3.1 Tutorial Overview
The tutorial is designed to teach new users about pc/MRP. The tutorial
has 18 lessons. Below is a description of each lesson.
| 3.1.1 pc/MRP manual and Contents | A brief discussion about the manual and where to find things. |
| 3.1.2 The Bicycle Shop | Discusses what the Bicycle Shop is and how to utilize the tutorial. |
| 3.1.3 Settings and Utilities | Explains a few custom settings that users should learn about. |
| 3.1.4 Creating a Practice Directory | Shows users how to make a backup copy and practice directory of pc/MRP. |
| 3.1.5 Address Book Module | Discusses where all of your vendor and customer information resides. |
| 3.1.6 Inventory Module | Covers where all of you part information exists and how to enter and edit parts. |
| 3.1.7 BOM Module | Explains how to build the recipes that are your assemblies. |
| 3.1.8 Inventory Flow Model | Explains the general flow of material from order entry, to production, and shipping. |
| 3.1.9 Sales Order Module | Order entry for customer sales. |
| 3.1.10 Work Order Module | Order entry for scheduling or building to stock. |
| 3.1.11 Single Bucket MRP Purchasing | Material Requirements Planning. This tells you what you need to buy based on your demand from Sales Orders and Work Orders. |
| 3.1.12 Infinite Bucket MRP Purchasing | Advanced Material Requirements Planning. This tells you what you need to buy, when you need to buy it, and schedules your builds and issues to and from manufacturing. (MPS) |
| 3.1.13 Purchasing Module | Ordering from your vendors. |
| 3.1.14 Receiving Module | Vendors fulfilling Purchase Orders and creating Accounts Payable. |
| 3.1.15 Stock Room Module | Using the stockroom to convert parts to assemblies and adjust inventory. |
| 3.1.16 Invoice Module | Creating invoices and building Accounts Receivable. |
| 3.1.17 Accounting | Posting GL transactions, paying bills, receiving payments from customers, and Posting Financials. |
| 3.1.18 Some Final Thoughts | Discusses where to go from here. |
3.1.1 pc/MRP manual
The manual for pc/MRP is broken down into five sections: Standard Modules, Accounting, Utilities and Configuration, Optional Modules, and Trouble Shooting. Take a few moments to review the chapter headings and become familiar with how the manual is formatted. The manual will become an invaluable tool while you are learning pc/MRP. The manual is available both in the drop down menus within pc/MRP and in hard copy form from Software Arts. pc/MRP manual
3.1.2 The Bicycle Shop
The Bicycle Shop is the fictitious company that will be used in this tutorial. Through running the bicycle shop we will carry out several tasks that companies perform in their day to day operations. Since the tutorial is in htmL and uses your Internet Browser (no you are not online, the tutorial simply uses your browser) you will often be asked to refer back to pc/MRP. You should thus learn the ALT-Tab function. By pressing ALT-Tab you will be able to go back and forth between applications. If you have the tutorial open and pc/MRP or any other program, simply press and hold down on the ALT key, now hit the tab key once. On most Windows operating systems, this brings up a bar in the center of the screen that has all of your currently open programs. To easily go between the tutorial and pc/MRP use the ALT-Tab function.
This is the tutorial. You are in the tutorial NOW. The tutorial is a written tutorial. There are no parts to load and or data sets available. Users should learn how to enter parts and build BOMs and run the program. That is why the tutorial was written. You can expect the tutorial to take about 2-4 hours.
3.1.3 Settings and Utilities
pc/MRP can be configured to operate in several different business environments. The Utilities and Configuration Module covers in detail all of the custom settings available depending on your business circumstances. Before you start using pc/MRP "live" you should have a thorough understanding of what these settings are and what they mean to your company. For the sake of this tutorial there are just a few that will be addressed now. To access the settings and utilities menu from within pc/MRP select: Configuration, and Settings & Utilities.
Option 4, Inventory Adjustment Method (S/A/P/W/R)
We recommend "A." The tutorial is designed around inventory adjustment method "A." This is the recommended method for manufacturers, distributors, and retailers. By default pc/MRP is set to this. You might find a setting that better fits your specific requirements. However, to successfully utilize the tutorial you must have this option set to "A".
Option 8, Auto Accounting On or manual
We recommend "M." The tutorial is designed around manually entering GL transactions. By default pc/MRP is set to manual. It is also recommended that it is always set to manual and never changed to automatic.
Take the time to study the settings and utilities chapter. You may find several things that are of specific interest to your circumstances. By reading this section you will be able to form ideas on how pc/MRP will work for your company. Be sure to make a list of all of the settings that will need changing for pc/MRP to run successfully with your company.
Note: The trial version of pc/MRP will accept any password and does not need a configuration code number. As you view the Settings and Utilities simply press OK when it asks you for your configuration code number.
Note: Throughout the tutorial references will be made to executable paths in pc/MRP. These paths will always begin in the drop down menus accessible on the main screen in pc/MRP.
Example: Select: Configuration, About pc/MRP. This means select from the drop down menus, Configuration, and then About pc/MRP. These executable paths will be used in performing specific tasks associated with completing the tutorial. When a letter is underlined you can press the Alt key and the underlined letter of the desired function. You can also use your mouse. At this time press OK to return to the main pc/MRP screen.
To view your current Settings and Utilities start pc/MRP and select Configuration, and then Settings & Utilities. Hit Next or Previous as desired. Hit Cancel to exit the Settings and Utilities.
Note: Throughout using pc/MRP you will constantly accessing the drop down menus. At this time take a few minutes to review all of the options accessible from the drop down menus. The tutorial will be referring to the various modules in pc/MRP. To access the module that is being discussed select Modules from the drop down menu.
3.1.4 Creating a Practice Directory and Backup Copies
We are finished creating a backup copy. You will want to become familiar with creating backup copies and practice directories. The file pcmrpw.exe starts pc/MRP and when ever you want to do a test run on something, simply make a copy of the pcmrpw folder and double click on the exe file. Do not however leave several copies throughout your network. This simply confuses end-users. Furthermore, we recommend using option number 19 in the settings and utilities to change the color of the pc/MRP screen to an ugly blue in test copies. This helps users recognize that they are in a test copy.
We have thus far built a reasonable framework. You should have an understanding of how to: find things in the pc/MRP manual, navigate through the pc/MRP menus, how to find and change the settings and utilities, and create and use practice directories. We will continue with explaining how to enter vendor, inventory and BOM information. This will be the foundation that we use enter orders and complete the Order-to-Cash process.
3.1.5 Address Book
The primary source of all of your data is found in the Address-book, Inventory, and Bills of Materials modules. All of this data, once entered, is automatically entered into sales orders, purchase orders, work orders, and receivers. We will first discuss the Address Book Module. The Address Book Module is the location in pc/MRP where all customer, vendor, employee, and contact information will be stored. At this time take a few minutes to read the Address Book Module. This lesson will assume the chapter has been read.
3.1.5.1 Entering an Address
While using pc/MRP in the course of running your business you will need to add addresses. To add new addresses simply select Modules, Address Book, New.
Note: You will find that all of the modules are setup very similar. To make a new purchase order select, Modules, Purchase, New. To make a new sales order select: Modules, Sales, New. This is constant throughout the program.
After selecting Modules, Address Book, New, you will be prompted to enter the company name that you wish to add to the address book. Please enter: "ABC TIRE COMPANY."
Note: when entering an address where most of the customer information exists in an address that is already entered into the address book, you can select "Import Address information from existing address" on this screen, to save time.
After entering the company name press: OK
As you can see there are many options and fields to enter data for each entry. Most are self-explanatory. For further details on what each field does refer back to the chapter in the manual on the Address Book . At this time take a few moments to look over this screen and refer back to the manual if there are questions about specific fields.
Enter the data as described in the picture below. Except for the date ENTERED. This will automatically be populated by the date in your computer.
To complete entering this address select OK. If you wish to Cancel this entry hit Cancel.
At this time save this entry, by selecting OK.
You have now entered your first address into pc/MRP. Take a few minutes to enter the addresses as depicted by the picture below. All of these addresses will be utilized in the tutorial. For the two remaining ABC TIRE COMPANY addresses use the "Import Address information from existing address" function.
To view the addresses you just entered select Modules, Address Book, and Edit.
Note: The EDIT function is similar throughout pc/MRP. If you wish to edit a Sales Order select Modules, Sales Order, and Edit. To edit a receiver select Modules, Receiver, Edit.
If you selected, Modules, Address Book, and Edit you should now be at the basic scroll selection screen.
To edit choices you must choose "Edit" under the Action square. To simply view select "View." You are also able to sort your selection in a number of different ways. Select the gray square with the black down arrow to access the drop down menu under "Sort Order." This allows your search to be sorted as specified. You can enter partial information or the entire entry to be selected. You can also select the check box "Save Settings", and this will save the desired settings.
Note: This scroll selection and actual scroll screens are similar throughout pc/MRP. Sales Orders, Work Orders, Invoices, Receivers, Purchase Orders, Stockroom Transactions, and the BOM engine all utilize this same screen. (If you ever edit something and the changes are not saved, you undoubtedly had the View checked in the Action Square.)
At this time, within the Address Book Scroll screen, select "Company Name" for sort order and enter the letter "C" in the "BEGIN SCROLLING AT:" box.
Now press: OK.
The next screen allows you to scroll through all of your addresses sorted by Company Name beginning with what you stated in the "begin scrolling" at box. Here you can select the desired address entry. Notice that it started scrolling at Canonwale
At this time once again simply select any one of the address entries. After selecting an address entry, take note that there are several fields that have drop down menus. These fields are user definable through Option 52 in the Settings and Utilities.
Example: ADDR TYPE allows users to define their relationship with the entry. Examples: EMP for employee, VEN for Vendor, CUS for customer, PRB for accounts on probation.
Some special features of this page include the ability to view receivers or invoices, view the current balance or average to pay (hit "Update Balance"), and keep a logbook of conversations or extra customer data. At this time there are not invoices or receivers to utilize these fields, but we will change this as the tutorial progresses. Simply hit Cancel to exit this entry.
3.1.5.3 Editing an AddressTo edit an address select: Modules, Address Book, and Edit. (Similar to making new entries the edit feature is the same throughout pc/MRP. To edit Receivers simply select, Modules, Receive, and Edit. To edit Inventory simply select: Modules, Inventory, and Edit)
Go ahead and press OK to get to the Scroll screen.
Notice at the top left there is a field called ID CODE. This field is an automatically generated field based on the company name when the address is first entered. Also take note that we have three different addresses for the same company. One for our contact, another for shipping, and finally one for accounting. If you have different ship to addresses and or billing addresses for a specific company we recommend entering the SHIP TO and BILL TO addresses as different addresses and then editing the address ID by changing it back to the original ID and adding a B or S to the address ID code as shown in the example that follows.
For ease of use, we recommend fashioning all of your address entries that have multiple addresses in this way.
To edit the address ID select ABC - Accounting. Now all you have to do is delete the 2 and add a 1B. Now press OK. It warn you that you are attempting to do a serious thing. Press YES. The next screen is very important.
Always select to edit everything. The Address ID is used to keep track of everything that deals with customers and vendors. To mess this up is serious. Press OK. If pc/MRP finds any history for the old ID it will automatically update it to the new ID. You have just successfully edit your first address. Repeat this process for the Ship-To address. Though both of these edits and understanding the address ID are important, let's go ahead and make another more traditional edit.
Select: Modules, Address Book, and Edit, find the Canonwale entry and select Edit in the Action square. If you do not know how to find this address or what the Action square is please scroll to the top of the address tutorial and start over.
Once you have found this address, press enter, to bring up the main address screen with his address. Change the phone number to 222-444-5555.
Press OK. This saves the changes made.
Look up the address again and see if the changes were saved. If the changes are not there, then you never made the changes, or you selected view rather than edit in the "Action Square," or you selected cancel after making the changes. If the changes are there, congratulations, you have successfully edited another entry.
Note: In view mode changes will not be saved.
Finally to delete an address or anything within pc/MRP you must take two steps. The record must first be marked for deletion. Then, the records marked for deletion must be deleted.
By example, find the address, "Bad Customer" and bring up this address as if we are going to edit this entry. Notice the Delete square under the OK and Cancel buttons. If the Delete button is not present, you are not in edit mode. Select, Cancel, then Modules, Address Book, Edit, "Edit" in the Action square and find the "BAD CUSTOMER" entry. Press Delete. This marks the record for deletion. This is the first step in deleting a record. If you were to view this entry again you would see a picture similar to the one below.
Notice that at the top of the record is says it is marked for deletion, but not removed from disk. The next step to take is to select, Modules, Address Book, and Remove Marked Records for Deletion. This two step deletion method is the same throughout pc/MRP.
Note: Once your software is activated into the full version deleting records marked for deletion will be secured by your configuration code.
You have now successfully deleted your first record.
Note: All fields within the address entry are manually entered excluding: CUR BALANCE. CUR BALANCE is the customers current balance and is increased when invoicing and decreased upon payment and or running either the Accounting function of updating Address Balances or creating a billing summary.
We have just learned almost everything about the Address Book. The steps above can be repeated for entering, looking up, editing, or deleting any address in the address book. For reports and label making refer back to the manual. We will continue with the lesson on data entry with the Inventory module.
3.1.6 Inventory Module
The Inventory Module contains price, quantity, lead time data and a number of other fields associated with parts, labor parts, and assemblies. Inventory does not contain information about how the assemblies are built. This is in the Bills of Materials. BOMs will be covered in the BOM lesson.
To become familiar with what the various fields do in the main inventory screen, please take a few minutes to read the Inventory Module chapter. You should not begin this lesson without having an understanding of the Inventory Module.
There are several things that should be considered when entering your own parts and creating a part number scheme. For the purpose of this tutorial we will keep all of the standard settings. As you begin entering your own parts you will want to read about Options, 28, 29, 48, and 49 in the Settings and Utilities module. For special cases and consignment parts read chapter 15.10.1, Special Cases (Non Stocking Rep,Outside Mfg,Consign,RMA)
3.1.6.1 Entering New PartsSimilar to the Address Book, when an end-user wants to enter a new part, simply select: Modules, Inventory, and New. You have the ability to make a few different choices at this time. Select next available part number.
Please enter the data so it appears like the picture below.
Since we build this part select Sales Price. Take a few seconds to understand the sales price matrix.
Note: This is an "Assembly." Thus, in the "PART/ASSY/LBR field an "A" was entered
Note: The PO Ratio field is set to one. This field must be 1 or greater. If it is set to ZERO purchase orders will be INCORRECT.
With all of the information entered select Save to have this entry saved. Congratulations, you have entered your first part.
3.1.6.2 Editing PartsAt this time we will edit the part we just entered.
Select: Modules, Inventory, and Edit. Select the same part number we just entered. Edit this part so that the Lead time is 2 days. Select Save.
Note: Did you select "EDIT" in the action square?
After making sure you successfully changed the lead time for the bike assembly, take a few minutes to enter the remaining parts for the bike as the picture describes below. For the sake of time many of the basic fields are left blank. Please enter 2 days for the lead times on all parts and assemblies.
Enter the parts listed below. To enter a vendor select the Vendor Lookup check box and type in the first few letters of the vendors name in the Vendor #1 field and press enter. Also enter a purchase price of $5.0000 for all items except the bolts. When you get to the bolts enter purchase price of $00.2500 for quantity 1 and enter quantity 100 at $ 00.1000. Furthermore, be sure to enter a PO ratio of 100 for the bolts. We purchase bolts for the bicycle assembly in boxes of 100.
Note: If you edit the part number, number, you must select "Change Part Number" from the Inventory drop down menu. This will allow you to change the part number in all applicable modules in just one step.
Similar to the Address Book there are numerous fields that do a variety of things. All of these fields can be manually edited. Most of these fields require manual data entry. Most of these fields are self-explanatory. Several of these fields are automatically updated through performing specific actions.
Below is a list of those fields that are automatically updated and how they are updated.
STD COST/UNIT: Standard Cost per Unit.
pc/MRP calculates the
standard cost per unit using purchasing history by running the cost roll-up
feature in Inventory and selecting Standard Cost. This STD COST/UNIT field is
populated when you run this feature.
AVE COST/UNIT: Average Cost per Unit.
pc/MRP calculates the average
cost per unit using purchasing history by running the cost roll-up feature in
Inventory and selecting Average Cost. This AVE COST/UNIT field is populated
when you run this feature.
LAST PO COST: Last Purchase Order Cost.
This field brings in the
cost of the last purchase order made for this part.
QTY ON ORDER: Quantity on Order
This field contains the quantity on
order from purchase orders. This field increases when purchase orders are made
and decreases when receivers are made. This feature will be further discussed
in purchasing.
QYT ON DEMAND: Quantity on Demand.
This field contains the quantity
on demand from open work orders and open sales orders. This field increases by
creating work orders or sales orders. This field decreases when sales orders
are invoiced or parts are converted into assemblies from the work order.
Furthermore, this field can be updated when edits are made to sales orders and
work orders by running the Audit On-Demand Quantities feature in the Sales
Order Module.
QTY AVAILABLE: Quantity Available.
This field contains the quantity
available after allocation. This field is updated by running the single bucket
purchasing report or the optional module Infinite Bucket MRP. The MRP programs
will allocate parts on hand and on order and populate the Quantity Available
field with the quantity available after allocation.
These features will become more obvious as we make sales and work orders and run MRP reports. For the time being, we will just let this sink in.
Note: pc/MRP does not allocate things every time an order is entered. The quantity available field is only updated as described above.
Deleting parts is exactly like deleting addresses. You must first mark the record for deletion and then remove marked records for deletion. To test this delete the TUBE ASSEMBLY, part number 000000012. Once again, in the full version, deleting entries will be secured by your configuration code.
Note: You can select alternate part numbers by entering alternate parts in the alternate part matrix. Alternate part numbers can then be uploaded onto the BOM module through the settings and utilities option number 54.
You should now be familiar with viewing, editing, and entering parts. If you have any questions about what these fields do or how to perform the tasks above, start the lesson over and refer back to the manual.
Up to this time we have discussed the Address Book and Inventory Modules. This next section completes the Data Entry Lesson by covering the Bills Of Materials Module.
3.1.7 BOM Module
The BOM module is where all of your bills of materials or recipes for assemblies will be stored in pc/MRP. At this time take a few minutes to read the Bills of Materials chapter in the manual. This lesson assumes you have read the BOM chapter.
The BOM module is set up very similar to all other modules. To edit a BOM simply select Edit from the BOM menu. To enter a new BOM simply select New from the BOM menu. Most modules when printing have the Report option. For the address book and BOM module end users select Print.
Note: All parts within a BOM must exist as an entry in inventory before you can create that BOM. Assemblies can exist in inventory but do not have to exist. If an assembly does not exist in inventory the BOM module will automatically create one.
Before we create a BOM in pc/MRP it would be best to see one on a piece of paper.
Bicycle BOM
Notice how all of the various levels are separated by periods. Parts are labeled as PART and bills of materials are labeled as BOM. From this picture we can deduct that parts and assemblies: 000000002, 000000003, 000000005, 000000006, 000000007, 000000011, 000000013 are all on the first level of the Bicycle BOM. The WHEEL assembly contains parts 000000004, 000000013, and 000000009 and the BOM 000000012. The TUBE assembly contains two parts, 000000008 and 000000010.
To reinforce this idea of indented bills of materials we will make this BOM using the parts entered into pc/MRP in the Inventory lesson.
3.1.7.1 Entering Bills of Materials
We are now going to begin by entering the lowest level of the Bicycle BOM.
Select: Modules, BOM, New.
Enter BOM number: 000000012 with a description of TUBE ASSEMBLY.
Select OK
You should now be at the main BOM data entry screen as depicted below.
Notice that the cursor automatically starts at the part number. We have just created the "TUBE ASSEMBLY." Now we have to add the parts and assemblies for this BOM level.
Simply type the first few numbers of the NGF Tube and press enter. This will take you to the scroll screen to select that part. To select that part scroll to it and press enter. We want one TUBE per TUBE ASSEMBLY. We also want to add one additional part so select Add Item. Notice that the NGF TUBE was now added and the cursor started back at the part number entry field. Enter the second part we want in this assembly, the STEM. Enter quantity 2 for the STEM. We are now finished building this level, press Finished.
Note: Bills of Materials are assembled in the BOM module one level at a time.
Note: reference designators can be infinite in length. Reference designators allow users to have instructions where each part goes in the assembly.
Note: Labor parts can also be entered into BOMs. This allows users to calculate theoretical job costs.
Now we are going to add our next level. This level we will add not only parts, but the newly built TUBE ASSEMBLY.
Select: Modules, BOM, New.
Enter BOM number: 000000002 with a description of WHEEL.
Select OK
This entry is a little different however. The WHEEL already exists in inventory. pc/MRP is going to warn you about this. Go ahead and select Proceed.
Now we can add our parts just as we did before. Enter the first part, Dirt Teaser Tire. Click on "Add Line Item". pc/MRP will warn us one more time that we are changing the WHEEL part into and assembly and just press Overwrite. This will change the P/A/L field in inventory into an A.
Now simply add the remaining items. Add the spokes, quantity 40. Add a few bolts, quantity 4. And finally add the TUBE ASSEMBLY just like you would any regular part. Press Finished.
Now on your own.....
Select: Modules, BOM, New.
Enter BOM number: 000000001 with a description of BICYCLE TOP ASSEMBLY.
Select OK
Enter the items that finish off this assembly to that it matches the picture below.
We have just completed the the entire Bicycle BOM.
A common mistake in editing and creating BOMS is depicted by the picture below.
When this happens simply select Remove. You selected Add Item rather than selecting Finished when you were done....and then you selected Finished. pc/MRP simply thinks you are trying to add a blank inventory item.
3.1.7.2 Editing the Bills of Materials.
Similar to everything in pc/MRP if you wish to edit something, select the module you wish to edit and select edit.
Select, Modules, BOM, and EDIT. Select BOM 000000001. When you select an item that is an assembly (depicted by an A in the Type column), you can use the STEP UP and STEP DOWN features to scroll through the various levels of your assembly. Scroll to the TUBE ASSEMBLY. In the quantity field under BOM DATA enter "1.0000" for the STEM quantity. We do not want do double up on or STEM ordering.
Are you in Edit or View Mode?
Now just to see what we have done select Modules, Boms, Print BOMs/Pick List/Where Used and select the exploded-costed report. Scroll to enter your BOM number. Select Print - Narrow and press the OK button. Your report should look very similar to the example report at the beginning of this section. If it does not, edit the BOM and run the report again. It will need to match for our purchasing results to match.
Note: If you wanted to change the part used in a specific place simply select the part you wish to change under BOM COMPENENTS and enter the replacing number in the Partnumber field under BOM DATA. If you wanted to scroll to the replacing part simply type in the first few numbers of that part number and hit enter. This will bring up the scroll screen.
3.1.7.3 Deleting Parts Within a BOM
Similar to all other areas of pc/MRP the deletion process is a two step process. You must first mark the entry for deletion and then delete marked records. If you go into a BOM to delete a part and the delete button is not accessible, you either do not have the Action Item Edit selected, or you do not have deletion rights in the Advance Password Module.
Note: There are several useful options in the BOM drop down menu. From that menu you can delete a BOM, duplicate a BOM, change a BOM number, change the BOM description, and Audit BOMs.
Note: You can sort the part in this level by selecting the headers under Components.
Note: You can view the image for that specific part or BOM by selecting BOM Image or PART Image.
Note: You can select and view alternate part numbers. (Updated through Settings and Utilities, Option 54.)
Note: bills of materials can have 26 levels in pc/MRP.
We have now covered data entry into the Address Book, Inventory Module and BOM Module. The next lesson covers the Order-to-Cash process.
3.1.8 Inventory Flow Model
pc/MRP has a simple Order-to-Cash process. Take a few minutes to view the diagram below.
As you can see Sales Orders and Work Orders start the entire process. These orders are based on your demand from customers or desire to build items to stock. Items that are available for sale are directly invoiced, inventory is automatically deducted from stock, and we can begin building some A/R (Accounts Receivable). Sales Orders on order entry and Works Orders that have to be built take a different path. The will go through the MRP process, purchase orders and receivers will be made for the piece parts required and build A/P (Accounts Payable), the stockroom will be used to convert parts to assemblies, and finally we will sell the item once again building A/R. It is important to understand this basic process. Through the next several sections we will follow this process.
3.1.9 Sales Orders
Sales orders and work orders generate demand for parts and assemblies. This demand sets in motion your purchase orders, receivers, stockroom, invoicing, and inevitably accounting. pc/MRP can use work orders and sales orders in a number of different ways since both can be issued into manufacturing. For complete details refer to the Sales Order Module and Work Order Module in the manual.
In short, the first method uses work orders to build to stock and sales order to build per customer order. The second method pc/MRP uses work orders to forecast demand while sales orders represent actual demand. pc/MRP can do this because demand from Sales Orders and Work Orders can be included or excluded from purchasing requirement reports. The differences between these two methods will become apparent once we run our MRP purchasing reports. For now, this tutorial will use method one, where we use work orders to build to stock and sales order for customers. The important thing to consider is once you have chosen how your are going to utilize Sales Orders and Work Orders you should stick to this method. If you are constantly changing how requirements are generated, you are increasing the probability of making mistakes.
3.1.9.1 Entering a Cash and Carry Sales Order
We will first simply create a Sales Order a few bikes.To do this, first view the bicycle assembly in inventory (part 000000001). Make sure the quantity in Area Stores is 2. If it is not edit the quantity so that it is 2.
Now, select: Modules, Sale Order, and New.
The next screen allows the user to select sales type, terms, tax code, product issuing area, and shipping method. For the purpose of this tutorial we will really only discuss the Sales Type. The other fields are explained more in the Sales Order Module chapter. Understanding the Sales Field type is essential however and deserves more attention.
The Sales Type field is essential to understand, because it directly effects inventory and invoicing. Sales Types entered as Cash and Carry or On Account and Carry automatically decrease the stores quantity of the line items on the sales order and creates an invoice. Thus, if you have these items in stock or not, by telling pc/MRP you are carrying the line items out the door, on-hand quantities will decrease.
Note: pc/MRP will not automatically convert parts into assemblies or back flush in the sales order module. All back flushing is done through the Stockroom Module or by running the convert parts into assemblies command.
Order Entry sales simply places demand on the line items chosen in the sales order. These items will be due on the date as specified by the end-user in the DATE REQ field. Demand for sub-components, that are part of the sales order line item, is not created until the MRP purchasing reports are ran. Invoicing is then done once the product has been assembled and is ready to ship.
To make this more clear, select a sales type of On Account and Carry, issuing from area 1, press OK.
On the sales order entry screen notice that at the bottom of the screen there is an Auto Look-up and Data selection box. Having the part number and root address checked means that data from the Address module and Inventory module will automatically be entered when you choose an address or part that already exists in those DBF files. To make an address or part from this screen select one of the check boxes under Data. You can select Bill Address and Ship Address if you need to change the BILL TO or SHIP TO addresses.
Note: To change the BILL TO or SHIP TO address, the customer address or part after initial selection simply check the desired box, highlight the root address of the desired entry, type in a partial for the entry and hit enter. This will bring back the scrolling box for selection of the correct entry.
At this time check "Make Address." We need to enter our new customer, TIM. Tim is purchasing two bicycles today. Once you have pressed, Make Address, enter some applicable data for Tim in his address entry. Then select OK to finish the address entry. Now put the cursor back into the top left CUSTOMER field and type T and press enter. This allows you to scroll to the applicable address. Select Tim as our customer and press enter.
The customer data for TIM should have automatically appeared on the sales order screen. Now put the cursor down into the description field and type "BICYCLE" and press enter. This automatically brings up the part number, model number, description, and price. We could have also selected the "BICYCLE" by entering the applicable part or model number.
Enter two for the quantity of bikes being purchased. Notice the SC field. Do not change this field. This field abbreviates the Sales Type and Tax Code information.
With the address entered and the bicycle assembly selected press F1. This is a shortcut method to view the part selected in the sales order. The inventory screen for this assembly should appear. Notice that we just happen to have 2 finished bikes in area Stores (1). Press ESC to get back to the sales order screen
Select Finish on the sales order screen.
This next screen confirms that an invoice is going to be made since the sale was entered as On Account and Carry or Cash and Carry.
Press OK.
This screen explains that two bicycles are being removed from inventory area One.
Press OK.
If you wish to print the Invoice you can do so at this screen.
On this next screen, if you wish to view or print a shipping label press OK.
On the final screen we can select NO.
At this time go to the inventory module and view the bicycle assembly part. Notice that in area one the quantity was driven to 0. As explained above and reinforced with this sales order, if you choose a sales type as cash and carry or on account and carry, it is automatically invoiced and the quantity field will decrease in the area chosen and by the quantity chosen in the sales order.
3.1.9.2 Entering Order Entry Sales Orders
Now, enter a new sales order for Tim but select Order Entry as the Sales Type. Put in quantity 1 and a DATE REQ (date required) of one week from today’s date. (The current date plus seven days.)
Note: to add additional line items we can select Add Item. Of-course to view these various items you can press Back and Next.
After entering the sales order view the bicycle assembly in inventory. Notice that since this is order entry we have only created demand for this assembly. The QTY ON DEMAND field should be 1.
Take a few seconds to view the other parts in this assembly. Notice nothing has changed with these parts and the various quantity fields associated with these parts. Once again as mentioned above, when we run our purchasing reports these fields will be updated.
3.1.9.3 Editing a Sales Order
To edit a sales order or work order is similar to editing any other entry in pc/MRP. Simply select edit in the drop down menu for that module. It is important to note however that if you frequently edit sales order item quantities that you should run the Audit sales order function. This function re-populates the on-demand quantity in inventory representative of updated sales orders. Edit the order entry sales order for TIM to be quantity 2. Make sure the edit took.
Go back and look in inventory. Notice that the On Demand field did not change. Run the Audit Ondemand Feature under Sales Orders to correct this. Once again however, our MRP reports will also update this.
3.1.10 Work Order Module
Besides our existing sales order, we want to build two bicycles to stock. At this time enter a Work order for two additional bicycles with a DATE REQ of 14 days from now. Work orders are entered the same way sales orders are. You do not need to enter a receiving customer though. Simply enter the desired assembly or subassembly, the quantity and date desired, and press Finished.
Note: Work orders only allow one line item.
Once again to edit work orders is similar to all other modules. Simply select edit in that module.
At this time we have entered demand for 4 bicycles. Take note in the inventory module that none of the subassemblies have been affected yet. The only thing that has happened is the QTY ON DEMAND for the BICYCLE has gone up. Since we have nothing on hand to build these bicycles we will now run our MRP purchasing reports. These reports will tell us everything we need to buy to fulfill our orders. We will run two purchasing reports, our standard MRP Single Bucket report, then the optional Infinite Bucket MRP report. After that we will briefly compare the two. Of-course from there, we will make purchase orders to fulfill the demand, receivers to receive the parts necessary to build, issue the builds to the stockroom, receive finished goods back into inventory, and then we will be ready to invoice.
3.1.11 MRP, Scheduling Production, and Purchasing
The Purchasing MRP (all parts required) report and Infinite Bucket optional module is where all of the demand calculations are made. Once we run one of these reports, demand will populate all parts necessary to build everything that has been entered as a sales order or work order. We will first run the standard MRP purchasing report.
Select Modules, Purchasing, Reports. On the drop down menu, scroll to the bottom of the list and select the MRP Report (all parts required).
Note: End users can choose to include or exclude demand from Sales Orders or Work Orders. As mentioned above, this allows users to use work orders in several different ways and prioritize demand.
Note: The Consolidated report looks at both true demand from Sales Orders and Work Order and takes into consideration MIN and MAX quantities set up in inventory. The MIN/MAX report only takes into consideration MIN and MAX quantities that were populated in the inventory entry screens.
Note: Print Trace Calculations creates a report that shows where demand is coming from for each individual part.
In the Include Demand from field leave the Sales Order and Work Order check boxes checked. Select Consolidated, area 1 Stores, Sort By Vendor, Display or send it to the Printer and press OK.
A report is created that shows all current demand. Take note that all
demand is representative of needing to purchase parts to build 4 bicycles.
Furthermore, even though our sales order is not due for a week and our work
order is not due for 2 weeks the standard MRP not utilizing lead-times does
not schedule purchasing or builds.
The Excess Inventory Report allows users to more closely track inventory. Go ahead and view this report as well by choosing the constraints you would like. At this time there will be really no misallocation.
After viewing the Excess Inventory Report or hitting cancel the next option is to automatically create purchase orders. At this time select NO. We are not quite ready to make purchase orders yet.
Take a few minutes to see all of the changes made in inventory. For all parts required the quantity available decreased since we do not have these parts available. Once again, the quantity available field in inventory is only updated through running the MRP reports. If we had parts in inventory the quantity available field would be the difference between existing inventory, on order parts, and demand representative of the constraints chosen. Further more, nothing in the sub-assemblies used has changed. pc/MRP does not place demand on these sub-assemblies unless they are directly created through a Sales Order or Work Order. Only the quantity available field for individual parts utilized in the builds have changed.
If you have a printer hooked up to your computer re-run the report above and rather than selecting display select Print Narrow. This way we will have a printed report to compare against the Infinite Bucket report. Once again select NO when you are prompted if you want to Automatically create Purchase Orders.
3.1.12 Infinite Bucket MRP Purchasing Reports
This time we will run the more advanced MRP, the Infinite Bucket purchasing report. What this will basically do is utilize our lead times and provide a schedule to buy, issue, make, and sell.
Note: The Infinite Bucket MRP is an optional module. This module like most of the other optional modules is fully testable in the trial. To activate this module or any other optional module select Configuration, Module Activation, Activate and Yes. Optional modules are testable throughout the use of the trial. Once the trial is activated into a single user or multi-user version, optional modules can be activated for a 10 day trial period.
After activating the Infinite Bucket MRP module, select optional, Infinite
Bucket. You should have the options as depicted below.
Select Generate Action Items. This step creates a data base that we will
access to query our purchasing reports. This action should be performed around
once a week pending on how fast things are in your business. Select to run your MRP on both Sales Orders and Work Orders and use just inventory area 1.
You will see several screens flash in front of you. If you receive any errors in this process you will have to view the errors and go back and fix them. Once the MRP generation process is complete you will be back at the main pc/MRP screen.
Now select Optional, Infinite Bucket, and Print Action Item reports.
We will keep the default settings to look at this report. However you should take note at all of the different options available to sort parse the data. Your report should look similar to the picture below.
Once again, if you have a printer that you can print to, print this report by going through the same steps as above and sending it to the printer. If you have additional calculations that need to be performed you can also send it to an XLS spreadsheet.
Note: At this time nothing has changed in inventory after running our regular purchasing report. Companies do not have to run both MRP reports. Either companies want the extra planning module or simply use the standard MRP Report (all parts required).
Take a few minutes to study the differences between the two different MRP reports. If you have a small company and like to take the time to plan things yourself, you might find the standard MRP in the Purchasing module adequate. If you want to schedule things and produce more detailed reports about what to do and when, then the Infinite Bucket is your best bet.
We are now going to act on the recommendations of our MRP reports and purchase the required parts for the sales order and work order entered above.
3.1.13 Purchasing Module
Entering purchase orders is the same as sales orders. This time however we are entering individual parts or purchased assemblies and choosing a vendor. At this time take a few minutes to read the Purchasing Module chapter.
Choose the Banana Bicycle part in inventory. Make sure this part has a vendor. If this part does not have a vendor add an applicable address or choose and existing vendor. After viewing this part in inventory take note what the quantity available field is -4. Now go to the Purchasing module and select New. Choose the bicycle seat by entering in the part number or entering the description. Vendor data should automatically appear.
Once again take note of the Auto Look-up and Data check boxes. These can be used to save time.
By entering the part number or description first a vendor list will pull up. If you were to enter the quantity first the STD/COST per unit price break is automatically entered with the best vendor for that quantity.
To add items to this purchase order select Add. These buttons by now should be very familiar.
Note: The Clone button and Breakdown buttons can be utilized to automatically duplicate or break down orders to have multiple shipping dates.
After selecting the Banana Seat enter the quantity of 4 and a due date of tomorrow. Press Finished. Now, go back to the inventory module to see what fields have changed. The QTY ON ORDER should now be 4.
Note: If purchase orders are often being edited the Audit PO function
should be ran. This function automatically corrects the QTY ON ORDER in the
Inventory Module.
Now that we have made our first purchase order we will have pc/MRP do the rest of the work. Go to the optional module, the Infinite Bucket, and select to Generate Action Items. By creating the purchase order our requirements have changed. After generating our action items you can view the reports and see that we no longer have a buy requirement for the seats. Now select Optional, Infinite Bucket, and Automatically create Purchase Orders. Select Weekly Orders under ORDER CONSOLIDATION. This will consolidate all of the multiple orders for the same part by week.
Note: Automatically creating purchase orders is very handy. However, take a look at the purchase order for my BOLTS. It did two things that we could have prevented. #1, we did not enter a standard order quantity into inventory. If we had entered a standard order quantity of 100, then we would have had one purchase order for quantity 100. #2, when we choose to automatically create purchase orders pc/MRP does not take advantage of any price/quantity breaks. To take advantage of our price break we would have had to manually entered the purchase order. These are all things to watch for.
After automatically creating the purchase orders we will bypass a few days and receive these purchase orders into inventory.
3.1.14 Receiving Module
The Receiving module is the next logical step in this process. We must receive parts and inform pc/MRP that we have parts to build our assemblies. This is what the Receiving module does. Refer to the Receiving Module chapter for complete details.
At this time enter a Receiver for the Banana Seat. As with the creation of new entries throughout pc/MRP, to do this, select New in the receiving module. You will be able to scroll for the associated purchase order and press OK. Once we have went through several screens informing us of everything that pc/MRP is doing we can accept this transaction. Continue to enter the rest of the receivers. You may also notice once you have started on a purchase order that has multiple line items you do have the option to automatically receive the remaining line items. You may want to take advantage of this to expedite this process.
Note: pc/MRP can receive partial shipments. You can also edit receivers. However there is not an audit function to correct edited receivers. Once a receiver is edited end users must edit both the corresponding purchase order and inventory parts. With out editing both areas your quantities in stores will be incorrect.
Now that we have received our parts into inventory we are ready to begin building. We will next utilize the Stockroom Module to convert parts into assemblies. Before convert these parts into assemblies. Once again view several parts in inventory. Your stores quantity should have increased. Also notice that for the top bicycle assembly still nothing has changed. You could even run an additional MRP and you will find that the Single Bucket MRP has no Action Items. The Infinite Bucket however will still have issues, sales, and, makes
3.1.15 Stockroom Module
The Stockroom module is where we turn piece parts into assemblies, or back-flush. Similar to everything in pc/MRP, when you want a new transaction simply select New in the module desired. In this case select Modules, Stockroom New. There are several types of transactions available. To issue sales orders and work orders to the manufacturing floor use the I type transaction. To review the rest of these transactions refer to the Stock Room Module.
At this time select the I type transaction and select the order entry Sales Order that we created. Enter and accept the issuing quantities. Notice in inventory parts have now moved from stores area 1 into WIP.
To receive this back as a finished assembly enter the R type transaction in the stockroom. Choose the Sales Order issued and receive this Sales Order back into area 1.
Take a few minutes to review this process entire process. Go into inventory and view a few parts and the final Bicycle assembly. You will notice that all of the individual component parts have decreased the precise amount used to build the bicycles. The bicycles in inventory have now increased.
Note: Once received, pc/MRP will only track one serial number per invoice line item. For multiple serial numbers per line item the optional module Serial/Lot Number Tracking can be utilized.
Note: You have the choice to issue sub-assemblies or parts only. You can also do partial issuing and then utilize the F or M stockroom transactions for makeup issues. There is also an undo feature, transaction T that takes back issued parts.
Note: If you are often editing stock room transactions you can use the audit WIP function in the Inventory module to help clean things up.
Note: It is always best to utilize the various stockroom transactions to help clean things up when mistakes have occurred. This creates a record for each transaction. When inventory is simply edited there is often no paper trail. To help with this you can lock-up various editing processes through option 62 in the Settings and Utilities.
Note: Work orders are issued and processed in the exact same way as sales orders.
Go ahead and build the work order too.
The final step in this process is invoicing. In this step we will relieve quantities in the storage areas representative of the order entry sales order we entered. This step is taken in the Invoicing Module.
3.1.16 Invoice Module
To enter a new invoice select, Modules, Invoicing, and New. You will have to choose the terms of the sale and accept the invoice information. Once again if the invoice must be edited, you may wish to edit the sales order as well. You may even want to edit the sales order first, thus the invoice will be automatically representative of the sales order. For more information refer to the Invoice Module in the manual.
Go ahead and invoice the sales order on account. Once you have invoiced the sales order, once again go into the Inventory Module and view what has changed. WIP for the parts used was cleared through the Stockroom, and now inventory for the finished assemblies has decreased by the amount of the sales order. The sales cycle is now complete. The process to pay vendors and track accounts receivable has just begun. If you anticipate using pc/MRP for accounting, continue. If pc/MRP is going to be just an inventory and planning tool now might be a good time to clean up this trial copy and start entering some of your inventory.
3.1.17 Accounting
For the purpose of the remainder of this tutorial we will use the standard Chart of Accounts. Users do have the option to modify the existing accounts, but we will not do that here. For further information about the entire Accounting Module you can start with the Accounting Overview.
This Accounting tutorial will walk you through posting A/P and A/R, entering a beginning balance for checking, and paying bills. To start things we will simply enter a starting balance for checking.
3.1.17.1 Entering Starting Balances
All starting balances can be entered through a one sided "A" type transaction. For complete details refer to the accounting module. We will however at this time enter a beginning balance for checking of $10,000.00.
Select Modules, Accounting, GL, and New. Select the "A" type transactions and press OK. Enter the transaction as depicted in the picture below and press save. (In the Debit Field type 10200000 and press Enter)
Entering beginning balances is as easy as that. Debits will not match credits on our beginning balance entries so if pc/MRP warns you about the imbalance press O.K. If we were setting up our entire company we would continue debiting and crediting the necessary accounts. We just want however enough data to look at a good close and post the month with financials.
Thus far we have built an invoice and receiving history through creating invoices and receivers. We should take note however that in accounting, other than our single entry into our Checking Account nothing has happened. If we were to select Modules, Accounting, GL, and Edit, there would only be one transaction. The GL is only changed by actually posting transactions to the GL.
With almost everything we do other than entering beginning balances and adjusting entries pc/MRP will require us to enter two transactions. One transaction posting the A/P or A/R to the GL, and, the other transaction registering the payment by a customer or to a vendor. The act of posting the A/P and A/R is what will build your aging reports. The transaction registering the payment completes the transaction. We will first post both an invoice and receiver.
3.1.17.2 Posting Transactions
Take a few seconds to view the invoice and receiver made. (Modules, Invoice or Receiver, and edit.) Find the Posted and Complete fields in both records. These fields are automatically populated as we post and complete each invoice and receiver. Do not manually populate these fields unless the manual specifically tells you to. We will come back to these fields as we perform these transactions.
Select Modules, Accounting, GL, and New. Take a few minutes to look at all of the available transaction types. pc/MRP will automatically DEBIT and CREDIT the necessary accounts based on the type of transaction chosen. Some of these default accounts can be changed, but if additional accounts need to be debited or credited the end-user will have to manually enter those account numbers.
Intuitively, we can see that to post or register and Invoice we would select the "O" type transaction. To post a receiver or accounts payable invoice we would perform an "I" type transaction. Select the "O" type transaction and press O.K.
pc/MRP will automatically assign the next available transaction number. (Never edit the transaction number. Always allow pc/MRP to automatically assign the transaction number.) Press O.K.
The next screen is asking us if an Invoice or A/R voucher was previously entered. Select Yes since we know we have two invoices to TIM. Scroll to the first Invoice and press enter. You can see that pc/MRP has automatically Debited and Credited the applicable accounts. Select Save. That is all it takes to post an Invoice.
Take a few seconds to view that invoice and notice that the POST field now has a "Y". Post the other invoice to TIM using the same method.
Now perform an "I" type transaction on the first receiver. pc/MRP will take you through the same steps: automatically creating a transaction number for you, asking you if you have previously entering the receiver or A/P voucher, allow you to scroll for that record, and finally automatically Debiting and Crediting the necessary accounts. Press save to save this transaction and post the remaining receivers.
You probably already noticed, but just like there are transactions to help you post A/P and A/R there are transactions to help you receive payment from customers and pay vendors. We will first receive payment from a customer.
3.1.17.3 Receiving Payment from a Customer
Select Modules, Accounting, GL, and NEW. The "R" type transaction receives payment from customers. Perform the "R" type transaction on both Invoices. (You have to perform the "R" transaction twice.) You should now be able to view the invoices and see that both the posted and complete fields are populated with a capitol "Y".
3.1.17.4 Paying Bills
Paying bills can be performed in two different ways. The first method utilizes the "E" type transaction in the GL. Choose the first receiver for the Banana Seat and perform an "E" type transaction against it. The transaction is exactly the same as all other accounting transactions. pc/MRP will: automatically creating a transaction number for you, ask you if you have previously Posted the receiver or A/P voucher, allow you to scroll for that record, and finally automatically Debit and Credit the necessary accounts. Press save to save this transaction. Always print the check even if you send it to the display. The act of printing the check populates certain fields in pc/MR. The "E" type transaction is a fine method to pay one A/P at a time. However the Pay Bills/Print/Clear Checks feature is a lot more efficient for paying multiple vendor invoices.
To pay the remaining vendor invoices select Modules, Accounting, and Pay Bills/Print/Clear Checks and select, Select PayBills, Print Checks. This screen as provided below allows you to select the checks you want to pay.
Select bills to be paid from: Over 0 days old. Notice that the check box Include Posted Bills Only is checked. If you ever think you should have a bill to pay and it does not show here, you probably have not posted the receiver or A/P voucher. Press O.K.
Even though we entered the beginning balance for the checking account, because we have not closed a month yet, we will need to re-enter the balance. Choose to manually Enter the $10,000.00.
You will see on the next screen all of the aging A/P. You can select multiple or individual A/P transactions to be paid. Select both of the transactions to be paid. Notice at pc/MRP will keep a running balance for you. Press O.K. to make the check.
pc/MRP will automatically assign a transaction number for you and automatically debit and credit the necessary accounts. Press O.K. then save. Always choose to print the check. In the top right corner of the next screen you can enter your check number. Go ahead and print this in a regular piece of paper. (If you have existing checks from another software package we should be able to modify our checks to match yours.)
3.1.17.5 Editing the GL
We do not recommend editing the GL. You should always choose to make adjusting entries. If you do choose to edit the GL you will be asked the question below.
Always choose to manually edit the GL. If you choose to automatically edit the GL and when you made the original GL transaction you added additional accounts to DEBIT or CREDIT, it will default back to the standard debits and credits.
3.1.17.6 Posting the Month with Financials
Finally we are at the last step in using accounting. Select Modules, Accounting, and Post Month with Financials. Here it is critical to understand a few things. Within the settings and utilities you have the option to change the start of your fiscal year (option number 5 in the settings and utilities) When you first select to close the month you will get the screen below.
No matter what you set your fiscal year to, month one will always be January, month two will always be February. pc/MRP automatically keeps track of this for you. Press O.K.
On this next screen select O.K. once again.
If you would like you can manually step through the posting process. At this time there are just a few transactions so doing this manually would not take much time.
Select to print out the Financials.
Select the Standard format.
This first time closing select all of the reports. This will give you an idea of what all of the reports do. In the future you might just choose to have several reports made.
One of the most important things to understand about pc/MRP Accounting is that we can close, re-close, and re-close any month. We do not have a trial balance, but rather just the Post Month with Financials. But, by having the ability to close as many times as necessary allows us to use the Post Month with Financials as a trial balance. Go ahead and press O.K. to begin the process. If you selected to manually step through the postings you will have to select continue a few times.
All of the reports will printout. If you have any errors in this process then someone has edited your chart of accounts. Just follow the recommendation in the error log.
The final step in Posting the Month with Financials is creating a backup of the account balance tables. We believe that it is so critical to make a backup of this information that we request that you back it up every time you close the month. You can use the same floppy several times and it just takes a few seconds.
When you are done creating your backup take a few minutes to look over the accounting financials we just produced.
3.1.18 Some Final Thoughts
We have taken our Bicycle Shop and entered some simple data and walked through the complete Order-to-Cash process. In months to come this tutorial will become more comprehensive. From here you can simply delete the pcmrpw directory and start fresh or continue with your testing within this copy. You can install and re-install pc/MRP as many times as necessary. If you have any questions or suggestions you can call our support lines at 408-226-7321 or e-mail to: support@pcmrp.com.