Inventory Module

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5.1.1 Inventory Module Overview

The Inventory Module in pc/MRP allows you to store, edit, and track information and pictures for each part and assembly number in your inventory. Part number information is automatically imported into sales orders, purchase orders, sales quotes, and purchase requests for quotes. The inventory module will be your primary source for part and assembly information.

5.1.2 Define the Part Number Size

Prior to entering part numbers, the size and configuration of the part number must be defined using pc/MRP's Configuration Menu. pc/MRP's part numbers can be numeric and/or alphanumeric.

Part number size - pc/MRP's configuration menu, option 28, allows the part number size to be set from 6 to 15 characters, see section 15.1.28 in this manual.

Part number prefix size - pc/MRP's configuration menu, option 29, allows the first X characters of the part number (including any dash) to be set as a prefix (product code), see section 15.1.29 in this manual.

Part number suffix size - pc/MRP's configuration menu, options 48 and 49 allow the last X characters of the part number (including any dashes) to be set as a suffix, see section 15.1.48 and 15.1.49 in this manual.

Below are some additional ideas to think about if you are free to define the part number size and structure:

A straight non-encoded numeric part numbering scheme could be employed. It is easier to maintain and expand a stock room with a non-encoded numeric part numbering system. However, with this method it is not easy to find part numbers by scrolling the inventory file.

Encoding the first two or three characters of the part number as a product code will allow scrolling to start in the product code. The size of the product code can be set on the in the Settings and Utilities Module.

Large part number structures slow down data input and lead to data input errors. Supermarkets do not trust people to put in $6.99 let alone an 18 character part number. In addition, large part number structures could make it difficult to switch over to bar-coding in the future.

Alphanumeric part number structures can lead to errors due to upper and lower case letters and 0's versus O's.

Companies selling to retail markets would do well to consider using a 9 or 10 digit numeric part number system to match retail UPC bar coding structures. Many retailers request their products be shipped with UPC bar code labels.

An eight character part number structure could be optimal for companies that plan to use Auto Cad to generate and store their drawings.

Companies dealing with consignment parts should read the chapter in section 15.10.5 which covers part numbering schemes (methods) for companies who carry a large number of consignment parts.

pc/MRP defaults to a 9 character part number size and a 2 character product code size unless modified by the user in the Configuration Menu.

5.1.3 Enter A New Part Number

Selecting New to enter a new part number, brings up the screen shown below. If your part number scheme is strictly numeric with leading zeros, select Next available part number. If you’re part number scheme contains a product code, and the remaining root of the part number is strictly numeric with leading zeros, select P, Next available part number for a product code. If your part number scheme includes a product code, the root of the part number is strictly numeric with leading zeros, and the last part of the part number contains a suffix, select S, Next available part number for a product code/suffix code. If none of the above matches your part number scheme, select Next available part number, and type in the part number you wish to enter.

 

5.1.4 Quantities/Cost Tab Screen

pc/MRP will then display the first page of the inventory data entry screen as shown below.

 

 

The Part Number field (partno) contains the part number for this part. pc/MRP will not allow you to edit the part number field in this data entry screen. To change a part number you must select Inventory and then Change Part Number.

The Type field (part_assy) should contain a P for component, A for an assembly, and L for labor. Assemblies should not be entered into the PARTMASTER by hand. The BOM module will automatically enter the assembly into the PARTMASTER and place an A in this field. Parts marked L will not be adjusted when parts are converted to assemblies or when they are invoiced or received. The Infinite Bucket MRP optional module does include L in the MRP report, but still does not adjust quantities. Vendor assemblies should be entered as parts. If you include labor as part numbers, select parts and assemblies only when running a costed inventory report.

The Rev (revlevel) contains the current revision level of the part or assembly, i.e. A, B, C etc. If the part or assembly is changed such that it is still backwards compatible roll the Rev. If the part or assembly is not backwards compatible, change the part number. pc/MRP's ECN module will automatically increment the revision level for a part number whenever a new ECN is created for that part number.

The Description (descript) should be such that similar items appear together in any report sorted by description. For example, the descriptions, "WIRE,BLUE" and "WIRE,RED" will allow all WIRE to be listed under WIRE.

Pressing the Ellipsis ... Button to the right of the description field will allow the user to select a pre-defined description. The predefined descriptions can be created using pc/MRP's configuration settings and utilities option 58. Predefined descriptions can be used to keep part descriptions uniform and in alphabetical order next to each other when printing out a parts list sorted by description.

A Displayed Currency drop-down list box is available with pc/MRP versions 6.82 and higher for users who have purchased the optional Alternate Currency module. The user can then display the cost and pricing information in any of the alternate currencies.

The Ave Cost/Unit (cost) contains the average cost per unit. The value in this field is recalculated every time a receiver is entered for that part number. The cost averaging formula and conditions are covered in the receiving section of this manual. The cost averaging defaults can be set with option 50 in the configuration settings and utilities module.

The Std Cost/Unit (stdcost) field contains the list cost of the part. If your company's accounting department is using standard costs to value inventory, standard costs should only be entered and changed with their permission.

The Last PO Cost (lastpocost) field contains the cost of the last PO for this part. pc/MRP automatically enters the last PO cost whenever a purchase order is created for a part number.

The Cost Detail Button will display the sum of the component, labor and overhead costs for an assembly. This button will not respond for a component or labor part numbers.

 

In the above example:

The Standard Cost, $2169.1400 is the sum from the last "Standard Cost Roll Up" and is stored in the stdcost field. The standard cost of labor is $9.7024 and is stored in the stdlabcost field.

The Average Cost, $2294.1900 is the sum from the last "Average Cost Roll Up" and is stored in the cost field. The average cost of labor is $27.5193 and is stored in the avelabcost field.

The Last PO Cost, $1337.1300 is the sum from the last "Last PO Cost Roll Up" and is stored in the lastpocost field. The last PO cost of labor is $4.8585 and is stored in the lplabcost field.

Option 60 in the configuration settings and utilities menu, sets the overhead %

Option 35 in the configuration settings and utilities menu, sets whether the average or standard cost will be inserted into sales orders and invoices as the cost of sales. Option 35 will also set what is included during cost roll ups:

·         Component costs

·         Component costs + labor costs

·         Component costs + labor costs + labor x %overhead (set with option 60)

The On Order (onorder) field contains the quantity on order from purchase orders. As explained above the quantity on order in inventory will be increased by the quantity ordered x the purchase ratio. When the PO is received, the quantity on hand will increase by the quantity received x the purchase ratio.

The On Demand (ondemand) field contains the quantity on demand from open work orders and sales orders. Whenever a work order or an "Order Entry" sales order is entered, the quantity on demand for that specific assembly is increased. It is important to note, the quantity ondemand for the component parts that go into that assembly do not increase. Instead, whenever an MRP is generated, pc/MRP decreases the quantity available field for the component parts to satisfy the demand from the open sales and work orders. Creating an invoice for a sales order will decrease the quantity on demand for the assembly listed in that sales order. Using the stockroom's "Receive completed assemblies from manufacturing" for a work order will decrease the quantity on demand for the assembly listed on that work order.

The On Order and On Demand can be displayed and updated by pressing the Display & Update button.

E

The Qty Available (avail) field contains the quantity available after allocation. This field is updated by running pc/MRP's Single or Infinite Bucket MRP program. The MRP programs will allocate parts on hand and on order and fill in the quantity available field with the quantity after allocation. For example, if a company has 1200 bearings on hand, the quantity available might be 800 after allocation. The Quantity Available field consist of the onhand quantity + PO quantity (on order) - the allocated quantity (future issues and sales) - the minimum quantity. pc/MRP Versions 7.02 and higher dynamically adjust the QTY Available field (new purchase orders increase the quantity available of component parts and invoices decrease the quantity available of finished assemblies).

The Estimated Usage/Week (usage) field is used by pc/MRP's Inventory Cycle Count Module to automatically determine which parts are to be reclassified as Class A, B , or C parts based on usage and unit cost. pc/MRP's optional Sales Analysis Report will fill this field in automatically based on past sales (invoice) history.

The Min Qty (minqty) field contains the quantity at which a part should be reordered. For example, if you use 2 parts per week and it takes 3 weeks to receive the part the min qty field should be set to 6. pc/MRP's optional sales analysis module has an option that will study your sales (invoices) and related BOMs for a specified period of time and automatically fill in this field.

The Max Qty (maxqty) field contains the quantity to re-order up to. This field is used by the min/max report found in pc/MRP's purchasing report module.

The Std Order Qty (ordqty) field is used by pc/MRP's Infinite Bucket module. If the infinite bucket module needs to create a buy action item for a part number, it will use the actual quantity required. However if the standard order quantity for that part number is greater than actual quantity required, it will use the standard order quantity.   If the part has been issued to manufacturing for a sales order and the parts lead time exceeds the final assembly lead time, pc/MRP will issue a buy action item for the quantity required.

The Order Multiple Qty (ordmult) field is used by the Infinite Bucket Module if a part is required to be ordered in a multiple. For example if eggs came one dozen to a carton, it will increment the buy to the next highest multiple.

The Stock and Issue Unit (unit) field contains the unit of measure (each, ft, lb, hrs, etc) that the part is issued to manufacturing and sold in.

The Lead Time field is used by the Infinite Bucket optional module. This tracks lead time by days. For component parts, this represents the delivery time needed to receive the part for the vendor. For assemblies, it represents the build time for the assembly. The default lead times for parts and assemblies can be set in Configuration, Settings and Utilities, Option 67. If pc/MRP's Infinite Bucket Module finds a 0 in the lead-time it will use the default lead times found in option 67.

The warehouse Area Names such as TEST/MRB,ENGINEER,R&D can be changed using option 34 in the configuration settings and utilities module. It is important to note, that these are areas that store parts & assemblies and are not manufacturing areas. pc/MRP has one area representing manufacturing and that area is WIP (work in progress).

The inventory fields Stores, 2-6, and WIP quantities (onhand,area2qty-area6qty,wipqty) fields contain the quantity stored in that area for that part number. Basically the onhand quantity of a part number is automatically increased whenever it is received by the receiving module. The onhand quantities are automatically decreased when they are "Issued to Manufacturing" and/or "Invoiced". Much of this depends on how you set your inventory adjustment method (see option 4 in the configuration, settings and utilities menu).

The stores and area quantity fields can be entered and edited directly. However, it would be better to enter the initial quantities using pc/MRP's physical inventory program and edit the quantities using the stockroom's "Adjust Quantities" option. Both the physical inventory program and the stockroom's "Adjust Quantities" programs leave records of the changes. This allows pc/MRP's "Inventory Movement" report to calculate the inventory at any specified date after the physical inventory was taken. Option 62 in the configuration settings and utilities menu allow users to turn off the option to enter and edit the stores and area quantities from the inventory screen.

The Parts Location Fields (locate,locate2-locate6) can contain any six-digit code you care to come up with to aid in locating parts.

The Delete button allows the deletion of and existing part.

The Logbook button opens an ASCII text file where additional comments or instructions regarding the part may be recorded. Important: Do not change the filename assigned to the log file. pc/MRP would no longer be able to associate the file with the part number.

The Where Used Button will open a pop up window listing all BOMs which use this part and the quantity per assembly.

The Ok button saves changes to the record and returns you to the main menu.

The Cancel button does not save the changes to the record and returns you to the main menu.


 

5.1.5 Vendors Tab Screen

Selecting the Vendors Tab will then display the second page of the inventory data entry screen as shown below.

 

The Purchase Ratio (poratio) field is the ratio of the number of issued units required for one purchase unit. For example, if you issue in ft. and purchase in yards, the PO Ratio would equal 3. The PO Ratio must be a positive number greater than zero. A zero could cause a divide by zero overflow error. Whenever a part number is created or data is imported into the partmast.dbf file, pc/MRP automatically inserts 1 into this field.

The Purchase Unit (pounit) field is the purchase unit of measurement. Referring to the example above this would be one yard. When entering a PO, enter the quantity of purchase units you require. pc/MRP will insert the purchase unit and multiply the vendor's unit cost by the purchase ratio. The quantity on order in inventory will be increased by the quantity ordered x the purchase ratio. When the PO is received, the quantity on hand will increase by the quantity received x the purchase ratio.

The Buyer (buyer) field contains the name of the buyer responsible for purchasing this part. Pc/MRP’s Infinite Bucket action item reports allows you to print out all buy action items by buyer or for a specified buyer.

The Vendor Lookup (id1-id3) allows you to enter vendor(s) from the address book for each part. Click on the "Vendor ID # " ellipsis button and enter the first few characters of the Vendor Name, Phone Number, or ID Number. Select the address you wish to enter and press the "Ok" key. That vendor's name, phone number, and ID number will then be filled in automatically.

The Quantity (qtyl2-qtyl5,qtyl2_v2-qtyl5_v2,qtyl2_v3-qtyl5_v3) fields contain the quantity breaks for the three primary vendors.

The Cost (stdcost1-stdcost5,stdcost1b-stdcost5b,stdcost1c-stdcost5c) fields contain the cost breaks for the three primary vendors. These fields will store the costs in your base currency if you have the alternate currency module. Changing the displayed currency to an alternate currency will display the vendor costs in that currency.

In the above example, vendor 1 will charge $2.75 per part for order quantities greater than and or equal to 100 and less than 500. Vendor 2 would charge $2.65 per part for the same quantity range.

The Vendor Currency (vendcurncy,vendcur2,vendcur3) drop-down list boxes are available for each vendor if pc/MRP's optional Alternate Currency module has been activated. This allows the user to set the vendor's base currency. If you change a currency rate in the alternate currency module, pc/MRP will change the vendor cost (stdcost1-stdcost5, stdcost1b-stdcost2b, etc.) for every vendor whose base currency is set at that currency. pc/MRP will calculate the new cost by using the following formula: OLD COST*(OLD RATE/NEW RATE). If you display the vendor costs in the base currency, pc/MRP displays the base currency as stored in those fields. If you select to display the cost in another currency the standard costs for each vendor will be displayed as a multiple of the standard cost for that vendor and the selected currency.

5.1.6 Sale Prices Tab Screen

Option 67 in pc/MRP's Configuration Settings and Utilities Menu, allow users to set the method pc/MRP will use to determine the selling prices for sales orders and invoices.

 

5.1.6.1 Sales Level and Quantity Price Method (first option)

With this method, selecting the Sale Prices Tab will display the sale price screen shown below.

 

 

 

 

The Sale Price Quantity fields (qtyl2-qtyl5,qtyl2a-qtyl5a,qtyl2b-qtyl5b,qtyl2c-qtyl5c, qtyl2d-qtyl5d,qtyl2e-qtyl5e,) contain the sales price quantity breaks for various levels (types) of customers. The customer's sales level is stored in the customer's address book record.

The Sale Price fields (saleprice,salepric2-salepric5,salepriceb,saleprice2b-saleprice5b, salepricec,saleprice2c-saleprice5c, etc.) contain the sales prices based on quantity and customer's sales level as per that customer's sales level found in the customer's address book record.

The Salesman (salesman) and Sales Commission(%) (commiss), fields are automatically inserted into sales orders, invoices, and accounting transactions to allow pc/MRP to track and report on sales commissions. A sales commission of 5.00 would represent 5%.

The Licensor (licensor) field is automatically inserted into sales orders and contains the name of the company that may have licensed this part number for resale.

The Royalty Rate (royalrate) field contains the royalty rate charged for this part number.

5.1.6.2 Category Matrix Sales Price Method (second option)

 

With this method, selecting the Sale Prices Tab will display the third page of the inventory data entry screen.

 

Each part can be assigned a category (A-9). The part in the above screen has been assigned as a category B type part. Each part can be assigned up to 25 different prices (A-Y). In the above example customer's whose key assigns them level D pricing for B type parts would pay $7.00 per part.

By selecting the Sales Contact Info tab in any address entry and pressing the Sales Level button within that tab, the price key screen will pop up as shown below.

 

In this case, the customer shown would pay the level G price for category B type parts. As such his price would be $9.00. We do not recommend using this pricing method as it is not simple and straightforward.

If a sales price level is left blank like E or F in the address entry or if the sales price category is left bank in inventory the sales price will default to sales price level A.

5.1.7 Manufacturers\Models\Alternate Part Number Tab Screen

Selecting the Manufacturers\Models\Alternate Part Number Tab will then display the fourth page of the inventory data entry screen as shown below.

 

 

The Manufacturers (manufacter,mfg2-mfg9) and Model Numbers (modelno,modelno2-modelno9) are self-explanatory. Manufacturer's part numbers can be entered into their respective model number fields.

The Alternate Part Numbers (altpart1 - altpart6) allow users to store up to six alternate part numbers that can be used in place of this part number. Option 54 in pc/MRP's configuration settings and utilities menu will set the alternate part numbers in inventory to update or not update the alternate part numbers in the BOM file.

5.1.8 Miscellaneous Tab Screen

Selecting the Miscellaneous Tab will then display the fifth page of the inventory data entry screen as shown below.

 

The Image File (image_file) field is used to store and display pictures of each part. GIF and JPG files are displayed directly within pc/MRP, while all other file types, (BMP, PDF, AVI, DOC.....) are viewed by clicking the External Viewer button. Plug-ins for your browser must be loaded to view file types other than GIF and JPG. We recommend that all files be deposited into a sub-directory of pc/MRP's main directory labeled BMP. This will eliminate difficulties that may occur when trying to view the image from workstations that have a different drive designation for the server. The size of the BMP file cannot exceed 280k. You can use Microsoft's Paint program to decrease the size of you BMP file. Select Accessories, Paint, Image, Stretch/Skew and reduce the % horizontal and vertical size. If you wish to view PDF picture or document files you must install Adobe Acrobat Reader. Adobe Acrobat Reader can be downloaded from http:\\www.adobe.com/products/acrobat/readstep.html. In versions 7.02K and higher a URL can be entered into this field. The URL must however contain the full URL. (http:\\www.xxxxx.xxx)

The General Info (altpartno) field is sort of a wild card field. It can be used to store information such as purchasing specifications, additional description, alternate part numbers, etc. Option 22 in pc/MRP's configuration settings and utilities menu can be set to automatically import the contents of this field into sales and purchase order comments field. Computer manufacturers and retailers who wish to increase the length of their descriptions by including 30 gig hard drive, 128 Megs RAM, etc. can use this option.

The following fields, Part Type, Value, Tolerance, Rating, Package Type, Schematic and Footprint were included to match similar fields in Orcad.

The Draw #/Size fields contain the part number’s drawing number (drawingno) and drawing size (drawsize).

The Debit Account (dacct1) field is automatically inserted into purchase orders and receivers. If a receiver's debit account field contains an 8 character chart of accounts number, pc/MRP will debit that account when posting the accounts payable voucher (receiver). If option 11 (multi-div) is set off or the division field is empty, pc/MRP will debit the default chart of account (inventory or purchases) found in option 9's account template file.

The Credit Account (cacct1) field is automatically inserted into sales orders and invoices. If an invoice credit account field contains an 8 character chart of accounts number, pc/MRP will credit that account when posting the accounts receivable voucher (invoice). If option 11 (multi-div) is set off or the division field is empty, pc/MRP will credit the default chart of account (business income) found in option 9's account template file.

The Division (division) field is automatically inserted into sales orders and purchase orders. pc/MRP uses this field to determine what division or department chart of accounts to credit or debit for sales orders and purchase orders.

The Weight/Unit (weight) field is self explanatory. This is the weight per unit.

The Shelf Life (shelflife) field contains the shelf life in days for that part number. If you have activated pc/MRP's optional serial/lot number module, receive completed assemblies back from manufacturing, and select to enter serial/lot numbers, pc/MRP will insert the expiration date into that serial lot/number based on the date and the shelf life.

The Class Field (class) is used by pc/MRP's Inventory Cycle Count Module. All Class A parts are counted every 30 days. All Class B parts are counted every 90 days. All Class C parts are counted every 180 days. This field must be filled in with either an A, B, or C. See the Cycle Count Module section in this manual for additional details on automatically filling this field.

The Catindex (catindex) field is utilized in the optional Sales Analysis module. This allows the end-user to leave min quantities for part numbers or assemblies unchanged regardless of usage figures by entering "SAV" into that part's or assembly's catindex field.

Checking the Floor Stock Item check box (floorstk) will prevent this part number from being decremented when the stock room module is used to issue parts to manufacturing. If a part number is stored on the manufacturing floor (such as nuts and bolts) and is not issued with the assembly, you would check the floor stock check box. Use the stock room's "Adjust Quantity" method to decrement the stores quantity when refilling the bin box on the manufacturing floor.

Checking the Web Item check box will allow you to mark a part number that is to be listed on your web site.

The Start Date (startdate) references to the date the part was first entered into the Part Master.

 

5.1.9 Edit/View A Part Number

This option allows users to scroll, edit, delete, undelete or run queries against Inventory records.

Selecting an Indexed Search allows users to search on indexed fields.  This allows pc/MRP to find the information much faster.  To perform an Indexed Search select the:

·         Indexed Search tab

·         Desired Sort Order, Partnumber, Model Number, Description, or Manufacturer

·         Enter the applicable data in the Begin Scrolling At: field

·         Select the desired Action, View or Edit

·         Press Search

pc/MRP will automatically scroll to the desired record or the nearest match.  Select the correct record by scrolling and press Ok to proceed to the edit screen for that record.

Selecting to run a Queried Search allows users to build, run, save, and load queries for the Inventory table.  For further details see chapter 15.14.

Pressing the Save Settings button will allow pc/MRP to default to the scroll screen settings you like the next time you decide to edit/view a part number. Your screen default preferences will be saved in a file with your log in name with an .usm extension.

Every field within the inventory edit screen is editable.  If fields within the inventory screen are gray and not editable, check option 62 in the settings and utilities. 

Within the inventory edit screen users can also mark inventory items for deletion or unmark inventory items for deletion.  If users press the delete or undelete button, pc/MRP will locate and mark for deletion or undeletion every occurrence of that part in every BOM. It will then ask for permission to remove those records from disk for both the inventory and BOM database files. If you have a number of parts to mark for deletion and wish to save time, answer No to removing the marked records from disk. Mark the remaining parts for deletion, then on the last part number allow the program to remove the records from disk.

5.1.10 Change Part Number

This option will change the part number in both the Inventory Database File and the BOM Database File.

5.1.11 Find Parts (Matching A Partial Description)

Allows users to search for all parts matching a specified description in the Inventory Description Field or Memo Field. For example, to search the Inventory Description Field for all elbows you could select D, for search on description and enter the letters ELB.

5.1.12 Reports (Print/Display Inventory Reports)

There are a variety of standard and custom reports to choose from in pc/MRP. See section 15.4.1 to create custom reports. All standard report options are as follows:

All parts uncosted (part.frx and cuspart0-cuspart9.frx with partmast.dbf)
All parts costed (onhand and wip) (part$.frx and cuspart0-cuspart9.frx)
All parts costed from a specified manufacturer(part$.frx and cuspart0-cuspart9.frx)
All parts costed from a specified vendor (part$.frx and cuspart0-cuspart9.frx)
All parts costed from a specified model number (part$.frx and cuspart0-cuspart9.frx)
All parts costed from a specified division (part$.frx and cuspart0-cuspart9.frx)
Inventory Movement Report (versions 6.59 and higher, parmov.frx with movement.dbf)

This report summarizes all part movements for a time period you specify and categorizes as Received (component parts received and assemblies received from manufacturing), Invoiced, Issued, and Adjusted Quantities. The Initial and Ending Quantities will be calculated, if the part number's last physical inventory date and last physical quantity fields are populated. This report can back calculate to the initial quantity if the physical inventory was taken after the report's start date. These two fields are automatically populated when you take a physical inventory or you enter the quantity when the part number is initially entered into inventory. The Inventory Movement Report has the following columns, part number, initial quantity, received quantity, adjusted quantity, invoiced quantity, issued quantity, and ending quantity. The initial quantity column will display the word "Unavailable" if the initial qty can not be displayed due to the lack of a physical inventory count. A "*" will be displayed next to the initial qty if the part's initial qty had to be back calculated to a date prior to the date the last physical inventory was taken.

Price List
Assigned Vendor List (version 6.90 and higher, avl.frx with avldata.dbf)


Include:

All records
Parts only
Assemblies only
Both parts and assemblies
Labor only
Field {field name} is {>, >=, =, <=, <} Value {user defined}
AVE cost > 0
Sale price > 0
Specified product code only
Specified suffix code only
Specified class only

The report sort options include:

Description
Part number
Part number root
Manufacturer
Model number/Part number
Model number/Division Location

Location
Primary Vendor
Unit cost
Cat index
Division
Extended cost
Cycle count class
Drawing Number

Buyer Code

The report output options include:

Displayed on screen
Printed in narrow carriage format
Printed in wide carriage format
HTML file

ASCII text file
XLS file
DBF file

If the Database, Comma Delimited or ASCII output options are chosen, pc/MRP will create a file of that type which contains all of the raw data used by the report. If you have the Windows Generic Print Driver installed, you may select one of the Print output options. Then select Print to File to generate a text file, which mirrors the actual report. Any portion of the printed report, which normally appears in bold, will be included in the text file three times. You may edit the report forms to remove the bolding and prevent the duplication. See Configuration, Settings & Utilities, option 24.

The report format options include:

Standard format
Custom format (see custom report section)

5.1.13 Labels (Print Part Labels)

Prints out labels for the following items:

All parts (parlabel.lbx or cparlab.lbx with pastmast.dbf)
Product Code (parlabel.lbx or cparlab.lbx with pastmast.dbf)
Part number (parlabel.lbx or cparlab.lbx with pastmast.dbf)
Division (parlabel.lbx or cparlab.lbx with partmast.dbf)
Assembly (bomlb.lbx or cusbomlb.lbx with bomtemp.dbf)
Receiver (reclabel.lbx with reclbtmp.dbf )
Work/Sales Order Serial Numbers (lblwo-sn.lbx with parlbtmp.dbf)

You can customize pc/MRP labels using Configuration Utility, option 24 or Visual FoxPro 6.0, see Customizing pc/MRP for Windows, section 15.4.1 of this manual.

The standard labels can be purchased at any office supply store selling 15/16" high by 3-1/2" wide single row pin fed labels designed for dot matrix printers. These labels are also available from Rapid Forms in white (5K350151), yellow (5K350151), blue (5K350151), or green (5K350151). To order from Rapid Forms call 800-257-8354.

The labels can be used to accurately label part bins, parts, etc.

pc/MRP labels are designed for dot matrix and laser printers. If you are using a laser printer, answer no when prompted to align labels as laser labels do not require alignment. If you are printing out labels with a laser printer, use 1"x4" labels 20/sheet. Use your laser printer to print the first row of labels, then reverse the sheet to print out the second row of labels.

The Work/Sales Order label option creates a MEM file (wosernum.mem) to store the last serial number issued. It increases the serial number and prints out as many labels as received for the Work/Sales order line item.

5.1.14 Sales Price Markup

Automatically mark up every part's sale price by a specified % of each parts current cost or sales price.

5.1.15 Cost Roll Up (Automatic)

Cost Roll Up uses the Bill of Materials to automatically update all assembly costs or the assembly cost for a single assembly. The new costs are then recorded in the Inventory Database File. You can update either the average cost, standard cost or last PO cost.

 

 

5.1.16 Physical Inventory (and Cycle Count Programs)

This option allows users to take a physical inventory and/or cycle count of all parts that have not been issued to the floor (WIP). See the Physical Inventory Section of this manual for a more complete description of the Physical Inventory and Cycle Count Programs.

5.1.17 Audit-Duplicate Parts

This function searches inventory for duplicate part numbers. You will be asked if you want to remove duplicate part numbers. If you answer yes, and it finds duplicate part numbers, it will mark the second part number for deletion. The program will continue searching the inventory database file for additional duplicate part numbers until it has marked all duplicate part numbers for deletion. The program will then remove the part numbers marked for deletion from the disk. If you answer no, pc/MRP will display or print a list of duplicate part numbers.

5.1.18 Audit-WIP Quantities

pc/MRP versions 6.78G and lower allow the user to correct inventory WIP quantities based on the open sales and work orders and the stock transaction records issued to manufacturing as per the pseudo code below:

Selecting the Partmaster Data Base File
Zero out all WIPQTYs
Select Stock Transaction Data Base File
Set filter to ACTION = "ISSTM"
Do while not end of file
   Store the SONO
   Store the Itemno
   Store the Qty issued to m_parts_issued
   Store the Qty required to m_parts_required
   Select Sales (Includes Work Order records also)
   Find the SONO
   If found()
      Store Original Qty required to m_assys_req
      Store Qtyassembled  to m_assys_assembled
      Store Qty shipped to m_assys_shipped
      If open and m_assys_req > m_assys_assmebled and _assys_req > 
                                                     m_assys_shipped
         Select the Partmaster Database File
         FIND the PARTNO
         If found()
            If m_assys_assembled = 0
               Replace the wipqty with wipqty + m_parts_issued
            Endif
            If m_assys_assembled > 0
               Replace the wipqty with wipqty + (m_parts_required x (1- 
                                          (m_assys_assembled/m_assys_req)))
            Endif
         Endif
      Endif
   Endif
   Select Stock Transaction Data Base File
   Skip to the next stock transaction record
Enddo 

 

pc/MRP Versions 6.78H, 6.79G and higher added the option to print out a WIP Variance report (WIPVAR.FRX). This report displays the quantity in WIP based on the stockroom records compared to the quantity in WIP based on the inventory WIPQTY fields. If you select "Show Detail" all related stock transactions for every part will be displayed under each part.

This report will only print or display open sales or work orders if it is not complete (the complete field does not contain a "Y"), the order was issued (in the stockroom there is an ISSTM record), and, the quantity issued is greater than the quantity returned. With pc/MRP version 6.91H and higher, the audit WIP report also displays parts with WIP quantities in inventory that do not have a relevant stockroom transaction if users check the "Include all parts option".

This report can be helpful in displaying which sales/work orders are currently open and are on the manufacturing floor.

The quantity issued column contains the quantity of that part number issued to that sales/work order. The quantity returned column contains the quantity returned (as part of the finished assemblies). The correct WIP quantity (stockroom) contains the quantity issued - (minus) the quantity returned. The current WIP quantity represents the quantity in the inventory WIP quantity field. The variance is the difference between the stockroom module and inventory module.

If the report's stockroom quantities are too small, determine which sales/work orders have not been issued by pc/MRP. Use the stock room module to issue them.

If the report's stockroom quantities are too large, determine which sales/work are open that were closed some time ago. Use the stock room module to receive these sales/work orders back from manufacturing or close out the sales/work orders by entering a Y the complete field of the sales/work orders.

Once the corrections have been made, run the report again. If the new quantities are correct run the "Correct WIP Variances" option to transfer the new WIP quantities into the inventory WIPQTY fields.

If you select the "Correct WIP Variances" option, pc/MRP will correct the WIP quantities in inventory as per the following pseudo code:

Replaces all partmast wipqtys with 0
Uses open sales and work orders (complete # Y)
Do while not end of file
   If the related stock transaction = ISSTM
      in_wip = qtyissued-qtyreturned in completed assys 
      If in_wip > 0 
         Increase partmast wipqty by in_wip
      endif
   endif 
Enddo   

Once WIP is correct, you can run a physical inventory on the stores area(s) and correct the quantities for that area (do not include WIP quantities as they have already been corrected at this point).

5.1.19 Index (The Inventory File)

Allows users to re-index the inventory main index files. pc/MRP automatically updates its index files under normal operation. However, if you ever get a "record out of range" error message, or you can not find a part number you know exists, re-indexing the index file is usually the cure.

 

5.1.20 Remove Marked Records

Removes all Inventory Records marked for deletion from the disk. The records will no longer be recoverable. The remaining records are then automatically re-indexed.

5.1.21 Un-displayed Inventory Fields

The Inventory table contains many un-displayed fields. The following is a list of those fields and the purpose for each of those fields.

pc/MRP's physical inventory program stores the physical inventory counts in the invarea1-invarea8 and invtot fields. Once the counts have been verified and the user pressed the update button. The counts are moved from the invarea fields to the stores and areaqty fields.

The lastphydat field stores the date the last time a physical inventory was taken with pc/MRP's Physical Inventory Module. The lastphydat field will also be filled when the part number is first entered.

The lastqty1-lastqty6,lastqtywip fields store the physical inventory quantities recorded on the date the last physical inventory was taken with pc/MRP's Physical Inventory Module. These fields will also be filled when the part number is first entered.

The above fields allow pc/MRP's inventory movement report to calculate the physical inventory at any date. However, for this to work, the following practices must be followed.

5.1.22 Inventory Technical Information

o        Databases

§         Partmast.dbf

o        Indexes

§         Bypartno.idx = upper(substr(partno,1,mnsize))

§         Bymodeln.idx = upper(modelno+partno)

§         Bydescri.idx = upper(descript + partno)

§         Bymanufa.idx = upper(manufacter+partno)

§         trunpart.idx = upper(substr(partno,mprodsize+1,mremsize))

§         vendcur.idx = upper(vendcurncy+partno)

§         vendcur2.idx = upper(vendcur2+partno)

§         vendcur3.idx = upper(vendcur3+partno)

§         Bydescri.idx = upper(descript + partno)

§         Bymanufa.idx = upper(manufacter+partno)

o        Programs:

§         Mrpmenu.mnx

§         Partmast.prg

§         Enterpar.prg

§         Generates next available part number with getnextp.prg

§         Creates memory variables using scatter memvar memo blank

§         Sets m.poratio=1,mltime=default or 7,mclass=A,mpart_assy=P

§         Do form Partscr.scx

§         If cancel button was clicked (mdebut = 2), return

§         Load the area qtys inot last phys qtys (m.lastqty1=m.onhand)

§         If part number exists, display error message and return

§         Insert into partmast from memvar

§         Store upper(mpartno) into m_rmt_part if this was entered from a PO or sales order

§         Editpart.prg

§         Do scroll2.prg to find record

§         Find part number

§         Creates memory variables and array aBeginValues from record including memo fields

§         Do form Partscr.scx

§         If cancel button clicked (mDebut = 2 ) or mpurpose is not E (edit), return

§         Scatter current record from dbf file to aEndValues array

§         If aBeginValues and aEndValues are not the same, edit again or exit

§         Gather changes and save record

§         If record marked for deletion, delete it

§         If audit trail activated save edits to audit trail dbf

§         Changeno.prg

§         Disppart.prg

§         Prpartl.prg

§         Labels.prg

§         Markup.prg

§         Allboms.prg

§         Entrphys.prg

§         Do Checkdbf with "duppart"

§         Auditwip.prg

§         Reindex.prg

§         Pack&shr.prg

o        Forms:

§         PartScr.scx Form

§         Data Enviroment:

§         None, Control Sources use memory variables