Caliach ERP/MRP exercise (to create a new TDK Hard drive)

Objectives:

1) To gain some basic working experience in using a modern MRP/ERP package.

2) To learn more about the various functions in BOM and MRP modules.
3) To learn about how to prepare the key data before you can run a MRP process.

Procedures:

1) Install Caliach on your computer from <K> drive, Scratch folder, with a subfolder <AL>.
2) Run the system, and log in as ‘SYS’, no password.
3) Allow system to extend all relevant dates.
4) We will explore around an existing product ‘AHD01000’, 100Gb removable hard drive.
5) From the Caliach menu bar, locate the option to view the Bills-of-Materials for AHD01000.
6) List its entire BOM assembly.
7) Now, draw a typical BOM graphical chart to layout the structure of the product. You will need
this information for the rest of the exercise. Do it now on a separate piece of paper.
8) From the BOM menu, you can also use the option to locate ‘where used parts’ by their
assemblies. ‘Where used parts’ is very useful if there is any design change to a particular part
which is used by many other assemblies.
9) Lets find the assemblies which use the following parts (one at a time):

 CNC Punch Die

 DSK 01000
 PSU00002

10) From the ScratchPads, select <Parts>, then <Parts ScratchPads options>, highlight
‘AHD01000’, then select <Show BOM for Selected>. This a quick way to shows a product’s
BOM, but note that it only shows a single level of components.

Try to understand more about BOM and the information it carries:

11) From BOM, select <Print Reports>. Enter the part number ‘AHD01000’ in both columns. Here,
you should find out what ‘Assembly Single Level’ and ‘Assembly multi-level’ mean by printing
the results to the screen and compare them.
12) Also experiment with <Component where-used single level> and <Component where-used
multi-level>. Try different part no., e.g. MET00001, MET00002, PSU0002.
13) In single level, the system only displays one level of details. Here, you should find that
MET00001 is immediately used by AHD01000, and MET00002 is immediately used by
MET00001.
14) Now try multi level for the same parts. Here, you will find that not only the immediately parents
are shown, but all assemblies which contain that particular part will also be displayed.

Parts information:

15) Now, select <Parts> from the <Masters> menu, then select <View>.
16) Browse through several parts and the information associated with each part.
17) Notice the <Index code 1> shows you the type of the part; it can be ASSY, Component,
Materials, Fixings, or Others.

1
Work Centre information :

18) Select <Process Routes> from <Masters>, then <Work Centre>. Have a look at the information
for each work centre (qty, hrs/day, setup labour and overhead, runtime labour and overhead.
Add a new work centre called ‘CNC2’, using the same details for CNC but with 10 hrs/day.
19) Select the process routes for assembly AHD01000 and take a look. Then change the assembly to
MET00003. Finally select route for CNC Punch Die. Notice process route information is only
for Assembly, not for components (make sense?).

Create new parts and assembly :

20) Now, lets try to create a few new parts and a new disk unit called ‘TDK HARD DRIVE’ (Hard
Drive made for TDK) .
21) ‘TDK HARD DRIVE’ is a new assembly. It is Class B in ABC code. Its level consists of
‘MET00011’ (new), MET00002 (exist), and Pla00003 (exist).
22) First, you have to create ‘TDK HARD DRIVE’ and ‘MET00011’ as new parts.
23) The description for ‘MET00011’ is ‘Hard drive unit for TDK HD’.
24) The new sub-assembly ‘MET00011’ consists of ‘CAB00002’ (exist) and ‘MET00003’ (exist) at
level 1.
25) After you have completed this, print the full list of BOM for ‘TDK HARD DRIVE’ assembly to
make sure all the components are there.
26) You can add work centres and operations to this new assembly ‘TDK HARD DRIVE’ if you
have time. Any work centres you want to use must first exist before you can add any operations
to an assembly.

Engineering Data

27) Take a brief look at the Engineering Data in the <Masters> menu. Scroll to part no. ‘FAS00001’
and browse its associated information. Note that you may attach a drawing to a document for a
part.

Inventory Control

28) Now take a look at <Inventory Control> option under the <Process>. Try to understand the
terminology used. For e.g. ’physically qty’ for Part FAS00001 is 5347, but there is a ‘safety
stock’ of 100, so leaving only 5247 as its ‘projected stock’.

MPS and MRP

29) We will create a Production Plan for our new assembly ‘TDK HARD DRIVE’. The plan is to
make 20 units of ‘TDK HARD DIRVE’ by 01 June 2009. Make sure you save it.
30) Now select ‘List Entire Production Plan’ and you should find all the existing Production Plans,
including the one you just created.
31) Now select <Forecast and Auto-Plan> under the <Material Planning> under the <Process>
menu.
32) Select ‘TDK HARD DRIVE’ and alter some of the forecast. Note that the customer order for
20 units due on 1st June is also there.
33) Now select Master Production Schedule. Make sure you <Production Plan Active Items> is
selected. Then click on <Build MPS list>. You should see the Production Plan we created for
‘TDK HARD DRIVE’ is now in the current MPS.
34) In theory, you have enough information to run the MRP now. Note that when you run MRP, you
may also include part requirement calculation for things like ‘Quotation’ and ‘Estimates’.