Product overview

Material and Resource Planning is designed specifically for Sage 200, Sage 200 BOM and Sicon Works Orders to provide a manufacturing solution, including suggested works orders, suggested purchase orders, suggested kits (if Kitting is enabled), labour and machine capacity planning and forecast sales order import.

The outcome of running Material Planning is that suggestions are generated for what you need to order, or what you need to make. These suggestions would then need to be actioned by the relevant user to create purchase orders, kits or works orders as appropriate. Having more accurate information held on the stock item with regards to supplier details (prices, lead time, order quantities) will lead to more accurate suggestions.


1. Material Planning

Material planning is based upon calculations of stock movements on stock items.  The stock movements are basically a timeline of incoming and outgoing stock on a stock item.  When stock levels fall below certain levels, or there isn’t enough stock to meet the demand from a sales order/works order/kit/forecast, then a suggestion is raised.

The stock movements for a particular stock item can be viewed from a number of places in the Sicon Manufacturing module.  One place to view these stock movements is on a stock item in stock control.  If a stock item is amended or viewed in Sage, then there will be a button called Stock Movements at the bottom of the screen. This screen is described in the Future Stock Movements section of this guide.

Having an understanding of stock movements will help when determining and investigating suggestions in material planning.

 

 

 


1.1. Options

Material planning has a number of options which affect the results of the material plan run.  These options are grouped into a number of sections. When you run material planning and then return to this screen again, the previous settings will have been retained (this is a company specific function, they are not stored per user).

At the top of the screen is a facility to select a single stock code. This will then run Material Planning to generate suggestions for that selected stock code.

Below this are options split for Suggested Kits (if Kitting is enabled), Suggested Works Orders (if Works Orders are enabled) and Suggested Purchase Orders. The tick boxes that start of each of these areas allow you to choose whether to run Material Planning for any combination of these three. So if you are running Material Planning having purchased just the Distribution module, then the only section that will be displayed will be the Suggested Purchase Orders.

Within the three sections, these settings are repeated allowing you to select specific settings for each section.

Warehouses button: This button allows you to select which warehouses should be included for the suggestions for that relevant section.

Separate suggestions per warehouse: If this option is ticked, then the demand and current stock levels would be analyzed separately for each warehouse that was enabled via the warehouse button. So if you were to run Material Planning for three warehouses, warehouse A would be looked at in isolation from warehouses B and C. If you don’t have this option ticked, then their current levels and demands would be grouped together. So you may have a sales order that needs stock from warehouse A where there isn’t any currently, but enough stock for it in warehouse C. In this scenario, potentially no suggestion would be generated as there could be enough stock in the three warehouses combined.

Group suggestions within: This drop down lets you select from ‘Never’, ‘1 week’, ‘2 weeks’, ‘1 month’ or ‘All’. This enables you to group suggestions together if they fit within the selected timeframe, i.e. two sales orders need the same stock item and they are scheduled to be dispatched within a couple of days of each other. Grouping within 1 week would combine them onto a single purchase/works order suggestion. Grouping will have the effect reducing the number of works orders and purchase orders suggested. Caution may need to be exercised with the ‘All’ option if you have demand loaded for the future (i.e. a sales order or forecast for many months’ time) and don’t mean to combine that with demand for the same item now.

Enable rescheduling: Ticking this box will cause Material Planning to look at existing kits, works orders and purchase orders to see if they can be rescheduled to fit current demand. This will only look to pull forward existing orders, it does not suggest that current orders can be rescheduled to later dates. This option will cause an additional column to be added to the Stock Movements screen to display the suggested reschedule date of the particular purchase or works order.

Stock level options: This drop down allows you to select from ‘ignore current stock’, ’Use minimum stock levels’, ‘Use reorder levels’ or ‘Maintain zero’. If you choose ‘ignore current stock’, then Material Planning will generate suggestions to fulfill all current demand, ignoring whatever you currently hold in stock. Otherwise, the other three choices form the target of that Material Planning is aiming to keep your stock at once all current demand is fulfilled. These are either the min level, the reorder level or zero. If you are using the facility in the Distribution module to calculate your min stock levels, then you would to use the min stock level option when running Material Planning.

Enable warnings: This setting will enable warning messages to be displayed in the results of Material Planning advising if existing purchase orders will not arrive in time for the demand, based on the supplier lead time.

From/To Date: These enable you to enter a date range, and have Material Planning only analyze demand within this date range. If you enter one of these dates and leave the other one empty, then either all demand from or to the entered date will be analyzed.

Allow over ordering: This option allows Material Planning to generate suggestions that could result in you having more stock than you require due to existing orders on the system. As an example, you have a purchase order due for delivery in several weeks’ time, but some immediate demand has entered your system. If the supplier lead time is short and you enable this setting, then Material Planning would generate an additional suggestion for this new demand, even though once the original purchase order arrives you will then have more than you need. Rather than enabling this setting, it may be preferable to enable the rescheduling option to generate rescheduling suggestions rather than additional orders.

Exclude existing…: This would ignore existing purchase orders/kits/works orders when making suggestions in these areas. So all of the demand would be assessed against the relevant stock level option and then suggestions generated regardless of current purchase orders/kits/works orders.

The Suggested Purchase Orders section also has separate settings to enable suggestions for the alternate fulfillment methods in Sage 200 – supplier via stock or direct delivery.

SIcon Material & Resource Planning Help and User Guide

There are additional options that can be enabled in the MRP settings; please see the later section on the Material Planning tab in MRP settings for details.

Once the options have been selected, the Run button can be selected.

The Show Previous Results button will display the previous results generated from the last material plan run, which could save time if you want to revisit suggestions yet to be actioned and don’t need to run the process again. This is not stored per user, so will the results generated on the last run, regardless of who ran it and what options they used.


1.2. Results

The Material Planning run may take a short while to complete, but the progress will be indicated on the left.  You can run Material Planning while other users are in the system, but be advised that if new sales orders or purchase orders are being entered/amended while Material Planning is being run, then the resulting suggestions may change depending upon where it had got to at the time. It is also possible to minimize Material Planning while it is running if you need to be doing something else.

The Results of Material Planning are displayed on multiple tabs, depending upon which modules you have enabled and which options were selected when running it.

These tabs are:- Warnings, Reschedule Messages, Suggested Purchase Orders, Suggested Works Orders, Suggested PO (Supplier), Suggested PO (Direct) and Suggested Kits.

A list of warnings are displayed on the Warnings tab if the Enable warnings options were selected. Warnings such as purchase orders not arriving on time or suggestions that may not be completed on time, are displayed in this list.

Sicon Material & Resource Planning Help and User Guide - Material Planning Warnings

To drill down on a warning item, the user can double click on an item to display the Stock Movements screen.

Rescheduling suggestions are displayed on the Reschedule Messages tab if the Enable rescheduling options were ticked.

Sicon Material & Resource Planning Help and User Guide - Material Planning reschedule

The Suggested Purchase Orders tab displays suggested purchase orders raised to meet demand from sales orders, live works order component lines, suggested works order demand component lines and minimum stock levels.  This list can be filtered using the filters at the top of the screen.

Sicon Material & Resource Planning Help and User Guide - Material Planning Suggested Purchase Orders

The user has the ability to change certain values in the list against each suggested purchase order, before generating the purchase order.  These can be date requested, quantity, warehouse, supplier and/or unit price.  The reason for the suggestion is in the last column.

There are a number of buttons to investigate suggested purchase order lines further.  For example, the View Details button will display the Stock Movements screen, while the Stock Item Details, Stock Item Balances and Monthly Trading Figures buttons will take you to those standard Sage 200 screens to provide further details about the stock item.

Purchase orders can be generated by ticking the suggested purchase order line(s) and then selecting the Generate Selected Purchase Orders button.  A summary screen will appear displaying the purchase orders that will be created.  Suggested purchase orders for the same supplier that are being generated at this point will be grouped together onto the same purchase order.

Sicon Material & Resource Planning Help and User Guide - Create Purchase Orders

To view the purchase order after creating them, put a tick in the box on the lines on the summary screen before generating them.

Once you have created the purchase orders, then the relevant lines will disappear from the list on the Suggested Purchase Orders tab, so you are only viewing suggestions that have not yet been actioned.

The Suggested PO (Supplier) and Suggested PO (Direct) tabs work in an identical fashion, just for the relevant fulfillment method.

The Suggested Works Orders tab displays a list of suggested works orders to meet demand from live works orders and sales orders.  Any suggested sub-assemblies would appear within their parent works order, and these could be expanded by clicking on the plus button to the left of the item code column.  We can also filter this list by warehouse, finished item stock code, finished item product group, a Due Date range or the reason for the suggestion (i.e. Sales Order number).

Sicon Material & Resource Planning Help and User Guide - Material Planning Suggested Works Orders

The reason for generating the suggested works order is shown in the last column to the right.  This reason can be a sales order, works order or to meet the minimum stock requirements (or re-order levels based on options selected in the Options tab).

There are a number of options to find out more details about the suggested works orders raised.  By selecting the suggested works order line and then selecting the View Details button, the stock movements screen can be accessed.  Also, stock item details can be obtained by selecting the Stock Item Details, Stock Item Balances or Monthly Trading Figures buttons. This grid can be sent to Excel via the button at the bottom of the screen, as the functionality of showing subassemblies in an expandable tree structure (via the plus symbol to the right of the tick box on a line) prevents the standard Sage export on right click from working.

To generate the works order, select the suggested works order(s) and click on the Generate Selected Works Orders button.  A summary screen will appear displaying which works orders will be created.  Clicking the Create button will create the works orders.

Sicon Material & Resource Planning Help and User Guide - Create Works Orders

Once you have created the works orders, then the relevant lines will disappear from the list on the Suggested Works Orders tab, so you are only viewing suggestions that have not yet been actioned.

The Suggested Kits tab displays a list of suggested kits for stock items that have a kit designed for them that have a demand (either for sales orders/forecast and based on stock level option).

The reason for the suggestion is displayed in the Reason column on the right hand side. As with the other screens, the buttons at the bottom of the screen are available to access those screens if more information is required. Once you are satisfied with the reasoning behind the suggestions, you can use the Create Kits button in the bottom right hand corner to create the kits.

Sicon Material & Resource Planning Help and User Guide - Suggested kits

Once you have created the kits, then the relevant lines will disappear from the list on the Suggested Kits tab, so you are only viewing suggestions that have not yet been actioned.


1.3. Sorting Suggestion Lists

The tabs for the suggestions in Material Planning can be sorted by clicking on the column header.


1.4. Exiting Material Planning

When closing Material Planning, you will see a box displayed that prompts warning that any changes will be lost. This refers to any ticks you have recorded against any suggestions, but not yet actioned. If you continue and then re-open Material Planning, then all outstanding suggestions will be unticked.

Sicon Material & Resource Planning Help and User Guide - Exiting message


1.5. Stock Item Settings

There are default stock item settings on the WOP/MRP tab when amending a Stock Item in Stock Control.  These settings can relate to material planning and override options set on in the Options tab of Material Planning.

Sicon Material & Resource Planning Help and User Guide - Stock WOP MRP tab

Default Production Lead Time: This setting is relevant for built items, and adds a number of days to the date calculation on works orders. So if this was set to 4 days, then works order suggestions would be dated 4 working days before the date of the demand.

Default Supplier Lead Time: This setting is relevant for purchased components, and adds a number of days to the date calculation on purchase orders. It’s overridden by a supplier lead time being set on the relevant supplier entry on the Suppliers tab, so was intended for situations where supplier information was not being recorded on the stock item.

Make/Buy/Make or Buy: This setting should be set for items that are tagged as built items on the Details tab (identifying them as items with a bill of materials) – and can be set against multiple stock items using the ‘Utility to Update Stock Items’ in the Works Order Processing/Utilities menu. Currently, Material Planning doesn’t prompt for the Make or Buy question when you run it, so you would need to change the option in the Preferred box before running Material Planning if desired. Built items need to be marked with the Make option in order to have works orders suggested for them.

When adding this item to a Works Order: This setting enables you to have a specific option set for this stock item that would override the default set in Works Order settings. It would only be relevant for a built item that is used as a sub-assembly.

Group Suggested Purchase Orders: When running Material Planning, in the options set before clicking Run you can select a default grouping option for purchase orders. This setting would act as an override to the option selected in Material Planning for this stock item.

Economical Batch Size: For a built item, this size setting is the minimum quantity that a suggestion for a works order can be for this item. So if there was a demand for 3 of an item, but this field was set to 20, then the suggested works order would be for 20.

Split by economical batch size: If you enable this and you have entered an economical batch size, then any suggestions for works orders would be split by the economical batch size. So a demand for 50, with an economical batch size of 20 would create three works orders for 20 each.

Do not round up last works order to economical batch size: If you have an economical batch size and the previous setting also enabled, then the final works order suggestion would be just for the remaining quantity, rather than for the economical batch size. So as per the example on the previous setting, you would have three works orders suggested, two for 20 and the third for 10.

Add extra quantity setting activated: If this option is ticked, when works orders are suggested for this stock item then an extra quantity will be added to the finished quantity, to reflect the fact that additional product needs to be manufactured for testing purposes. The quantity added can be changed via the All Settings button within Works Order Settings, with the value being recorded on the setting with description of ‘AddExtraQuantityWhenBuildAmount’. Note that this setting is not stock code specific, so for stock items with the ‘add extra quantity setting activated’, they will all add the same quantity.

Ignore free stock quantity in material planning: If this option is enabled for this stock item, then when running Material Planning, the stock level options setting selected on the Options tab of Material Planning would be overridden for this stock item to use ‘Ignore current stock’.

Production unit of measure: Enables you to select the unit of measure that should be used for the finished item on suggested works orders for this stock item.

Purchasing unit of measure: Enables you to select the unit of measure that should be used for suggested purchase orders for this stock item.

Default component warehouse: Enables you to select a warehouse that should be used as the default component warehouse on suggested works orders for this stock item as the finished item.

Default finished item warehouse: Enables you to select a warehouse that should be used as the default finished item warehouse on suggested works orders for this stock item as the finished item.

On adding line to works order round quantity up to: When adding this item as a component on a works order, this option allows you to specify how many decimal places the value entered will be rounded to.

Round up purchasing quantity to: This setting allows you to specify the number of decimal places the value on a suggested purchase order for this stock item will be rounded to.


1.6. Over Ordering

The Allow over ordering option is available on the first screen during the material planning process. These options are used when generating suggested purchase orders and suggested works orders.

Sicon Material & Resource Planning Help and User Guide - Material Planning Allow over Ordering

The following examples are for suggested purchase orders.  However, the theory is the same for suggested works orders.

If the allow over ordering option is selected, suggested purchase orders will be generated even if there is future purchase orders still coming that will fulfil stock demand.  Suggested purchase orders are generated to keep the stock level above the stock level option selected.

If the allow over ordering option is not selected, suggested purchase orders will not be generated if there is a future purchase order still coming to fulfil the stock demand.  However, this purchase order may arrive late and a warning could be generated if warnings are enabled, or a rescheduling suggestion would be made if that option was enabled.

The default selection for this option is Off.

Example of Over Ordering is turned On

In the following screenshot, a suggested purchase order is generated on the 28/06/2017 to meet the demand of sales order 0000005235.  However, there is a purchase order on the 24/07/2017, which increases the stock level above the minimum stock level.  This purchase order is after the due date of the sales order, as such, the suggested purchase order is generated in order to keep the stock level above minimum.

Sicon Material & Resource Planning Help and User Guide - OverOrderingExample1

Example of Over Ordering is turned Off

In the following example, no suggested purchase order is generated for sales order 0000005235, because purchase order 0000003416 will push the stock level back above the minimum stock level; even though the purchase order is after the due date of the sales order.

Sicon Material & Resource Planning Help and User Guide - OverOrderingExample2

A warning will be generated on the Warnings tab stating that the purchase order may not arrive on time, if the option for Enable warnings is selected when Material Planning is run.

If the option for Enable rescheduling is selected when Material Planning is run, then the Stock Movements results would be displayed by the newly calculated Reschedule Date, and the Rescheduling suggestion would be displayed on the Reschedule tab of the Material Planning results.

Sicon Material & Resource Planning Help and User Guide - OverOrdering example 2

NB: If the stock item is required for a works order, the item will show in the expediting report and will show in red or amber if stock may not arrive on time to fulfil the demand.

Notes

There is an option to allow over ordering for suggested works orders as well.  This is a separate option on the first screen in material planning in the suggested works order section.  The theory for allowing over ordering for suggested works orders is the same as over ordering for suggested purchase orders.

The minimum order level and/or usual order quantity may affect the quantity on the suggested purchase order (if set on the preferred supplier), thus increasing stock levels even if ‘allow over ordering’ is turned off.


1.7. Suggestion Dates

The dates that are used for generating the suggestion are based on the date of the demand. For a sales order line, this is either the promised delivery date or the expected dispatch date if different. The Expected dispatch date is the requested delivery date less the delivery buffer, which is either read from the default delivery buffer setting in MRP Settings or uses the buffer specified on the MRP tab of the customer account.

Demand dates for forecasts are the date of the forecast; demand dates for works order components are the start date of the works order. Demand dates for kit components are either the promised delivery date of the sales order line that the kit is linked to, or the current date if the kit is not linked to a sales order line.

Suggestion Quantities

Settings that Affect the Quantity of a Suggested Purchase Order

The rules below are applied to suggested purchase orders when running Material Planning:

Usual order quantity on preferred supplier: The quantity of a suggested purchase order will be a multiple of the usual order quantity of the preferred supplier.

Minimum order quantity on preferred supplier: The quantity of a suggested purchase order will be above the minimum order quantity set on the preferred supplier.

NB: If no preferred supplier is set on the stock item, then the above two rules will be ignored.

Re-order level on the warehouse on the stock item: If Material Planning is set to use re-order stock levels when generating suggested purchase orders, suggested purchase orders will be raised if the quantity of the stock item will fall below the re-order level on the warehouse.  The quantity for the raised suggested purchase order will bring the stock level back up to the re-order level.

Minimum level on the warehouse on the stock item: If material planning is set to use minimum stock levels when generating suggested purchase orders, then suggested purchase orders will be raised if the quantity of the stock item will fall below the minimum stock level on the warehouse.  The quantity for the raised suggested purchase order will bring the stock level back up to the minimum stock level.

NB: If stock levels are ignored for suggested purchase orders, then the above two rules are ignored.

Warehouse Selection

If multiple warehouses are selected when running material planning, then the minimum/re-order stock levels on the warehouses for a stock item are added together.  Therefore, suggested purchase orders will be raised to bring stock levels up to the combined minimum/re-order stock level.

Settings that Affect the Quantity of a Suggested Works Order

Minimum level on the warehouse: If suggested works orders are generated for meet minimum stock requirements, then raised suggested works orders will bring the stock level of the BOM stock item back up to the minimum stock level.

Economical batch size: The quantity of a suggested works order will always be a multiple of the economical batch size if the economical batch size is set.

Round quantity up to: This affects the component demand from a suggested works order. Component demand lines from suggested works orders could be rounded up if the Round quantity up to settings is set on the relevant stock item.

Add extra quantity setting: This affects the component demand from a suggested works order.  The quantity of component demand lines from suggested works orders could be increased if the Add extra quantity setting is set on the stock item.  The amount of increase depends on the AddExtraQuantityWhenBuildAmount setting in Works Order Processing Settings.


2. Future Stock Movements

Sicon Material & Resource Planning Help and User Guide - Future Stock Movements

This screen is also available from within Material Planning, and via the Stock Movements button on screens such as View Stock Item. Its purpose is to summarize all future expected stock movements that will impact your free stock level in the selected warehouse(s). As it is working with free stock, once stock is allocated (i.e. to a sales order), that demand will not be displayed in this screen as the starting Free Stock figure will already have taken this into account.

The stock movements will start with the Free Stock figure and then have a running total downwards, by date, displaying the resultant balance.  Each line can be drilled into by double clicking the line.  Some lines may be works orders, some sales orders and others purchase orders.

The Reschedule date column will only be accurate if the previous run of Material Planning had the option of Enable Rescheduling selected. If so, then this stock movements screen will be sorted in reschedule date order. Note that the Reschedule date is only provided for information purposes, the intention is that the user would update the dates on the relevant works order/purchase order to the reschedule date manually if they have confirmed that it can be rescheduled.

If you have selected the Include suggestions from last MRP run, then there may also be lines for suggestions from material planning or component demands from other works order suggestions.  These will be identifiable on the details columns by the fact that they will be preceded with the letters SUG.

The Warehouses button can be used to filter the screen to reflect movements for the selected warehouse(s), and beneath this are From and To date options to filter for a selected date range.

The fields displayed in the Stock Item Quantities section are totals based on the warehouses selected, while the supplier information is pulled through from the preferred supplier (if any) on this stock item. The Earliest date suggested purchase order can arrive based on lead time displays a date calculated based on current date plus lead time in working days.

The fields displayed in the Summary section are populated when you click on a sales order line in the Stock Movements window, and display the relevant information from that sales order.

The Delivery buffer days looks at either the default delivery buffer set in Material Planning Settings or the Customer delivery buffer on the MRP tab of the customer details (if populated) to calculate an Expected dispatch date for that sales order. This is the date that Material Planning will be using to aim for with regards to fulfilling demand for that sales order.

The buttons at the bottom of the screen provide access to the standard Amend Stock Item Details, Stock Item Balances and Monthly Trading Figures screens. Immediate access to the amend stock item details screen is very useful if this screen is displaying information related to the stock item supplier that needs to be updated.


3. Forecasts

Forecasts can be entered into the system to reflect expected sales orders and create demand for them. It is important to know that once an order has been received, the correct procedure is to remove the forecast manually from this screen, otherwise the demand from the forecast and the order will be combined in the next run of Material Planning.

To import forecasts via a csv, select the Forecasts menu option.  Imported forecasts will overwrite previous forecasts.  Select the forecast csv file using the browse button (the ellipsis button) and then select the Import button to import the forecasts. Alternatively, forecasts can be manually added via the Add button.

Sicon Material & Resource Planning Help and User Guide - Stock Forecasts

To delete all forecasts, select the Delete All Forecasts button, or individual forecasts can be selected and then deleted with the Remove button.

Material Planning and Forecasts

The Material Plan uses the forecasts when checking to create suggested works orders, suggested kits and suggested purchase orders.

Forecasts will be used in this process and where a forecast is a BOM item, a suggested works order may be generated, or a kit for a stock item with a kit designed for it.  Where a forecast is for a normal stock item, a suggested purchase order may be generated depending on stock levels.


4. Capacity Plan

The Rough Cut Capacity Plan is designed to provide a rough graphical representation of your scheduled works order operations in comparison with your availabilities of those resources.


4.1. Examining the Rough Cut Capacity Plan

Rough cut capacity will show the available hours against the actual or estimate (if there is no actual hours) for the labour and machine operations on your works orders.

The chart can be filtered using a start date and end date filter.  The results can also be further filtered by area or operation.

Sicon Material & Resource Planning Help and User Guide - Capacity Plan

Labour demand and availability is shown in blue and red.  Machine demand and availability are shown in green and purple.

To drill down for a demand column on a particular day, double click on the Demand column.  A list of works orders will be shown, which relate to the demand on that particular day. An edit button is available at the bottom of the screen if you wish to change the dates on any of these works orders.

The results can be moved a week forward or back by using the ‘<<‘ or ‘>>‘ buttons.

All days for operations need to have available hours set using the Availabilities screen.

The Department Work Schedule tab allows you to view boxes displaying a list of current works orders based on their due dates. The three lists are split as Overdue, Due Today and Due Tomorrow Onwards. When you first click on this tab, you will see all current works orders displayed but these can then be filtered by Area using the filter in the top right.

Sicon Material & Resource Planning Help and User Guide - Department Work Schedule


5. MRP Settings

 


5.1. Material Planning TAB

Sicon Material & Resource Planning Help and User Guide - MRP Settings Material Planning tab

Show advanced settings in Material Planning: Enabling this setting adds some additional options into the Material Planning screen when it is run.

Sicon Material & Resource Planning Help and User Guide - Advanced Works Order Settings

This screenshot is for Advanced Works Order Settings, but these options also appear in the Purchase Order section and Kitting (if enabled). The Create suggestions for date in the past would backdate suggestions to a date prior to today if the demand was prior to the current date. In other words, if you don’t have this setting enabled, then demand for items prior to the current date would generate suggestions that were dated for the current date. The other options in this advanced section allow you to include sales proformas, quotes and orders that are on hold – otherwise these are all ignored for Material Planning suggestions. It is also possible to exclude the demand from sales orders if desired by choosing the Exclude sales orders option. These settings are replicated for works orders, purchase orders and kitting (if applicable), and could be set to different values in these three areas if desired.

Run Works Order process before Kitting process: If you have Kitting enabled, then ordinarily Material Planning would process Works Order suggestions after Kitting suggestions. Selecting this option would reverse the order in which this happens. The order that you need this to happen is dependant upon whether you have components on a kit that are manufactured items that would be built on a works order, or whether you have components on works orders that would be built as kits. Material Planning will create the demand for these components in the order dictated by this setting. So by default, it will run Kit Suggestions first. If you had works orders that did have kits as components, then you would enable this setting in order for the works orders to be suggested first, which would then create the demand for the kits.

Preallocate purchase orders to reasons: Once suggestions from material planning are actioned, they will then be preallocated to the demand that caused their suggestions. For example, a suggested purchase order could be preallocated to components lines on one or more works orders, or to a sales order line if the item being purchased was being sold to a customer. When the purchase order is received, then a window would be displayed allowing the user to confirm where the items should be allocated to. If a suggested works order was created, then the finished item on it could be preallocated to one or more works orders if the item being booked in was a component needed elsewhere. If this option is not selected, then no preallocations will happen meaning that when stock is received into the system it will need to be manually allocated.

Use requested date of the sales orders in material planning: By default, the promised date is the field used for demand from sales orders, but by selecting this setting it would use requested date instead.

Default delivery buffer: This is a default number of working days to deduct from sales order line promised delivery dates to arrive at an expected dispatch date. This value will be overridden for a sales order if the applicable customer account has a value entered on their MRP tab.

The Legacy Material Planning settings are present here for clients who have updated to v17 and are still using the Legacy Material Planning screen.

Use multiple delivery dates on purchase order lines: When material planning is enabled on a Sage 200 system, then the standard Sage Multiple Dates button on purchase order lines is disabled. It can be re-enabled using this button, but Material Planning will not use any breakdown of dates on this purchase order line, it will only use the Requested delivery date for the whole of the line when calculating when this purchase order is expected to be delivered.


5.2. Stock and Warehouse TAB

Sicon Material & Resource Planning Help and User Guide - MRP Settings Stock and Warehouse tab

Default component warehouse and Default finished item warehouse can be used to select the defaults that will be applied to works orders generated by Material Planning. These would be overridden if any default warehouses were set on the stock item (on the WOP/MRP tab).

The Quarantine list of warehouses lets you select which warehouses should be excluded from Material Planning.


6. Availabilities

Setting Available Hours for Operation Resources

On the availabilities screen, we can set the available hours for each labour and machine item on a day by day basis.  Availabilities are used to calculate the available hours on a works order and is used in the Capacity Plan screen.

Sicon Material & Resource Planning Help and User Guide - Availabilities

To set the available hours for a labour item, select the date criteria and then enter the hours available against the labour item in the grid.  The default daily availability can also be set and will be used if no hours are set.

Hours can be copied to all selected dates by selecting the cost item and then selecting the Copy defaults to all visible work days for selected labour item button at the bottom of the screen.  This will copy the default daily availability to all working days for the dates selected.

Areas can also be set against the labour item.  This is used when entering actual hours on work lists and also on the Capacity Plan.


7. Legacy

Within this folder are menu items for Legacy Material Planning and Legacy Stock Movements. Both of these screens have now been superseded by the Material Planning and Future Stock Movements screens, but exist within the menu structure to enable clients upgrading from a previous version to compare.


8. Enable Module


9. Release Notes

The Release Notes document below shows which release of the Manufacturing & Distribution Manger system includes which new features and for which version of Sage these will work.

The version number indicated in the Distribution Manager Release Notes includes a full release number and a sub version number; e.g. ’6.1′ indicates the full release version number of the software.  Pre-release version builds of the software are available to certain clients requiring new or enhanced features being developed from the wish list.  If these versions are installed on your system, you will see an additional number e.g. 39.113 making up a specific database version and interim build number of 6.1.39.113.

It is unlikely that these features will be documented in this help and user guide until the end of the development phase.

Manufacturing & Distribution Manager Release Notes


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