows all where conditions defined on A.60.06 for the ‘C1005_5’ module. Double-click in the field to open the A.60.06 screen. This optional where condition is used by the forecast/reservation run for the shortage option ‘2-Pass CIP’.

Next, select a value from the drop-down list in the Priority Type field. The available values are listed below.

ATTRIBUTE

INSTALL_PAY_ITEM (CIP)

ISSUED FIRST

WEIGHT (CIP)

WORK PACKAGE

Select an attribute from the LOV in the Attribute field. All attributes defined on A.50.01 are available for selection.

For more information about the Priority Type and Attribute fields, see Forecast Run (on page 28).

With the Locked indicator, you can lock a work package, which means that the assigned where conditions, BOM paths, and so forth cannot be changed.

Only users with the UNLOCK WORK PACKAGES privilege are allowed to reset the Locked indicator of a work package.

Enter the user who is responsible for this work package in the Name field. By default, the login user is entered when a new work package is created.


Explanation In the second (Work Package Details) block, you assign BOM list nodes to the selected work package. To select the nodes in the WBS (Work Breakdown Structure), click the Nodes button on the right at the top of the second block, or use the LOV in the List Node field to open the B.20.01 Search and Select screen.

This screen shows all available BOM list nodes. Double-click on a node to expand it and to show the sub-nodes. The Pos.Available indicator shows which list nodes have outstanding quantities, which means (list position quantities - issued quantities) > 0.

Select the Sel check box of all nodes that should be added to the work package. You can click the Select All button to select all available nodes in one step. Click the Unselect All button to cancel the selection. Finally, click the Fill In button to close the screen and to assign all selected nodes to the work package.


Explanation At the bottom of the B.20.01 Search and Select screen, you can enter a search criterion and then click the Search button to search for particular nodes. A new window displays all nodes matching the search criterion.

The check boxes and buttons are described above.

The sequence number in the Seq field of C.10.05 is filled automatically. This sequence number defines the order in which the reservation/forecast run will process the list positions. If necessary, adjust these sequence numbers manually. The sequence numbers must be unique within a work package.

If you have defined BOM sets for the login discipline on C.10.18, the LOV is limited to the BOM list nodes assigned to these BOM sets. For more information, see Site BOM Setup Nodes (on page 17).

If you have completed and saved the work package, click the Result button on the right at the bottom of the screen. A new window displays all list positions identified by the where conditions and the BOM nodes assigned to the selected work package.


Explanation This screen is a CWS (core workflow screen). Read more about CWS in the Core Workflow Screens section of the SmartPlant Materials User Interface Basics document, available from the Printable Guides page in the software.

Site BOM Setup Nodes You can define BOM sets that will be applied as filters on site screens when calling the B.20.01 BOM LOV or the B.20.01 Search and Select. By means of these LOVs, you can select BOM list nodes, for example, on the C.10.05 Work Packages or the C.20.22.01 MIR by BOM Commodity screens.

The Site BOM sets can be defined on the C.10.18 Site BOM Setup Nodes screen.

Select the discipline in the first (Disciplines) block. Then click in the BOM Set field in the second (Sets of BOM Setup Nodes) block and click the LOV button to display all available BOM setup nodes defined on the R.10.31 BOM Setup Nodes screen. Select a BOM set and click OK to close the LOV and to copy the selected set to C.10.18. You can add further sets in the same way. Finally, save the changes.

For each discipline you want to use on site, you can assign various BOM sets. With the assignment of the BOM sets, all including BOM list nodes and their sub nodes will be available for site.

Forecast Run Setup A forecast run (FR) is a tool to simulate material availability. That is, it is used to verify whether the material required for construction or fabrication is -- or will be -- available for use. It is also a ‘look-ahead’ function used to plan subcontractor staffing.

A forecast run will NOT change on-hand quantities in the inventory or BOM expected quantities.

A typical question the material controller may have to answer is:

How many and which BOMs could be pre-fabricated or installed at a specific date in the future, if all material that has already been received, plus all material that is currently on purchase orders and on approved requisitions, will be delivered on that specified date?

The result of a forecast run will answer such a question. Forecast runs require the following aspects to be defined:

Header - General information about the forecast run.

Options - Analysis options defined for each forecast run or calculation.

Assigned Warehouses - The warehouses to be queried for material.

Assigned Work Packages - The scope of material to be included in the forecast.


Explanation Run Limitations - Limiting factors affecting the material.

A forecast run is defined on the C.30.01 Forecast Run screen.

Each forecast run is based on a forecast header that defines parameters like work packages, warehouses used, and so forth for this run.

Forecast Run Header A forecast run (FR) is defined within a project by a forecast code and a run number unique within this code.

To define a forecast run, enter the name in the Forecast Code field and descriptions in the Short Desc and Description fields. The Run Number field is automatically set to 1, and the Job Status field is set to NEW. The Job Status field can have these values:

NEW – The job has not been executed.

FORECASTED – The job has been successfully run with results.

ERROR – The job run was not successful.

The New Run button can be used to create a new job run for the selected forecast. This button copies all of the selection parameters from the old forecast header and increases the run number by 1.


Explanation When the forecast run is successful, the results can be used to generate a reservation run to reserve the material for issue. This action ensures the material is reserved in exactly the same way as the forecast result. To create a reservation run (RR) from the forecast run, click the Create RR button.

For information about the Notification button, see Forecast Shortage MRR Notification in the SmartPlant Materials Site User’s Guide, available from the Printable Guides page in the software.

Run Options Select the shortage option from the drop-down list in the Shortage field. With the shortage option, you define the acceptable short quantities for allocating the Bill of Materials. It is possible to specify that only entire drawings should be allocated, or an alternate kind of shortage. The available options are listed below.

Only entire Drawings - The FR/RR includes only nodes in its reservation result set for which all material could be allocated, with no shortage allowed.

1-Pass Single (Any) - The FR/RR includes all nodes in its reservation result set for which any material could be allocated, thus allowing any shortage.

2-Pass Optimized - In the first step, the FR/RR attempts to allocate only complete BOMs. In the second step, it tries to allocate the remaining BOMs, allowing a 1-position (1), a 2-position (2), or any shortage (Any) per BOM node.

2-Pass CIP - In the first step, the FR/RR attempts to allocate only complete BOMs. In the second step, it tries to allocate the remaining BOMs, allowing any shortage per BOM node. Afterwards, the CIP m_pck_forecast_custom.check_reserve is applied. Depending on the returned value of this CIP, the list node is unreserved or not. The standard behavior is that nothing will be unreserved. For further information about how to program this CIP, read the comment block of m_pck_forecast_custom. You can give the CIP a free parameter list, definable on the A.30.21 Attached Parameters screen, which you can call from C.30.01.02 Assign Work Packages using the Parameters button.

The Allocate Level option allows the procedure to query other SmartPlant Materials modules for material that was not yet received on site. The forecast run starts on the inventory level and looks for material up to the pre-receiving level that has been selected here. For this search, only list positions with outstanding quantities are taken into account. The Allocate Level option should be used in combination with the Shipment Option Start/End dates so that SmartPlant Materials knows when the material is expected on site. The available values for Allocate Level are listed below.

Only Inventory - Material must be in the inventory and must be found in a warehouse that has been assigned to the forecast run via screen C.30.01.01.


Explanation Shipped Items - Material must be shipped. That is, the Actual Ship field must be filled in expediting.

Approved Purchase Orders - Material may not be shipped but the PO must be approved. If approved change orders exist, these change orders are taken into account. If you work with NOCs (notices of commitment), these notices are used instead as long as no approved POs are created for them.

Approved Requisitions - Material of the latest approved PO requisition supplements is also taken into account. An unapproved supplement must not exist. The result of 'Total Release Qty - Last Total Release Qty' is used as the quantity.

All Requisitions - Similar to 'Approved Requisitions', with the difference that the latest supplement is taken into account regardless of whether it has been approved or not.

The Delivery Destination value of the allocated level must correspond to the Delivery Type field. Otherwise, the FR/RR will not include the material in the allocate level. For example, if the destination was shop but we are looking for site material, the quantities will not be found.

With the Split Type option, you can define if and how the forecast run is split. The following split types are available:

None (default)

Node Name

Node Attribute

Position Attribute

If you select the Node Attribute or Position Attribute split type, you must select an attribute from the LOV in the Split Attribute field. Based on the value of this attribute, the forecast run will be split.

Select a pre-defined (A.10.39) delivery type or delivery designation from the LOV in the Delivery Type or Delivery Designation field. By default, the value is set to the Delivery Type value defined on C.10.21 Set Environment.

Select the tag number option from the drop-down list in the Tag No Option field. Valid values are: Ignore Tag Number and Not Ignore Tag Number.

Select the All Positions indicator when positions that were not forecasted shall be traced.

The selected Positions with full site-qtys check box indicates whether all BOM positions that are in the scope of run definition are marked regardless of their site quantities.

Select the Auto Subst/Trans indicator when substitution/transformation should be done automatically by the FR/RR.

If the exclude MIR Qty's? indicator is selected, the issue quantities on unposted MIRs by BOM are considered for the list positions in FR/RRs. In the case of an existing unposted MIR by BOM for a list position, the forecasted/reserved quantity is reduced for this list position in FR/RRs.

The project default ZC_EXC_MIR controls whether the exclude MIR quantities? check box is set by default or not on the C.30.01 Forecast Run and on the C.30.11 Reservation Run screens. If the project default is set to Y, the exclude MIR Qty’s? check box is automatically selected when you create a new forecast run. If the project default is set to N, the check box is not selected. You can change the setting of the check box on the screen.

Specify the type of priority for nodes assigned to the work packages within this FR by selecting a value from the drop-down list in the Priority field. The available options are:


Explanation NULL - Default

ISSUED FIRST - Material that has an issue quantity first

NODE ATTRIBUTE - Material with the entered node attribute first

(CIP) - All procedures of custom package M_PCK_FORECAST_CUSTOM with parameter P_WPTF_ID and data type in ('NUMBER', 'FLOAT') - customized logic

Weight Option It is possible to determine material availability by weight. For example, if a steel fabrication shop capacity is rated by tons/week and if SmartPlant Materials has weights associated with material, the FR uses the weight option. Choose a weight option from the drop-down list in the Sort Order field if you intend to calculate the weight of nodes assigned to the work packages. This option affects the attribute sort order on the C.30.01.02 Assigned Work Packages screen. The available options are:

None - No weight calculation is needed.

Heaviest First - The weight attribute is mandatory. The attribute sort order of C.30.01.02 is in descending order.

Heaviest Last - The weight attribute is mandatory. The attribute sort order of C.30.01.02 is in ascending order.

You must select a list node attribute from the LOV in the Attribute field, when you have selected a weight option in the Sort Order field. This weight attribute determines the node attribute where the calculated weight is assigned. The Priority Type field on the C.30.01.02 Assigned Work Packages screen is set to 'Attribute,' and the Attribute field on the C.30.01.02 screen is set to the selected attribute.

The LOV in the Attribute field shows you an intersection of all node attributes existing in all nodes and subnodes defined by the assigned work package, whose node type is marked as ‘Use for Weight Calculation' on B.10.03.

The weight calculation will be processed for all nodes and subnodes defined by the work package, whose node type is marked as ‘Use for Weight Calculation' on B.10.03.

If you have selected an attribute, it is not possible to change any value on the C.30.01.02 screen.

During an FR/RR, the calculated weight is assigned to the selected node attribute, displayed on the B.20.03 screen.


Explanation

Shipment Options The FR/RR searches for item shipments for which the promised on site date is after the date defined in the Start Date field and earlier than the date defined in the End Date field. See also the description of the Allocate Level option in Run Options (on page 19).

Select the Not handle null dates indicator when item shipments with an empty Pred on Site date field should be ignored.

BOM Options The BOM options include Best Quantity, Use Only Site Status, Only Endnodes, Issue Status, and List Status.

Select the Best Quantity indicator to use the best quantity logic. If the indicator is not checked, you must select an issue status from the LOV in the Issue Status field. The Use Only Site Status option is used in conjunction with Best Quantity. If you select this option, only those statuses that are marked as Use on Site on B.10.08 are considered; the others are ignored.

Select the Only Endnodes check box when only terminal BOM nodes should be processed by the FR/RR. The default behavior is to process all nodes with the check box not selected.

Select the list status from the LOV in the List Status field.

Calculate Options The calculation options allow advanced techniques of forecasting, rather than just considering material availability. Weight may be specified if there is a tonnage capacity of a fabrication shop (discussed earlier). Cost may be a limiting factor if there is a budget or expenditure limit per week (or other period). Hours may be a factor if site personnel can only perform a limited number of hours per week.

Each option requires that the appropriate information (for example, weight, cost, time, and so forth) is stored against the work and material in SmartPlant Materials.

Select the Weight, Cost, and/or Hours indicator if weight, cost, and/or hour information should be calculated and displayed when the result of a forecast run is viewed.


Explanation

Job Execution Statistics The user who launched the job is shown in the Job Start User field, and the job start and end time are shown in the Start Date and End Date fields. The FR/RR creates a log file at runtime; the name of the log file with the entire path appears in the Log File field. To open the log file, click the View Online Log button. The log file should always be reviewed because it provides information as to why a process has failed and also general information about the success of a job. The Execution Summary field shows a brief status of the job execution.

Job Control Click the Start button to launch the execution of the selected FR. The Interaction Mode option is available for online execution only, not for batch mode. The Interaction Mode option allows the user to affect the processing sequence of the FR, as a manual method of applying priority to the forecast.

If you click the Start button, the A.60.84.01 Job Scheduler box opens.

Click the Online button to immediately start the selected job in online mode. Click the Batch button to immediately start the job in the background in batch mode. Click the Cancel button to exit the job.


Explanation If you click the Schedule button, the box expands to show the Schedule Details block.

Enter the planned date and time for the job in the Date/Time field. The Comments field can be used to enter any comments. Click OK to continue. The box closes, and the job is started at the specified date and time in the background in batch mode.

You can use the A.60.84 Scheduled Jobs and A.60.85 Job Status screens to check the status of scheduled batch jobs. For more information, see the Scheduled Jobs and Job Status topics in the SmartPlant Materials Administrator’s Guide, available from the Printable Guides page in the software.

Each completed job creates a log file. Click the View Online Log button to open the A.60.72 Show Log File screen, which displays the log file details.


Explanation

Split Results This section shows the split results that were created by the forecast run. The split results are created based on the split type (and the attribute name if applicable) that was defined for this run.

Assigned Warehouses Warehouses must be assigned to the forecast run header to be used to reserve and issue material.

Use the Fastcall to open the C.30.01.01 Assigned Warehouses screen.

In the second block, enter a sequence number in the Seq field and select the warehouse from the LOV in the Warehouse field. All warehouses assigned to the login user on C.10.03 are available for selection. Select the Sel check box of all warehouses you want to assign, and click Fill In.

The forecast run searches in the assigned warehouses for the required material in the order specified by the sequence.

Assigned Work Packages Work packages are defined on C.10.05 as described in Work Packages (on page 13) in the Setup section.


Explanation Use the Fastcall to open the C.30.01.02 Assigned Work Packages screen.

To assign a work package in the second block, enter a sequence number in the Priority field, and select a pre-defined work package from the LOV in the Work Package field. The other fields in the second block and the list nodes in the third block are populated automatically from the work package. For the description of the fields, see Work Packages (on page 13) in the Setup section.

The priority determines the order of processing the work packages by the FR.

When a ROS date exists for a work package assigned to the forecast run, this ROS date is used during the forecast instead of the end date specified for the forecast run in the Shipment Options section on C.30.01 Forecast Run.

Run Limitations You can define run limitations for a forecast or reservation run. The significance of these limitations is that during the BOM processing in the forecast procedure, attribute values for the attributes you specify in this module are summed up. Once a sum reaches the specified limit, the forecast processing stops.


Explanation Use the Fastcall to open the C.30.01.03 Run Limitations screen.

To define run limitations, select a BOM node attribute from the LOV in the Attribute field to be used as a limitation criterion.

With the Sum Type field, you define how attribute values for BOM positions processed should be summed up. There are two options available:

Relative (default option) - If for a BOM position an allocation/reservation is made, the software adds the fraction of the value for the selected attribute to the overall value that corresponds to the fraction of the total BOM quantity for which a reservation/allocation will be made. Values for such a BOM attribute are interpreted as being relative to one piece/unit of BOM quantity.

Absolute - If for a BOM position any fraction of the BOM quantity is allocated or reserved, regardless of whether the complete quantity or only a partial quantity is allocated, the absolute value of the BOM position attribute value is added.

Select the type of limitation from the drop-down list in the Limitation Type field. Two options are available:

Greater - Processing stops as soon as the sum of the attribute values for the BOM positions processed so far exceeds the specified value.

Greater or Equal - Processing stops as soon as the calculated sum reaches or exceeds the specified value.

Specify the run limitation for the selected attribute in the Limit Value field. The quantity unit is copied from the attribute definition in the Unit field.

The Actual Value field shows the actual value calculated by the forecast/reservation run. The number of BOM positions processed during the forecast/reservation run that contributed to the actual value for this run limitation attribute is shown in the Positions field. The Stopped On Limit check box indicates that forecast/reservation processing was stopped because the limitation criterion for this attribute was reached or exceeded, according to the specified limitation type.


Explanation

Forecast Run When the forecast run definition is completed, click the Start button to launch the selected forecast run. The A.60.84.01 Job Scheduler box opens.

Click the Online button. Before the forecast run is started, the CIP procedure m_pck_forecast_custom.check_before_rr is executed.

When the job runs successfully, FORECASTED is shown in the Job Status field on top.


Explanation You can click the View Online Log button to open A.60.72, which displays the contents of the log file created by the forecast run.

To check the status of a FR/RR, use the fastcall on C.30.01 to open the A.60.85 Job Status screen.


Explanation

Reserved Nodes Next, use the fastcall on C.30.01 or double-click the forecast run name in the Forecast Code field to open the C.30.02 Reserved Nodes screen.

This screen shows the result of the forecast run. It shows all BOM nodes (usually isometric sheets) for which material will be available if all material is received within the dates specified on the outstanding POs and approved requisitions.

To reverse the selected FR/RR and to reset all quantities calculated by the FR/RR, you can use the Undo Reservations button in the first (Reservation Run Definition) block. The status of the FR/RR will be set to REJECTED.

In addition, you can select the Sel check box of particular BOM nodes to be reversed in the second (Included List Nodes) block, or click the Select All button to select all displayed list nodes. To cancel a selection, use the Deselect All button. Finally, click the Undo BOM Nodes button to reverse the selected BOM nodes.

You must acknowledge the message with OK to continue. When the node is deleted, another message appears. Click OK again.


Explanation The Best Qty uses only Site Status check box at the top of the screen controls which issue statuses the best quantity algorithm considers. If this check box is not selected, it means that any issue status is considered. If the indicator is checked, only issue statuses marked as Use on Site in B.10.08 are considered.

To display the WBS structure in tree mode, click the Tree Mode button.

To change back to the normal mode, click the Normal Mode button.

The second (Included List Nodes) block displays the BOM nodes associated with the selected FR/RR.

The Node Status before FR / RR field shows the status of the selected BOM node as it was before running the FR/RR. Possible values are listed below.

Complete - The node was already completely forecasted / reserved.

Partly - The node was partly forecasted / reserved.

None - Nothing was forecasted / reserved before this FR/RR.

The now field shows the status of the selected BOM node as it is after running the FR/RR. Possible values are listed below.

Already Complete - The node was already complete before this FR/RR.

Complete - The node is now completely forecasted / reserved.

Partly - The node is now partly forecasted / reserved.

None - Nothing was forecasted / reserved by this FR/RR.

The Reason if actual nothing reserved field indicates that the node could not be forecasted / reserved due to the reason shown in this field. The possible reasons are listed below.

Already Complete - The node is already complete.

Mandatory LP - Nothing was reserved due to the mandatory LP option.

Shortage - Nothing was reserved due to the entered shortage option.

Exclude MIR Qty's - Nothing was reserved because the list positions are on unposted MIRs by BOM.


Explanation No Material - No material is available for all positions of the selected node.

The Issue Progress field indicates how much of the required material for this BOM node has been issued. Possible values are:

None - No material was issued.

Partly - Required material was partly issued.

Complete - Required material was completely issued.

Overissued - More material was issued than required.

The calculation for this issue progress is based on the same best quantity logic that applies to the MTO and the forecast run.

The % Issued field gives you an overview of how much material has already been issued for this node. The calculation is based on the best quantity logic; however, it just gives the ratio of overall issued material quantities to overall required list position quantities, without considering different quantity units.

The Total List Qty field shows the sum of all quantities for positions beneath the selected node, according to the forecast / reservation definition. The Total Res Qty field shows the total quantity reserved for the selected node. The Total Issued Qty field shows the quantity issued for the selected node. The quantity that was reserved by the current FR/RR appears in the Actual Res Qty field. The quantity that was reserved manually during the current FR/RR appears in the Manual Res Qty field.

Click the Weight/Cost/Manhours tab to display the calculated weights, costs, and manhours.

The % Shortage Weight value is calculated from Delta Weight * 100 / Total List Weight. This value enables the user to make a judgment on what is still outstanding and to see if the shown node could be issued to a contractor.

The % Total Issued Weight field gives an overview of how much material calculated by weight has already been issued for this node. The calculation is based on best quantity logic; however, it just gives the ratio of overall issued material quantities to overall required list position quantities, without taking into account that these quantities consist of different positions.

The Total List Weight value is the sum of all weights for positions beneath the selected node, according to the forecast / reservation definition. The Total Reserved Weight value is the weight that is reserved for the selected node. The Total Issued Weight value is the weight that has been issued for the selected node.

The Actual Res Weight value is the sum of all weights for BOM positions forecasted in the selected run. This weight is only calculated if the Weight check box has been selected in the Calculate Options portion of this run. The calculation is done as specified in the CIP function m_pck_forecast_custom.weight.

The Delta Weight value is calculated as follows: Total Reserved Weight + Actual Reserved Weight - Total List Weight.

The Weight Unit field shows the common weight unit for positions beneath the selected node. If different weight units exist, unit to unit conversion rules must be defined on the A.10.13 Units to


Explanation Units screen. The most common unit for positions beneath the selected node will become the Weight Unit. If a conversion is not possible, the weight unit is 'N/A' and the values are left blank.

The Actual Res Cost value is the sum of all cost values for BOM positions forecasted in this run. This value is only calculated if the Cost check box has been selected in the Calculate Options portion of this run.

The Actual Res Manhours value is the sum of all manhour values for BOM positions forecasted in this run. This value is only calculated if the Manhours check box has been selected in the Calculate Options portion of this run.

Reserved Positions Next, use the Fastcall on C.30.02 or double-click the list node in the BOM Path field to open the C.30.03 Reserved Positions screen.

The screen displays the selected BOM node in the first (List Nodes) block. You can use the Undo BOM Node button to reverse the selected BOM node.


Explanation You must acknowledge the message with OK to continue. When the node is deleted, another message appears. Click OK again.

In the second (List Positions) block, the list positions of the selected list node appear, with their allocated quantities, reserved quantities, and forecasted shortage quantities. If the forecast run allocation was made against item shipments, traffic, or requisitions, this situation is indicated by the enabled Traffic, Ships or Req LI check box, respectively. You can click the Item Ships button to display the shipment information for this reserved position. The same can be done for requisition line items (Req Line Items button), bills of ladings (Bill of Ladings button), and containers (Containers button).

The LP Status Now field shows the current status of the selected list position. Available values are:

Complete - The position is now completely forecasted / reserved.

Partly - The position is now partly forecasted / reserved.

None - Nothing is forecasted / reserved by this FR/RR.

The Reason if actual nothing reserved field indicates that the position could not be forecasted / reserved due to the reason shown in this field. The possible reasons are listed below.

Mandatory LP - The position is mandatory for the construction of the selected node, and therefore the entire node was not reserved.

Shortage Option - 2-Pass Optimized(1) or 2-Pass Optimized(2) was set as the shortage run option for this FR/RR. More than (1) / (2) positions of this node could not be reserved completely; therefore, the entire node was not reserved.

Already Complete - The position was already reserved completely.

No Material - No material was available for this position.

Click the Quantities (BOM) tab to display the BOM quantities.

Unit - Quantity unit, copied from the BOM list position.

List Quantity - Required list position quantity entered.

Outstanding Qty - Quantity that is not already issued or reserved against the position.

Issued Quantity - Quantity already issued for this position.

List Pos Resv Qty - Sum of the reserved quantity of all reservation runs for this position.


Explanation Click the Quantities (FR/RR) tab to display the quantities calculated by the FR.

Total On Hand Qty - Total on-hand quantity to be used for manual reservations against the inventory. This field is for information only.

Total Reserved Qty (actual+manual) - You can enter (at a maximum) the sum of Total On Hand Qty + Actual Resv Qty.

Total man Resv Qty - Total manual reserved quantity; this field is for information only. If you want to reserve more material for this ident than calculated by the FR/RR, you can insert a total reserved quantity, which should be manually reserved from the inventory.

Actual Resv Qty - The quantity forecasted by the current forecast run. This quantity would have been reserved if the job was a reservation job.

A forecast run does not reserve any material from the inventory.

Forecast Short Qty - The forecasted shortage quantity is the difference between the outstanding quantity for the list position and the quantity that could be allocated by the forecast run. This quantity would be a real shortage quantity in a reservation run.

Click the Subst/Trans tab to display the substitution/transformation details.

If any substitutions/transformations have been defined, the suggestions are listed on this tab.

Subst/Trans Status - Status of completion by substitution / transformation. Available statuses are:

Done Complete

Done Partly

Possible Complete

Possible Partly

Not Available

The Subst check box indicates a substitution. The Trans check box indicates a transformation.

The quantity shown in the Subst. Resv Qty field, the reserved quantity of the substituted/transformed ident code, will only be reserved if you approve the substitution/transformation by clicking the Approve Subst. button. This action will check the Approved indicator of the selected position. To cancel an approval, you can use the Unapprove Subst. button.


Explanation Click the Available Subst. Idents button to open the C.20.14 Inventory Items (LOV) screen, which displays the available and acceptable substitutions.

The available inventory items are listed with their on-hand quantity and the assigned warehouse/location/status. To select an ident, check the Sel check box. Click the OK button to complete the selection or the Cancel button to cancel.

To initiate an automatic substitution search, click the Auto Subst. button.

You can use the Undo BOM Pos button to reverse BOM positions.


Explanation Window 2 displays the list positions of the selected list node. Select the Sel indicator of the positions to be reversed, or click the Select All button to select all positions. To cancel a selection, you can use the Unselect All button. Finally, click the Undo BOM Positions button to reverse the selected BOM positions.

You must acknowledge the message with OK to continue. When the positions are deleted, another message appears. Click OK again.

Reservation Run The main functionality of reservation runs is similar to the forecast runs defined on C.30.01. But unlike a forecast run, a reservation does real reservations against the inventory. The inventory on-hand quantities and the BOM expected quantities are decreased by the reservation run. Furthermore, the Allocate Level options cannot be defined for a reservation run, because the inventory is the only basis for the material availability check.

A reservation run can be defined on the C.30.11 Reservation Run screen in the same way as a forecast run. For more information, see Forecast Run Setup (on page 17).


Explanation Or, you create a reservation run based on a successfully completed forecast run on the C.30.01 Forecast Run screen.

Select the forecast run, and click the Create RR button to create a reservation run.

This message appears when done:


Explanation Click OK, close the C.30.01 screen, and open the C.30.11 Reservation Run screen.

As in C.30.01, you can use the fastcall to open C.30.01.01 Assigned Warehouses, C.30.01.02 Assigned Work Packages, and C.30.01.03 Run Limitations to check and change any of the settings copied from the forecast run.

If the reservation run definition is ok, click the Start button to launch the selected reservation run. The A.60.84.01 Job Scheduler box opens.

Click the Online button.


Explanation When the job runs successfully, RESERVED is shown in the Job Status field at the top.

You can click the View Online Log button to open A.60.72, which displays the contents of the log file created by the reservation run.

Similar to the forecast run, you can use the fastcall or double-click the reservation run name in the Reservation Code field to open the C.30.02 Reserved Nodes screen to check the result of the reservation run.

Here you can check the status, quantities, weights, costs, and manhours calculated for the list nodes. In addition, you can use the Undo buttons as described in Forecast Run (on page 28).


Explanation You can use the fastcall or double-click the list node in the BOM Path field to open the C.30.03 Reserved Positions screen.

Here you can check the status and quantities calculated for the list positions, and in addition, you can use the Undo buttons as described in Forecast Run (on page 28).

Click the Quantities (FR/RR) tab to display the reserved quantities calculated by the RR.

Total On Hand Qty - Total on-hand quantity to be used for manual reservations against the inventory. This field is for information only.

Total Reserved Qty (actual+manual) - You can insert (at a maximum) the sum of Total On Hand Qty + Actual Resv Qty. If you insert a total reserved quantity less than the actual reserved quantity, click the Process Qty button to change the reservation run quantity and the reserved quantity on the list position. Positions with a total reserved quantity less than the actual reserved quantity originally calculated by the RR are highlighted with a red background color in the Pos field. If you now insert a total reserved quantity higher than the actual reserved quantity, the difference is reserved as a manual reserved quantity.

Total man Resv Qty - Total manual reserved quantity; this field is for information only. If you want to reserve more material for this ident than calculated by the FR/RR, you can insert a total reserved quantity, which should be manually reserved from the inventory. When the Process Qty button is clicked, this quantity is reserved in the inventory and can be issued with C.20.21 MIR by Reservation in addition to the quantities reserved by the FR/RR for each list position. The manual reservation can be controlled on C.30.31 Manual Material Reservation and on C.20.26 Inventory History.

Actual Resv Qty - The quantity forecasted by the current forecast run. This quantity would have been reserved if the job was a reservation job. A forecast run does not reserve any material.


Explanation

Forecast/Reservation Overview To get a quick overview about forecast and reservation jobs and their reservation status against the BOM, you can use the C.30.21 Forecast/Reservation Overview screen.

With the options at the top of the screen, you can control which FR/RRs appear. The available options are listed below.

Jobs all - Shows all jobs (FR/RRs) of the logged in project.

own - Shows only jobs created by the logged in user.

Status issued - Shows all FR/RRs with job status ISSUED.

forecasted/reserved - Shows all FR/RRs with job status FORECASTED or RESERVED.

all - Shows all FR/RRs independent of the job status.

Type all - Shows all FR/RRs.

Forecast Run - Shows only FRs.

Reservation Run - Shows only RRs.

The FR/RR name is shown in the Forecast/Reservation Code field, the run number in the Run field, the type in the Type field, and the status of the FR/RR in the Job Status field.

The Split Results indicator is selected if splits exist. The type by which the FR/RR is split is shown in the Split Type field. The Attribute field shows the name of the attribute to be used if the split type was set to Node Attribute or Position Attribute. You can use the Show Splits button at the bottom of the screen to view the split results.


Explanation The Allocate Level field defines up to which pre-receiving level the allocation run should look, and this field is only relevant for FRs.

The Shortage field shows the acceptable short quantities for allocating the Bill of Materials as defined with the FR/RR definition. For more information, see Run Options (on page 19) in the Forecast Run Setup section.

The descriptions of the FR/RR header appear in the Short Desc and Description fields.

Click the Show Results button to open the C.30.02 Reserved Nodes screen to check the result of the selected FR/RR. For more information about C.30.02, see Reserved Nodes (on page 30).

Click the Undo button to reverse the selected FR/RR and to reset all quantities calculated by the FR/RR. The status of the FR/RR is set to REJECTED.


Explanation


S E C T I O N 3

The purpose of this tutorial is to configure the site setup and to create and perform forecast and reservation runs in the Site module of SmartPlant Materials.

Be sure to read the Explanation (on page 9) section of this training document before starting the tutorial.

Before starting the tutorial, please log in to the TRAINPROJ project and the PIPING discipline. You can check the project and discipline by looking at the bottom of the screen.

Define a Work Package Purpose This section explains how to define a work package that is used for forecast and reservation runs. The work package defined in this exercise includes the BOM nodes created during the ‘How to Manage BOM’ tutorial. For more information, see SmartPlant Materials A-Z Training - How to Manage BOM, available from the Printable Guides page in the software.

Exercise 1. Open the C.10.05 Work Packages screen from the SmartPlant Materials > Site > Field

Material Control > C.10 Setup menu branch.

Tutorial


Tutorial

2. Click Exe Query to view the existing work packages.

3. Click New Record to create a new record.

4. Enter WP_PIPING in the Work Package field.

5. Select the required on site date from the LOV in the ROS Date field.

6. Enter Piping in the Short Desc and Description fields.

7. Save the changes using the Save button.

8. In the second block, click the Nodes button.


Tutorial

The B.20.01 Search and Select screen opens where you can select BOM nodes to be assigned to the work package.

9. Double-click PIPING in the tree to expand the node.

10. Select the Sel check box for the nodes A100 and A300.

11. Click Fill In.

12. Click Results.


Tutorial

A window opens where the work package result appears, that is, the BOM positions included in the work package.

13. Close the screen.

Define a Forecast Run Purpose This section explains how to define a forecast run to simulate materials availability.

Exercise 1. Open the C.30.01 Forecast Run screen from the SmartPlant Materials > Site > Field

Material Control > C.30 Construction Planning menu branch.


Tutorial

2. Click Cancel Query to switch to new record mode.

3. Enter FR-TRAIN01 in the Forecast Code field.

4. Enter FR-Training1 in the Short Desc and Description fields.

5. Select the status 0 from the LOV in the List Status field.


7. Open the Fastcall menu in the upper right corner.

8. Select C.30.01.01 Assigned Warehouses from the menu.

9. Enter 1 in the Seq field.

10. Select STORE from the LOV in the Warehouse field.


Tutorial



You return to C.30.01.


14. Select C.30.01.02 Assigned Work Packages from the menu.

15. Enter 1 in the Priority field.

16. Select the pre-defined WP-PIPING from the LOV in the Work Package field.



Tutorial

The BOM list nodes assigned to the selected work packages appear in the lower block.



Run Materials Forecast Purpose This section explains how to run a materials forecast to simulate materials availability.


Tutorial Exercise 1. Open the C.30.01 Forecast Run screen from the SmartPlant Materials > Site > Field


2. Click the Exe Query button to view the FR-TRAIN01 forecast run.

3. Click Start to launch the forecast procedure.

The job status changes to FORECASTED when the run is successful.


5. Select C.30.02 Reserved Nodes from the menu.

6. Select a BOM node in the BOM Path field.



Tutorial 8. Select C.30.03 Reserved Positions from the menu.

9. Select the Quantities (BOM) tab to check the BOM position quantities.

10. Select the Quantities (FR/RR) tab to check the quantities calculated by the forecast run.



12. Repeat steps 6 to 10 for the other BOM nodes.


Tutorial 13. Close the screen by selecting File > Close All from the main menu.

Reserve Materials Purpose This section explains how to reserve materials based on the forecast run results.

Exercise 1. Open the C.30.01 Forecast Run screen from the SmartPlant Materials > Site > Field


2. Click the Exe Query button to view the FR-TRAIN01 forecast run.

3. Click Create RR.

A reservation run with the same settings as defined for the selected forecast run is created.

4. Click OK to acknowledge the message.



Tutorial 6. Open the C.30.11 Reservation Run screen from the SmartPlant Materials > Site > Field


7. Click the Exe Query button to view the FR-TRAIN01 reservation run.

8. Click Start to launch the reservation run.

The job status changes to RESERVED when the run is successful.



Tutorial 10. Select C.30.02 Reserved Nodes from the menu.

11. Select a BOM node in the BOM Path field.


13. Select C.30.03 Reserved Positions from the menu.

14. Select the Quantities (BOM) tab to check the BOM position quantities.


Tutorial 15. Select the Quantities (FR/RR) tab to check the quantities calculated by the forecast run.



17. Repeat steps 6 to 10 for the other BOM nodes

18. Close the screen by selecting File > Close All from the main menu.

Check Reservations Purpose This section explains how to check which material is reserved.

Exercise 1. Open the C.30.21 Forecast/Reservation Overview screen from the SmartPlant Materials

> Site > Field Material Control > C.30 Construction Planning menu branch.


Tutorial

2. Click the Exe Query button to view the FR-TRAIN01 forecast and reservation run.

3. Click Show Results.

The C.30.02 Reserved Nodes screen opens and displays the BOM nodes assigned to the selected run.

You can open C.30.03 Reserved Positions from the Fastcall menu as described in the previous exercise.


5. Open the B.20.03 Adv. Maintain BOM screen from the SmartPlant Materials > E&PI(BOM) > B.20 Maintain BOM menu branch.

6. Select the top node.

7. Open the shortcut menu with a right mouse-click.


Tutorial 8. Select Expand All from the menu.

9. Double-click an end node, for example, PIPING/A100/NF12004/01.

The Multi Position View displays the positions of the selected node.

10. Select the Single Bulk Material View tab.

The quantity reserved by the reservation run is shown in the Resv Qty field.



Tutorial


S E C T I O N 4

In this tutorial, you learned how to:

Administer the Site setup

Define work packages

Define forecast runs

Run material forecasts

Reserve materials

Check reservations

Helpful References SmartPlant Materials and Reference Data - User Interface Basics

SmartPlant Materials A-Z Training Material Receiving on Site

SmartPlant Materials A-Z Training Site Inventory Management

Comments and Questions Please send comments or questions to [email protected] (mailto:[email protected]).

Summary


mailto:[email protected]

Summary


A Assigned Warehouses • 25 Assigned Work Packages • 25

B BOM Options • 22

C Calculate Options • 22 Check Reservations • 57 Comments and Questions • 61

D DBA Settings • 12 Define a Forecast Run • 48 Define a Work Package • 45

E Explanation • 9

F Forecast Run • 28 Forecast Run Header • 18 Forecast Run Setup • 17 Forecast/Reservation Overview • 42

H Helpful References • 61

J Job Control • 23 Job Execution Statistics • 23

O Objectives • 7 Overview • 7

P Prerequisites • 7 Project Defaults • 10

R Reservation Run • 37 Reserve Materials • 54 Reserved Nodes • 30 Reserved Positions • 33 Run Limitations • 26 Run Materials Forecast • 51 Run Options • 19

S Setup • 10 Shipment Options • 22 Site BOM Setup Nodes • 17 Split Results • 25 Summary • 61

T Tutorial • 45

W Work Packages • 13 Workflow Diagram • 10

Index


smartplant materials a-z training - material reservation...

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