Ingeniero

Troubleshooting MRP problems
Author: QAD Support Article ID: AA-01518 Views: 605 Created: 1997-09-11 20:30 Last Updated: 2012-10-08 13:02 | 0 Rating/ Voters | |
goal: Troubleshooting MRP problems
goal: How to search for and delete stranded qad_wkfl records.
fact: MFG/PRO All Versions
fact: 23.1 Net Change Materials Plan
fact: mrmpnc.p
fact: 23.2 Regenerate Materials Plan
fact:mrmpup.p
fact: 23.3 Selective Materials Plan
fact: mrmprc.p
fact: stranded qad_wkfl
fact: qad_wkfl
fact: qad_key1 = "mrp/drp"
fact: MRP required flag
fact: MRP Required = YES
symptom: MRP not planning an item
symptom: Planned orders are not created for all Lower Level components
symptom: MRP does not plan orders for all components
symptom: MRP not planning for all items
symptom: MRP planningincorrectly
symptom: MRP not planning correctly
symptom: MRP required flag remains at "YES" after running MRP
symptom: MRP required flag not reset to "NO" after MRP run
symptom: Stranded qad_wkfl records are not deleted when session is terminated
symptom: ** No pt_mstr record is available. (91)
symptom: MRP hangs
cause: Any abnormal termination of an MRP run could leave stranded records inthe qad_wkfl.
fix:
Search for stranded records in the qad_wkfl by running the following Progress query:

for each qad_wkfl where qad_key1 = "mrp/drp":
display qad_wkfl with side-labels.

If there are stranded qad_wkfl records they need to be deleted by running the following Progress query:

for each qad_wkfl where qad_key1 = "mrp/drp":
delete qad_wkfl.

Note: Above search/queryshould only be used when MRP is NOT being run.
Stranded qad_wkfl's are usually caused by any abnormal termination of MRP (Control C, power failure, spike, etc.). This search/query should be added to any recovery procedure if the system goes down, or possibly added as an additional batch job on an as-needed basis, if users are prone to using Control C during MRP.

If the above queries do not resolvethe issue, follow the steps below.

IDENTIFICATION
--------------

Non-Processing of an Item may occur in the following situations:

1. Low-Level codes are not properly set.
2. An Item Master (pt_mstr) exists but the Inventory Master (in_mstr) does not.
3. An Inventory Master (in_mstr) exists, but the Item Master (pt_mstr) does not.
4. The MRP parameters did not include the Itemnot being planned
5. MRP is abnormally terminating.
6. The Plan Orders (ptp_plan_ord) flag for the Item is set to "no" in 1.4.7 Item Planning Maintenance (ppptmt02.p) or 1.4.17 Item-Site Planning Maintenance (pppsmt02.p)
7. The parent Item is a purchased Item. &nbs. p;
8. The parent Item is a phantom and quantity on-hand exists.
9. The MRP horizon is shorter than the time fence.10. No activity has occurred for an item since the last MRP run.
11. The Order Policy for an Item is "blank".
12. MRP does not pass demand across sites.
13. The Plan Orders flag in 1.4.1 Item Master Maintenance(ppptmt.p) or 1.4.17 Item Site Plan Maintenance (pppsmt02.p) is set to "no".
14. The Order Policy(pt_ord_pol) field is =FOQ and the Order Qty(pt_ord_qty)=0.
15. There is a BOMattached to the parent item in 1.4.7 Item Planning Maintenance (ppptmt02.p) or 1.4.17 Item-Site Planning Maintenance (pppsmt02.p)
16. No shop calendar exists.

IDENTIFICATION AND CORRECTIVE ACTION
------------------------------------

A) Run 23.3 Selective Materials Plan (mrmprc.p) for the Item not processed. If this works and the Item processes correctly, MRP cause 1, 2, 3, 4 or 5 may havecreated this situation.

CAUSE 1: To reset the Low-Level Codes run 36.25.3 Low-Level Code Update (utllup.p).

CAUSE 2: To determine if an Item Master (pt_mstr) exists but the Inventory Master (in_mstr) does not, run the following PROGRESS program:

for each pt_mstr no-lock:
find first in_mstr where in_part = pt_part no-error.
if not available in_mstr then
display pt_part with title...