Distribution Resource Planning (DRP)

Overview

The goal of the distribution resource planning (DRP) functionality is to allow users of xTuple to be able to generate planned transfer orders between sites either manually or using netting logic contained in the material resource planning (MRP) and master production schedule (MPS) algorithms. You will be able to manage and release planned transfer orders using the same tools that are currently provided to do these activities for other planned order types.

New Terms and Definitions

  • DRP

    • Distribution resource planning: An aspect of the MRP and MPS planned order generation process that nets demand at a site per planning settings and generates planned transfer orders for a designated supply site.
  • Planned Transfer Order

    • An order record that may be created manually or by MRP and MPS runs, recommending a transfer order of inventory from one site to another.
  • Transfer Order Status

    • A transfer order may be in "unreleased," "open," or "closed" status. Unreleased means the order is eligible to be appended to by the releasing of planned transfer orders, but may not be shipped or received. A transfer order may be released to "open" status at which point it is eligible for shipping and receiving.

User-Level Functionality

You have the ability to designate item sites as being supplied by other sites. MRP or MPS will generate planned transfer orders based on the planning parameters and netting of the demand item site. In turn, planned transfer orders and real transfer orders may be seen as demand by supplying sites, which may also generate planned orders.

Transfer orders may also be released from the "released planned orders" window or the "planned orders by planner code" and "by item" windows. When releasing a planned order, the system either creates a new unreleased transfer order, or attaches the items to existing unreleased planned transfer orders if any exist with the same from and to sites. This makes it possible to aggregate multiple planned transfer orders onto a single transfer order.

Transfer Order

In order to make releasing planned transfer orders practical, we have provided a mechanism for releasing multiple planned order records to the same transfer order. The pre-existing paradigm for purchase requests release provides the model for how this is being handled for transfer orders. When you release a purchase request to purchasing, the application checks to see if there is an un-posted purchase order for the selected vendor, if so, it prompts you if you want to add the item to that existing purchase order. This way, you can build a single purchase order from several independent purchase requests. In order for transfer orders to offer the same functionality, we have introduced a header status to designate whether transfer orders are in a unreleased or open status.

List Transfer Orders

The list transfer orders screen may be filtered on all statuses—or selected statuses that may include open or unreleased orders. A button and right click option allows you to select and release orders.

To open the "List Open Transfer Orders" window follow these steps:

  • Go to "Inventory" from the top menu
  • Select "Transfer Order"
  • Select "List Open"
  • The "List Open Transfer Orders" window will open:

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On the transfer order header, there is an "Order Status" option having the hard-coded statuses of "Unreleased", "Released", and "Closed". The default status for a new transfer order is unreleased, with you having the option of being able to change the order to any status if they have appropriate privileges. The privilege "ReleaseTransferOrders" is required to change the status to released. Changing the order status to closed will close all line items.

For the purposes of this example we will be working with Order #99012. You can see the order status option by following these steps:

  • Choose "99012" from the "Transfer Orders" list and choose EDIT
  • The "Transfer Order" window will open:

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Release Transfer Orders by Agent

A new feature has been added that allows users with "ReleaseTransferOrder" privileges to release transfer orders in batches according to agent criteria selection.

To open the window to release transfer orders, follow these steps:

  • Go to "Inventory" from the top menu
  • Select "Transfer Order" and go to "Release by Agent"
  • The "Release Transfer Orders by Agent" window will open:

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Issue Stock to Shipping, Ship Shipment and Inventory Receipt

Transfer orders in an unreleased status may not be shipped or received. Checks have been added to the issue stock to shipping, ship shipment, and order receiving windows to ensure that transfer orders can only be transacted when in an open status.

Configure Schedule

To open the schedule configuration menu, follow these steps:

  • Go to "Schedule" from the top menu
  • Select "Setup" from the submenu
  • The "Setup" window will open, from the left menu click "Configure" and select "Schedule"

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Site

A new option labeled "Schedule Sequence" has been added to the site window. This sequence number will determine the order in which sites are processed when MRP or MPS is run against all sites.

To open the site window follow these steps:

  • Go to "Inventory" from the top menu
  • Select "Site" from the drop down menu
  • Select "List"
  • The "List Sites" window will open 
  • From the sites list, select "WH1" and click the EDIT button
  • The "Site" window will open:

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Item Site and Update Item Site by Class Code

The "Item Site" and "Update Item Site by Class Code" windows have been modified in several ways to accommodate the ability to specify item sites that receive supply from other sites. The "Planning" tab can be seen by following these steps:

  • Go to "Inventory" from the top menu
  • Select "Item Site" from the drop down menu
  • Select "List" and the "Item Sites" window will open
  • From this list, scroll down and open the WH1 YTRUCK1 item number

The "Item Site" window will open for this selected item:

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The "Planning" tab is used to aggregate all settings related to, but not limited to, MRP and MPS. The "Planning System" combo box has been moved from the item screen to the item site screen. This enables you to specify MPS planning at one site, and MRP planning at another. The planning system option will always default to "None." If the planning system is changed from MRP or MPS to "None," all planned orders should be deleted for that item site. A new group, "Create Planned Transfer Orders," will be added to designate that planned transfer orders from another site will be created rather than purchase orders or work orders for this item site. When this option is selected, an existing supply site for the item must also be selected.

Items and Item Sites

These screens will run a pre-check when deleting an item site to make sure that the item site being deleted is not referenced by another as a default transfer order supply source.

Run MRP by Planner Code and Run MPS

Alter the queries run by these windows in order to ensure that warehouses are processed in the order dictated by the site sequence settings.

Planned Order

The "Planned Order" window allows you to define what supply type the planned order will be. To open the "Planned Order" window follow these steps:

  • Go to "Schedule" from the top menu
  • Select "Reports" from the drop-down menu
  • Choose "Planned Orders" (alternatively, you can click "Planned Orders" from the icon menu)
  • The "Planned Orders" window will open, from here choose "YTRUCK1"
  • The "Planned Order" window will open for the "YTRUCK1" item number

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The enabled state and default type selection is based on a combination of item and item site settings as follows:

  • The type group is disabled until an item and site are selected.
  • "Purchased" is enabled as an option if the item type is purchased, an outside process, or manufactured and the selected item site is flagged to allow items to be purchased. Otherwise the option is disabled.
  • "Work order" is available as an option if the item type is purchased or manufactured and the selected item site is flagged to allow items to be manufactured, otherwise, it's disabled.
  • "Transfer order" is enabled if valid item sites exist from which the item may be transferred, otherwise it's disabled. The "from" site will only be enabled if transfer order is selected. The "from" site should default to the be the same as the demand site when it is disabled.
  • "Purchase order" is selected as the default option for purchased items unless the item site is flagged to create transfer orders.
  • "Work order" is selected as the default option for manufactured items unless the item site is flagged to create transfer orders, or is not a designated manufacturing item site.
  • "Transfer order" is selected as the default option for item sites which have been flagged to create planned transfer orders. The default transfer order supply site will be selected as the default when enabled.

The "Planned Order" window is used to edit planned orders which may include changing the order type, date or quantity. As such the CREATE button will be re-labeled to SAVE. Underlying code changes are made at the developer's discretion to support the notion of editing a planned order from this window.

Planned Orders by Planner Code and Item Displays

The planned order release process for transfer orders behaves like other planned orders. Modifying "Planned Orders by Planner Code" and "by Item" displays re-labels the "Site" as "To Site." A new column is then created, labeled "From Site." All pre-existing order types have both columns populated with the same site information while planned transfer orders specify corresponding from and to sites.

Right click options on the planned order list are as follows:

  • "Firm Order..." firms the order as it does today
  • "Change Order Type" is replaced by "Edit Order" which, when selected, will open the planned order in edit mode as described in the planned order section above.
  • "Released Order" will look for existing unreleased transfer orders with matching from and to site information. If it finds one or more, it asks you if you would like to append to the existing order or create a new one. After you make your choice, you are prompted with a transfer order item window that is automatically populated. When you click SAVE, the transfer order window will open populated by the transfer order that was created or appended to, the planned order is then deleted and the planned order window refreshed. This behavior is modeled after the process flow of releasing purchase requisitions which should be used as a reference.
  • "Delete Order" will operate as it does today.

Release Planned Orders By Planner Code

The "Release Planned Orders by Planner Code" window provides a mechanism to release planned orders in batches. With regards to the release of transfer orders, it will follow the same rules as the manual process above by aggregating all planned transfer orders specifying the same from and to site on to a single transfer order. In the manual process, you are prompted with an option to append to an existing unreleased transfer order if one is found. In this window, that option will be handled by a new check-box added to "Append planned Transfer Orders to existing unreleased Transfer Orders." If the option is checked the release process will first check to see if any unreleased transfer orders exist for a given from and to site combination. If one is found, planned transfer orders will be appended as line items to that order. If not, or if the option is not selected, a new transfer order will be created for which all items on the given from/to site combination will be appended.

To open the "Release Planned Orders by Planner Code" window, follow these steps:

  • Go to "Schedule" from the top menu
  • Select "Scheduling"
  • Select "Release Planned Orders" 
  • The "Release Planned Orders by Planner Code" window will open
  • Click the SELECTED radio button and choose the "MRP-MRP Items" option
  • Choose a "Cutoff Date"
  • The order will be ready to be released:

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More about xTuple for Distributors.