MRP, capacity and job work
hayaterp.com ↗Plan production in Hayat Manufacturing — MRP plans from sales orders, minimum stock and a manual plan, netted against stock, open orders, purchase orders and requisitions; Make and Buy suggestions level by level; creating draft production orders and one purchase requisition; the capacity heat map per work centre; and job work — sending material to a stitching unit or dyeing house, receiving it back, the contractor's bill and what it costs the order.
MRP (material requirements planning) answers what do we need to make, and what do we need to buy, and by when. Capacity shows whether the work centres can do it. Job work covers the work you send out to contractors. MRP needs mfg.plan; job work needs mfg.produce.
MRP plans
- MRP plans → + Plan.
- Give it a name and date, the horizon in days (the settings' MRP horizon by default) and, optionally, one store to plan for.
- Choose what counts as demand: sales orders, minimum stock and open orders; add manual demand lines (item, quantity, due date) for anything else — a forecast, a trade show, a buffer.
- Create plan, then Run MRP.
- Check the Suggestions, change quantities or due dates, Ignore what you do not want.
- Tick the lines (or Select all open) and click Create documents.
What MRP counts
| Demand | Supply |
|---|---|
| Open sales orders (confirmed or part delivered) due within the horizon | Stock on hand (all your stores, or the plan's store) |
| Manual demand lines | Output still to come from open production orders |
| Materials not yet issued to open production orders (when open orders is ticked) | Open purchase orders not yet received |
| Minimum stock: when stock would fall below an item's minimum (else re-order) level, top up to its maximum | Requisitions pending or approved and not yet ordered |
Items are netted level by level. An item with an active BOM gets a Make suggestion, and its components become demand on the next level (phantoms pass straight through); everything else is Buy. Each suggestion shows the gross need, on hand, on order, the net need, the suggested quantity, the due date and where the demand came from.
Create documents turns the ticked lines into:
- Make → one draft production order each (planned start today, end from capacity), linked to the plan. Release them from Production orders.
- Buy → one purchase requisition in Purchasing (source MRP), sent for approval if you leave submit requisition ticked.
Running a plan again replaces its open and ignored suggestions; lines already turned into documents stay. A plan whose documents were created is Firmed and cannot be edited.
Capacity
Capacity is a heat map: one row per work centre, one column per day (the next 14 days by default, up to about three months). Each cell shows the load % — routing hours of open orders' unfinished steps, spread evenly over each order's planned working days, against the centre's capacity hours. Overloaded days are red, and the list below names the overloaded centres and which orders load them.
Off days are skipped; late orders count from today. Capacity only warns — nothing is blocked. To fix an overload, reschedule orders or add capacity hours to the work centre.
Job work
Job work is material you send to a contractor — a stitching unit, a dyeing house, an embroidery shop — who sends back finished or part-finished pieces and charges per piece. Contractors are your Purchasing suppliers (not blocked or inactive).
There are two kinds:
| Kind | When | What comes back |
|---|---|---|
| For an order | One step of a production order is done outside, e.g. washing | Pieces that continue on the order; the step gets the quantities |
| Standalone | The contractor makes an item from your material | The output item, into your store |
- Job work → + Job work (or Send step for job work on the order's Job work tab).
- Choose the contractor, and either the order and step or the output item; enter the quantity, rate per unit, tax %, expected back date and the materials to send with their batches.
- Save (Draft), then Send. The materials move to a store named after yours with – Job work (at contractors) (code ending
-JW), so you always see what is lying at contractors. - When goods come back, Receive: quantity received and rejected, the contractor's bill no., the lot, and, if different from the default, the materials actually consumed. Tick final on the last receipt.
- Return materials sends back anything unused; Close when nothing is left at the contractor.
What each receipt does:
- Materials consumed — by default the share of what was sent for the pieces received and rejected (everything left on a final receipt).
- For an order — the consumed materials are issued to the order, the step gets the pieces in, out and rejected and a progress line (operator = the contractor, machine = Job work).
- Standalone — the output item goes into your store at (materials + charges) ÷ pieces received.
- Charges — received × rate becomes a Purchasing bill, posted at once on the contractor's account; the order's subcontract cost goes up by it. The receipt shows the bill number.
Statuses: Draft → Sent → Partially received → Received → Closed. Cancel works on a draft, or on a sent job with nothing received (the materials come back). Change expected date moves the due date; every 12 hours supervisors are told about job work past its expected date. An order cannot be closed while it has job work at a contractor.