Material Mgmt Workbook v2

Material Management Quick Study Guide

Table of Contents Event Process in FabTrol MRP Production ………………………………….……….

Creating Projects for Production ……………………………………….…… Project Specifications ……………………………………………………...….

ABM Material Management Event Process …………………………………………. Reviewing ABM Sequencing …………………………………………………. Creating ABM Nests in the OptiMiser module ………………………………… Reviewing the Parts to Cut ……………………………………………………. Reviewing Available Stock ………………….……………………………… Reviewing Purchasable Lengths …………………………………………….. Setting Optimization Options and Calculating Nests …………………………… Reviewing Nestings ………………………………………………………… Adjusting Nestings ………………….………………………………………. Approving Nestings …………………………………………………………. Using a “Check Me” Nest to Identify Outstanding Items …………………… Reviewing the ABM Buy List ………………………………………………… Creating Purchase Orders ………………………………………….…………. Filling Purchase Orders from the Buy List ……………………………………… Issuing and Printing Purchase Orders …………………………………………… Preposting Purchase Orders ……………………………………………………… Reviewing ABM Reports ……………………………………………………

DBM Materials Management Process ………………………………….…………… Linking Detailed Jobs to Advanced Bill Jobs ………………………….………… Reviewing Sequence Assignments ……………………………………………… Nesting DBM Cut Lists with ABM Material ……………………………..……… Creating DBM Cut Lists ……………………………………………………… Reviewing the Parts to Cut …………………………………………………… Reviewing Available Stock ……………………………………………….…… Reviewing Purchasable Lengths ………………………………………………… Setting Optimization Options and Calculating Nests ………………………….. Reviewing Nestings ……………………………………………………………. Adjusting Nestings …………………………………………………………… Approving Nestings ………………………………………………………….. Using a “Check Me” Nest to Identify Outstanding Items ……………………… Reviewing the Buy List ……………………………………………………… Creating Purchase Orders ……………………………………………….…….. Filling Purchase Orders from the Buy List ……………………………………… Issuing and Printing Purchase Orders …………………………………………… Preposting Purchase Orders ……………………………………………………… Receiving Purchase Order Items ………………………………………….……… Verifying Cut Lists …………………………………………………………… Managing Unverified Items ……………………………………………………… Working with the Expanded Cut List …………………………………………… Confirming Cut Lists ………………………………………………………….. Adjusting Nestings in the Confirm Cuts window …………………………..……

1 2 3 4 5 6 7 8 9

11 13 14 15 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 33 34 35 35 36 37 38 39 40 41 43 44 45 46 47

Managing Stock with the StockMiser module ……………………………………… Adding, Editing, and Reviewing Stock Items …………………………………… Stock Status ……………………………………………………………………. Stock Categories ……………………………………………….…………….. Manually Allocating Items ………………………………….………………… Stock Usage Report …………………………………………………………….. Stock Reports ……………………………………………………………………

The PurchaseMate module: Integrated Purchasing and More ……………...……..……… Setting Purchase Order Preferences ………………………………….…….……… Purchasing Reports …………………………………………………………..

48 49 50 50 51 52 53 54 55 56

FabTrol MRP – Interface Basics

FabTrol MRP Version: 2.0.x Quick Study Guide edition: January 2007

i

Interface Basics Welcome to FabTrol MRP. Following is an overview of the tools available in FabTrol MRP, plus an introduction to basic functions you’ll need to know.

Menus When you first open FabTrol MRP, you’ll see a conventional set of Windows menu commands across the top of your computer screen. These menus provide access to all FabTrol MRP functions.

The File, View, Tools, Edit, and Help menus contain functions common to all FabTrol MRP modules. The Estimating, Projects, Drawings, and Production menus are module-specific. The Materials menu provides access to functions associated with the purchasing, nesting, and stock maintenance modules.

Toolbar Just below the menu bar, you’ll see a toolbar. The buttons on this toolbar provide single-click access to many of the program's most common functions. This toolbar can be repositioned at the bottom, top, or sides of the window view area by clicking on it and dragging it to the desired location.

Add, insert, or delete items in a list or table

Move through fields or records in a list or table such as the Takeoff Entry or Bill of Materials windows

Switch views between imperial and metric units of measure

Create a new project

Open an existing project

Open the Reports window

Use the search function available in some windows (usually the size searcher)

FabTrol MRP – Interface Basics


ii

Materials Management – Quick Study Guide


1

Event Process in FabTrol MRP Production

Create new Detailed project

Is an ABM necessary?

Create Advanced Bill project

ABM Materials Management

Project SpecificationsCustomer notationPaint CalculatorShipping destinationMiscellaneous information

Project Organizer

Import Bill of Materials

DBM Materials Managment

Drawing Management

Production Management

Ship to job site

Interim Shipping

YES

NO

TRACK DETAILED PROJECT INFORMATION

AND SCHEDULE



2

Creating Projects for Production When you are awarded a contract, the first thing you should do is create a Detailed job. If necessary, you can also create an Advanced Bill job.

To open this window click: File menu > New

Things to remember about new jobs Project numbers must be unique.

Project numbers allow up to eight alphanumeric characters.

Project numbers can not contain the following characters:

/ \ [ ] < > ~ ! @ # $ % ^ & * ( ) + = Project numbers can contain the following characters:

- _ Advanced Bill project numbers can be suffixed with an “A”.



3

Project Specifications After you have created a new project, you should open up the Project Specifications window and fill out some information about the project.

To open this window click: View menu > Project Specs

Fields to enter in the Project Specifications window At a minimum, the following Project Specification fields should be filled out for a Detailed job:

Project tab:

Related estimate no.

Related advanced bill no.

Contacts tab:

Customer

Coatings tab:

Fill out the fields for a finish code in the Paint Calculator

Shipping tab:

FOB point

Destination

Directions

Misc. tab:

Shop order number (if different from FabTrol MRP project number)

Customer PO number



4

ABM Material Management Event Process

Create Advanced Bill project

Review Sequencing in the Bill of Materials

Create Advanced Bill cut lists in the

OptiMiser

Adjust nestings in Nest Explorer

Approve cut lists in Optmiser

Create a “Check Me!” nest to look for

outstanding items

Create purchase orders from the Buy List in PurchaseMate

Issue purchase orders in

PurchaseMate

Confirm delivery dates by Preposting PO’s to

stock in PurchaseMate

Receive PO items as they arrive in

PurchaseMate



5

Reviewing ABM Sequencing Sequences in an Advanced Bill project are used to establish the order of fabrication. Using sequences in an Advanced Bill project help you establish the purchasing priority of your project.

To open this window click: View menu > Bill of Materials



6

Creating ABM Nests in the OptiMiser module Once you have a preliminary bill of materials, you can create nestings in the OptiMiser module. Trial nests are the first step of the nesting process.

To open this window click: Materials menu > OptiMiser

Things to remember about creating trial nests A nesting, a cut list, and a multing are synonymous terms in the OptiMiser module.

To create a trial nest, do the following: 1. Remember to set a nest filter and nest name. The nest name should reflect the nest

filter.

Nest filters will generally be by sequence and material type.

2. After you set your nest filter, review the items on the Parts to Cut tab.

3. Review the items on the Available Stock tab.

4. Review the items on the Purchasable Lengths tab.

5. Calculate your nesting by clicking the Next >> button on the Calculator tab.



7

Reviewing the Parts to Cut The Parts to Cut tab will show you the bill of material items that meet the criteria of the nest filter.

To open this window click: Materials menu > OptiMiser > Parts to Cut tab

Things to remember about the Parts to Cut tab You can adjust the nest filter with the Filter button.

The Print button will print a filtered listing of parts on this nesting.

The Status button will show you if like part marks are cut on other nestings.

The Cut Info button will show you if a part has contours or miters.



8

Reviewing Available Stock The Available Stock tab will show you the items in stock that meet the filter conditions of both the Nest filter, and the Available Stock filter.

To open this window click: Materials menu > OptiMiser > Available Stock tab

Things to remember about the Available Stock tab If stock items do not match both the Nest filter and the Available Stock filter, then a “No

stock matches the filter condition” Alert! window will open:

The stock filter can also be accessed from the Optimization Options window.

When nesting into stock that has a category of “On Order,” the Use materials on or available before date filter must be adjusted.



9

Reviewing Purchasable Lengths The Purchasable Lengths tab is where you specify what material lengths are available from your vendors.

To open this window click: Materials menu > OptiMiser > Purchasable Lengths tab

Things to remember about the Purchasable Lengths tab Every setting on the Purchasable Lengths tab is adjustable by the selected material type and

size.

Allowances for saw kerf, trim cutting, and clamping are set on the Purchasable Lengths tab.

The scrap remnant threshold is set on the Purchasable Lengths tab.

Each item must have a unit cost in order to nest.



10

Setting and saving lengths in the Purchasable Lengths tab Each material type in FabTrol MRP is assigned a default set of purchasable lengths. These lengths are stored in the Unit Price File. However, alternate lengths can be saved and filled in the OptiMiser window.



11

Setting Optimization Options and Calculating Nests When you are ready to calculate your nesting, click the Next >> button on the Calculator tab.

To open this window: Materials menu > OptiMiser > Click Next>> on the Calculator tab

Things to remember about setting optimization options Set the planned cutting date according to your project schedule.

The stock available date should be set to one day before the cutting date.

Cut to size nestings are calculated by de-selecting both Purchasable bars and Stock items, and selecting Order new material cut to size.



12

Setting Advanced Optimization Options If you adjust Advanced Optimization Options on your first nest, then the settings will be copied to subsequent nestings.

To open this window click: Advanced Options in the Optimization Options window

Things to remember about the Advanced Optimization Options window Optimize for waste, not cost will set all costs for purchasable lengths to the same value. This

value setting will only be for calculation purposes only.

Do not use this option if you have entered pricing and lengths from multiple vendors into the Purchasable Lengths tab

A Power factor value of six results in the most comparisons between nesting solutions

A Material handling factor will result in longer bars used over shorter bars.

The Stock valuation is turned on by default. It ignores the actual value of stock and values stock at 10 cents on the dollar for calculating purposes only. The actual value of stock is not affected.



13

Reviewing Nestings After you calculate a nesting, you can review it by clicking Nest Results.

To open this window click: Nest Results in the OptiMiser window

Things to remember about the Summary of Nesting Results window The Summary of Nesting Results window provides a “bird’s eye view” of a nesting.

The Copy to Clipboard button will allow you to copy the contents of the Summary of Nesting Results window into an email.

The remnant length is the total remnant length for all bars.

The percentages are calculated by dividing the total remnant length by the total bar length.



14

Adjusting Nestings Once you have calculated a nesting, you can adjust it in the Nest Explorer window.

To open this window click: Nest Explorer button in OptiMiser

Things to remember about the Nest Explorer window The Nest Explorer window may be used for cut list adjustments when a nesting is in a trial or

approved state.

Bars are a nesting solution. Parts are nested into bars.

Bar numbers begin at 3 and restart for every material type, size, and grade.

Bars appear in the tree-view (left-hand side) of the Nest Explorer window.

Information about the bar appears in the upper right-hand side of the Nest Explorer window.

Information about parts nested on each bar appears in the lower right-hand side of the Nest Explorer window.

Nestings may be adjusted in four ways in the Nest Explorer window:

Freeze Bar This option holds a nesting solution for a bar during a recalculation.

Remove Bar This option will allow you to un-nest all parts on a bar and delete a bar instance.

Substitute Bar This option will allow you to choose a different bar length and/or source. You may substitute any bar that is the same length or longer as the parts nested into it.

Remove Part This option will allow you to un-nest one or more parts within a bar.



15

Approving Nestings When you get a nesting that you are satisfied with, you should approve that nesting.

To open this window, click: Next >> in OptiMiser on a trial nesting

Things to remember about approving nestings When you approve a nesting:

Stock bars included on the nesting become Allocated. They are given a status of Assigned.

Bars to be purchased are placed onto the Buy List.

Parts from the bill of materials become Allocated. Parts from the bill of materials can not be nested on a different nesting once they reside on an approved cut list.

All of the options in the Nest Explorer window are still available when a nesting has been approved.

Using A “Check Me!” Nest to Identify Outstanding Items Every time you approve a cut list, the nesting’s parts can not be re-nested. Therefore, each nesting that is added will show you what items are not on any cut list. Items not residing on a cut list are outstanding, and should be identified.

To obtain a “CHECK ME!” nest, simply add a new cut list and label it CHECK ME! You can then see the outstanding items on the Parts to Cut tab.



16

Reviewing the ABM Buy List One of the great features of FabTrol MRP is the Buy List. Items on the Buy List can only be placed on a purchase order once. This means that you can not over purchase items nested through the OptiMiser.

Reviewing Buy List Items There are three reports that are used to review items on the Buy List. They can be found on the Nesting tab of the main reports window.

Quotation request form

This report will provide a faxable listing of the bars that need to be purchased for each cut list. This report would be faxed off to vendors who would fill in material pricing, and fax the report back to you.

Buy list

This report will list each item that must be purchased for a cut list. In addition, the total purchased length, stock length, remnant, and other material allowances are listed. After items have been purchased, the purchase order number will appear for the bar in place of the Vendor ID code.

ABM codes still to be nested or purchased

This report will list any item from the bill of materials that does not reside on an approved cut list or a purchase order. In essence, it is a “check me” listing for both nesting and purchasing.



17

Creating Purchase Orders The next step in the ABM materials management process is to purchase the Buy List on purchase orders.

To open this window click: PurchaseMate button in OptiMiser > Add button

Things to remember about creating new purchase orders You must “Add” new purchase orders by clicking the Add button on the toolbar. If you do

not add a PO, you are editing an existing PO!



18

Filling Purchase Orders from the Buy List After you have added PO and selected a vendor, you can populate the purchase order by filling it from the Buy List.

To open this window click: PurchaseMate window > Items on Order tab > Fill PO Items

Things to remember about filling PO items There are two ways to place the items on the OptiMiser Buy List on a PO. You will not be allowed to over-purchase items if you use either of these options to fill out your purchase orders:

OptiMiser Buy List This option will allow you to place all items from one or more cut lists on a PO.

Multiple Buy Lists This option will allow you to set a filter on the cut list items placed on a PO.

To fill a purchase order, do the following:

1. On the Items on Order tab in the PurchaseMate window, click Fill PO Items. The Purchase Order Fill Options window will open.

2. Click the Multiple Buy Lists button. The Filling a Purchase Order window will open.

3. Click the Select Cut Lists button.

4. Move the nestings to filter on from the left hand side of the list to the right hand side.

5. Click Okay to close the window.

6. Click a box to set a filter on the nestings you have just selected. In the pick list window that appears, select the items you wish to filter on.

7. Click the Fill PO button to place the filtered items on to the purchase order.



19

Issuing and Printing Purchase Orders Once you have filled out a purchase order and set the pricing, you may issue a purchase order number. The issue box can be found in the upper right hand corner of the Items on Order tab in the PurchaseMate window.

Things to remember about issuing PO’s You can not pre-post or receive PO’s until they have been issued.

Only issued PO’s can be included in the Accounting Export.

Printing purchase orders PO’s are printed by clicking the Print PO button in the PurchaseMate window. The Print PO button is found on the bottom row of buttons in PurchaseMate window.

To open this window click: Print PO button in the PurchaseMate window

Things to remember about printing purchase orders The intent of the PO without costs is to provide a document for shipping and receiving

personnel.

PO’s printed for multiple jobs can have each job’s items grouped by selecting the List by job number option.

Purchase orders for mills can be printed with a Recap by Type/Size/Length option. This will “roll up” all like items into a single line.



20

Preposting Purchase Orders Preposting purchase orders simply confirms a delivery date for items on a purchase order.

To open this window click: Prepost PO button in the PurchaseMate window

Uses for preposting Allows Detailed Job materials to be nested into ABM stock before ABM stock arrives.

Provides a mechanism for proactive materials management.

Things to remember about preposting purchase orders Each preposted item will add a record in the StockMiser module.

This record in the StockMiser module will have a category of On Order.

The preposted date will be the stock available date.

In order to be preposted, the Preposted checkbox must be selected ( ).

To prepost PO items, do the following: 1. Navigate to the PO item to receive using the PO Number hyperlink in the PurchaseMate

window.

2. Click the Prepost PO button. The Prepost a Purchase Order window will open.

3. Change the Due date for each PO item.

4. Select the Preposted checkbox for each item.



21

Reviewing ABM reports Once you have purchased and preposted your preliminary listing of materials, the FabTrol MRP ABM project is completed. Here are some reports that are specifically designed for ABM’s.

These reports can be found in the main Reports window. They are listed by report tab.

Purchasing tab

PO Breakdown

This report will list the parts that are nested into each item on selected purchase orders. For each PO line item, the quantity, ABM code, and sequence is shown.

This report is used as a reference for finding ABM nesting patterns.

Nesting tab

ABM codes still to be nested or purchased

This report will list any item from the bill of materials that does not reside on an approved cut list or a purchase order. In essence, it is a “check me” listing for both nesting and purchasing.

Nesting Status by ABM code

This report will list each item in the bill of materials. For each part the nest number, source (stock or purchase order and line number), stock area, and due date are listed.

ABM Snapshot

This report summarizes each ABM sequence. For each sequence, the total weight is listed. This weight is then contrasted with the weight outstanding to order, the weight ordered from mills†, the weight ordered from service centers, and the weight allocated from stock.

† Mill order, rolled, and delivered weights require that bars be linked to the Mill Rolling schedule. The determination of a mill or service center source is not determined by vendor. Currently, the Mill Rolling Schedule only allows effective entry for one mill. In the US release of FabTrol MRP, the schedule must be populated and maintained manually.



22

DBM Materials Management Process

Link Advanced Bill project to Detailed Job

in Project Specifications

Review Sequencing in Sequence

Assignments

Create DBM cut lists into ABM material in

the OptiMiser

Adjust nestings in Nest Explorer

Approve cut lists in Optmiser

Create a “Check Me!” nest to look for

outstanding items

Create purchase orders from the Buy

List in PurchaseMate

Issue purchase orders in

PurchaseMate

Confirm delivery dates by Preposting PO’s to

stock in PurchaseMate

Receive PO items as they arrive in

PurchaseMate

Create DBM cut lists for non-ABM material

in OptiMiser

Adjust and approve nestings

Verify Cut lists in OptiMiser

Print:Expanded Cut ListDetailed Job Pull List

Give to shop / return when complete

Confirm nestings in OptiMiser



23

Linking Detailed Jobs to Advanced Bill Jobs In order to use the ABM material in your Detailed job, you must link the two projects in the Project Specifications window:

To open this window click: View menu > Project Specs > Related advanced bill no. hyperlink

Things to remember about linking ABM’s to DBM’s If you link the ABM project to the DBM before you import your first set of drawings, the

Drawing Manager module’s revision checking will compare the import file to your ABM for differences.

It is necessary to link the Advanced bill project to your Detailed job in order to nest your detailed bill of materials to your preliminary purchases.



24

Reviewing Sequence Assignments Cut lists in the OptiMiser module are generally created in the order that they will be cut in the shop. This order of fabrication is determined in FabTrol MRP with sequence assignments.

To open this window click: Materials menu > Sequence Assignments

Sequence An area on the job site that determines the fabrication and erection schedule.

Lot An optional subdivision of a sequence.

Things to remember about sequence assignments Sequence and lot names can be up to ten characters in length.

Assemblies are assigned to sequences and lots.

Parts are assigned to Phases (codes).

Sequences and lot assignments can be imported from your detail drawings.

Sequences should be assigned prior to creating DBM cut lists.

To manually assign sequences in the Sequence Assignments window, do the following: 1. Select the sequence/lot on the left to pull assemblies from.

2. Select the sequence/lot on the right to move assemblies to.

3. Select the assemblies on the left and use the Move buttons to move the assemblies to the right.



25

Nesting DBM Cut Lists with ABM Material If you have purchased material in an Advanced bill project, you will want to nest your Detailed job into your ABM material before you create other cut lists.

To nest DBM items into ABM stock, do the following: 1. In the OptiMiser window, create new cut lists.

2. Set your filters in accordance with the nestings in the ABM project.

For example, if your ABM nestings were filtered by sequence and material shape, then your DBM cut lists should be filtered by sequence and shape.

3. Set your stock filter to include (at a minimum):

Stock Categories

Received

On Order

Stock Status

Reserved for this job

Material reserved for the linked ABM job

Material assigned to a nesting for the linked ABM job

Further limits on stock

Type/size/grade combinations from the cut list

Use materials on or available before:

Set the stock available date to one day before your planned cutting date.

4. Calculate your ABM material nests.

Do not select purchasable bars in the Optimization Options window.

5. Adjust your ABM material cut lists in the Nest Explorer window. You have the following options:



Substitute Bar This option will allow you to change the bar properties. You may substitute any bar that is the same length or longer as the parts nested into it.


6. Approve your ABM material nestings.



26

Creating DBM Cut lists Once you have reviewed your sequence assignments, you can create DBM cut lists in the OptiMiser window.

To open this window click: Materials menu > OptiMiser

Things to remember about creating Trial Nests A nesting, a cut list, and a multing are synonymous terms in the OptiMiser window.

To create a trial nest, do the following: 1. Remember to set a nest filter and nest name. The nest name should reflect the nest filter.

Nest filters will generally be by sequence and material type.

2. After you set your nest filter, review the items on the Parts to Cut tab.

3. Review the items on the Available Stock tab.

4. Review the items on the Purchasable Lengths tab.

5. Calculate your nesting by clicking the Next >> button on the Calculator tab.



27

Reviewing the Parts to Cut The Parts to Cut tab will show you the bill of material items that meet the criteria of the Nest filter.

To open this window click: Materials menu > OptiMiser > Parts to Cut tab

Things to remember about the Parts to Cut tab You can adjust the nest filter with the Filter button.

The Print button will print a filtered listing of parts on this nesting.

The Status button will show you if like part marks are cut on other nestings.

The Cut Info button will show you if a part has contours or miters.



28

Reviewing Available Stock The Available Stock tab will show you the items in stock that meet the filter conditions of both the Nest filter, and the Available Stock filter.

To open this window click: Materials menu > OptiMiser > Available Stock tab

Things to remember about the Available Stock tab If stock items do not match both the Nest filter and the Available Stock filter, then a “No

Stock matches the filter condition” Alert! window will open:

The Stock filter can also be accessed from the Optimization Options window.

When nesting into stock that has a category of On Order, the Use materials on or available before date filter must be adjusted.



29

Reviewing Purchasable Lengths The Purchasable Lengths tab is where you specify what material lengths are available from your vendors.

To open this window click: Materials menu > OptiMiser > Purchasable Lengths tab

Things to remember about the Purchasable Lengths tab Every setting on the Purchasable Lengths tab is adjustable by the selected material type and

size.

Allowances for saw kerf, trim cutting, and clamping are set on the Purchasable Lengths tab.

The scrap remnant threshold is set on the Purchasable Lengths tab.

Each item must have a unit cost in order to nest.



30

Setting and saving lengths in the Purchasable Lengths tab Each material type in FabTrol MRP is assigned a default set of purchasable lengths. These lengths are stored in the Unit Price File. However, alternate lengths can be saved and filled in the OptiMiser window.



31

Setting Optimization Options and Calculating Nests When you are ready to calculate your nesting, click the Next >> button on the Calculator tab.

To open this window: Materials menu > OptiMiser > Click Next>> on the Calculator tab

Things to remember about setting optimization options Set the planned cutting date according to your project schedule.

The stock available date should be set to one day before the cutting date.

Cut to size nestings are calculated by unselecting both Purchasable bars and Stock items, and selecting Order new material cut to size.



32

Setting Advanced Optimization Options If you adjust Advanced Optimization Options on your first nest, then the settings will be copied to subsequent nestings.

To open this window click: Advanced Options in the Optimization Options window

Things to remember about the Advanced Optimization Options window Optimize for waste, not cost will set all costs for purchasable lengths to same value. This

value setting will only be for calculation purposes only.

Do not use this option if you have entered pricing and lengths from multiple vendors into the Purchasable Lengths tab

A Power factor value of six results in the most comparisons between nesting solutions.

Applying a material handling factor will result in longer bars used over shorter bars.

The Stock valuation is selected by default. It ignores the actual value of stock and values stock at 10 cents on the dollar for calculating purposes only. The actual value of stock is not affected.



33

Reviewing Nestings After you calculate a nesting, you can review it by clicking Nest Results.

To open this window click: Nest Results in the OptiMiser window

Things to remember about the Summary of Nesting Results window The Summary of Nesting Results window provides a “bird’s eye view” of a nesting.

The Copy to Clipboard button will allow you to copy the contents of the Summary of Nesting Results window into an email.

The remnant length is the total remnant length for all bars.

The percentages are calculated by dividing the total remnant length by the total bar length.



34

Adjusting Nestings Once you have calculated a nesting, you can adjust it in the Nest Explorer window.

To open this window click: Nest Explorer button in OptiMiser

Things to remember about the Nest Explorer window The Nest Explorer window may be used for cut list adjustments when a nesting is in a trial or

approved state.

Bars are a nesting solution. Parts are nested into bars.

Bar numbers begin at 3 and restart for every material type, size, and grade.

Bars appear in the tree-view (left-hand side) of the Nest Explorer window.

Information about the bar appears in the upper right-hand side of the Nest Explorer window.

Information about parts nested on each bar appears in the lower right-hand side of the Nest Explorer window.

Nestings may be adjusted in four ways in the Nest Explorer window:



Substitute Bar This option will allow you to choose a different bar length and / or source. You may substitute any bar that is the same length or longer as the parts nested into it.




35

Approving Nestings When you get a nesting that you are satisfied with, you should approve that nesting.

To open this window, click: Next >> in OptiMiser on a trial nesting

Things to remember about approving nestings When you approve a nesting:

Stock bars included on the nesting become allocated. They are given a status of assigned.

Bars to be purchased are placed onto the Buy List.

Parts from the bill of materials become allocated. Parts from the bill of materials can not be nested on a different nesting once they reside on an approved cut list.

All of the options in the Nest Explorer window are still available when a nesting has been approved.

Using A “Check Me!” nest to Identify Outstanding Items Every time you approve a cut list, the parts on the nesting can not be nested again. Therefore, each nesting that is added will show you what items are not on any cut list. Items not residing on a cut list are outstanding and should be identified.

To obtain a “CHECK ME!” nest, simply add a new cut list and label it CHECK ME! You can then see the outstanding items on the Parts to Cut tab.



36

Reviewing the Buy List One of the great features of FabTrol MRP is the Buy List. Items on the Buy List can only be placed on a purchase order once. This means that you can not over purchase items nested through the OptiMiser module.

Reviewing Buy List items There are two reports that are used to review items on the Buy List. They can be found on the Nesting tab of the main Reports window.

Quotation request form

This report will provide a faxable listing of the bars that need to be purchased for each cut list. This report would be faxed off to vendors who would fill in material pricing, and fax the report back to you.

Buy list

This report will list each item that must be purchased for a cut list. In addition, the total purchased length, stock length, remnant, and other material allowances are listed. After items have been purchased, the purchase order number will appear for the bar in place of the Vendor ID code.



37

Creating Purchase Orders The next step in the DBM materials management process is to purchase the Buy List on purchase orders.

To open this window click: PurchaseMate button in OptiMiser > Add button

Things to remember about creating new purchase orders You must add new purchase orders by clicking the Add button on the toolbar. If you do not

add a PO, you are editing an existing PO!



38

Filling Purchase Orders from the Buy List After you have added PO and selected a vendor, you can populate the purchase order by filling it from the Buy List.

To open this window click: PurchaseMate > Items on Order tab > Fill PO Items

Things to remember about filling PO items There are two ways to place the items on the OptiMiser Buy List on to a PO. You will not be allowed to over-purchase items if you use either of these options to fill out your purchase orders:

OptiMiser Buy List This option will allow you to place all items from one or more cut lists on to a PO.

Multiple Buy Lists This option will allow you to set a filter on the cut list items placed on to a PO.

To use Multiple Buy Lists, do the following:

1. From the Items on Order tab in the PurchaseMate window, click Fill PO Items. The Purchase Order Fill Options window will open.

2. Click the Multiple Buy Lists button. The Filling a Purchase Order window will open.

3. Click the Select Cut Lists button. Move the nestings to filter on from the left hand side of the list to the right hand side.

4. Click Okay to close the window.

5. Click a box to set a filter on the nestings you have just selected. In the window that opens, select the items you wish to filter on.

6. Click the Fill PO button to place the filtered items on the purchase order.



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Issuing and Printing Purchase Orders Once you have filled out a purchase order and set the pricing, you may issue a purchase order number. The issue box can be found in the upper right hand corner of the Items on Order tab in PurchaseMate.

Things to remember about issuing PO’s You can not prepost or receive PO’s until they have been issued.

Only issued PO’s can be included in the Accounting Export.

Printing Purchase Orders PO’s are printed by clicking the Print PO button in the PurchaseMate window. The Print PO button is found on the bottom row of buttons in the window.

To open this window click: Print PO in PurchaseMate

Things to remember about printing purchase orders The intent of the PO without costs is to provide a document for shipping and receiving

personnel.

PO’s printed for multiple jobs can have each job’s items grouped by selecting the List by job number option.

Purchase orders for mills can be printed with a Recap by Type/Size/Length option. This will “roll up” all like items into a single line.



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Preposting Purchase Orders Preposting purchase orders simply confirms a delivery date for items on a purchase order.

To open this window click: Prepost button in the PurchaseMate window

Uses for Preposting Allows Detailed Job materials to be nested into ABM stock before ABM stock arrives.

Provides a mechanism for proactive materials management.

Things to remember about preposting purchase orders Each preposted item will add a record in the StockMiser module.

This record in the StockMiser module will have a category of On Order.

The Preposted date will be the stock available date.

In order to be Preposted, the Preposted check box must be checked ( ).

To prepost PO items, do the following: 1. Navigate to the PO item to receive using the PO Number hyperlink in the

PurchaseMate window.

2. Click the Prepost PO button. The Prepost a Purchase Order window will open.

3. Change the Due date for each PO item.

4. Select the Preposted checkbox for each item.



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Receiving Purchase Order Items When materials arrive, you should receive the purchase order items.

To open this window click: PurchaseMate window > Receiving tab

Things to remember about receiving purchase order items There is a grid for receiving each purchase order line. This allows you to have many

receiving records for each PO line item for situations such as:

Partial shipments/back orders

Multiple heat certification numbers for one PO line item.

You can not “over-receive” purchase order items.

If you wish to accept over-shipments, change the quantity on the Items on Order tab.

To receive purchase orders, do the following: 1. Open the PurchaseMate window by clicking the Materials menu and selecting

PurchaseMate.

2. Click on the Receiving tab.

3. Using the PO Number hyperlink, navigate to the PO to receive.

4. Fill in the default receiving fields found below the receiving grid.

“Delivery note” is another way of saying “Vendor’s delivery ticket number” or “Vendor’s bill of lading number.”

5. To add a receiving record, click the Add button on the toolbar.

6. Enter the Quantity and Heat cert number for the receiving record.



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7. Click Okay.

8. Repeat steps 5 through 7 for each heat cert number.

9. In the Item # box, select the next PO line item.

10. Repeat steps 5 through 9 until your items have been received.



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Verifying Cut Lists Everything that has been done up to this point has been in preparation for releasing cut lists to the shop. When you are ready to release cut lists into the shop, you will want to verify that all items on the cut list have a stock record.

To open this window: Select an approved cut list > click Next>>

Things to remember about verifying cut lists Wait to verify cut lists until you are ready to give the shop a cut list.

If you have checked the user preference option to “Wait to post remnants until confirming cuts,” your remnant options will be deactivated.

After you have verified your nesting, stock will be given a status of Committed.



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Managing Unverified Items When you verify a nesting, the OptiMiser module verifies that each bar in the cut list has a currently available stock record. Therefore, unverified items are bars that do not have a currently available stock record.

Understanding the OptiMiser Verification window This OptiMiser Verification window has two sections:

Bars not Verified This is the top section of the window. Bars will appear in this section if they have not been purchased, preposted, or if they have been manually allocated in the StockMiser window. The cut list will not finish verification until this section is empty. You may remove bars to verify the remainder of the cut list.

Bars on Order This is the bottom section of the window. Bars will appear in this section if they have been preposted and not received. Print the Call in Report to expedite your outstanding materials. Your cut list will verify with preposted bars.



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Working with the Expanded Cut List After you have verified your cut list, you will want to print the Expanded Cut List and Pull List for detailed job reports. These reports are located on the Nesting tab of the main Reports window.

To print this report click: Reports button in OptiMiser > Expanded cut list

Things to remember about the Expanded Cut List Each instance of a bar is listed on the Expanded Cut List. This allows your sawyer to note a

single alteration to a cut list.

Have your sawyers note if they cut different heat cert numbers than what are specified on the cut list.

Have your sawyers measure and write down usable remnants on the cut list.

Pre-posted bars (bars on order) will be noted in the bar information line with the purchase order number and vendor.

Bars that have been received will be noted in the bar information line with the stock record number.

After the Cut List goes out to the shop, it must return so that you can confirm a nesting as cut.



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Confirming Cut Lists After your materials have been cut and the Expanded Cut List returns from the shop, you will want to confirm your cut lists.

To open this window: Select a verified cut list > click Next>>

Things to remember about confirming cut lists Bars are not cut and remnants are not reposted to stock until two events happen:

1. The bar is selected ( )

2. The Confirm Selected Bars button has been clicked.

When you click Confirm Selected Bars, you have four options for reposting off-cuts: Scrap all remnants

This option will not return any remnants to stock. Save usable remnants as free stock

This option will return off-cuts to stock if the length is over the scrap less than threshold. The returned remnant will not be held for any job. Note: The scrap rems less than option is set on the Purchasable Lengths tab.

Reserve remnants for this job This option will return off-cuts to stock if the length is over the scrap-less than threshold. The returned remnant will be held for the current job.

Reserve remnants for linked ABM This option will return off-cuts to stock if the length is over the scrap-less than threshold. The returned remnant will be held for the linked ABM job.



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Adjusting Nestings in the Confirm Cuts window You have two options for adjusting nestings in the Confirm Cuts window:


Parts from removed bars will appear in the “Check Me!” nesting. You will also be given an option to set the status of the bar in stock to either reserved or free stock.

Swap Bar This option will allow you to choose a different bar that is currently in stock. You may swap any bar that is the same length or longer as the parts nested into it.

Things to remember about swapping bars You may swap bars with any bar in stock that is the same type, size, and grade. You may

even swap bars with other FabTrol MRP projects.

If your swap causes a nesting problem elsewhere, you will be asked to print a report identifying the problem.



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Managing Stock with the StockMiser module The StockMiser module is where the items in your yard are managed.

To open this window click: Materials menu > StockMiser

Things to remember about the StockMiser module: The StockMiser window opens without a filter set. You must set a filter to view stock items.

Received items are entered automatically.

Preposted items are available after the due date.

Cut items are not deleted, but change status and become used.

A filter can be set to view material by selecting a type from the Mat’l Types box.



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Adding, Editing, and Reviewing Stock Items The Edit Stock Item tab is where stock is added. It is also the best place to edit stock items.

To open this window click: Materials menu > StockMiser > Edit Stock Item tab

Things to remember about the Edit Stock Item tab The stock Date available box reflects one of the following:

If the item is still on order, the Date available will be the Due date from the PurchaseMate module.

If the item is received, the Date available will be the date it was actually received (or manually entered).

If the item is a remnant that was reposted, then the Date available is the date the remnant was reposted.

The Date used box will only be populated when a stock item has actually been used.

Adding stock items is done with the Add button on the toolbar.

The stock price is the original purchase price

The original heat certification number and purchase order information will be retained as an item is cut and remnants are reposted.



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Stock Status Stock statuses reflect the stage of nested items in a project. Should a stock item have a status other than Free, the project number it is allocated to will appear in the Reserved for project box.

Here is a brief synopsis of the stock statuses:

Free The item is available for use on any job.

Reserved The item has been held for a job, but has no particular assignment to a nesting.

Assigned The item is listed on an approved cut list for a job. The cut list number appears in the Nest Number box.

Committed The item is listed on a verified cut list for a job. The cut list number appears in the Nest Number box. Because a verified cut list ahs been issued to the shop, when an item is committed, it also means that the listed entry is on a cut list report somewhere in your shop.

Used The item no longer exists. It has been cut on a project.

Stock Categories Stock categories reflect whether an item is on hand or not.

Here is a brief synopsis of the stock categories:

On order The item has not been received, but a delivery date has been confirmed by the merchant.

Received The item has arrived.

Used The item no longer exists. It has been cut on a project.



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Manually Allocating Items You may manually allocate items in the StockMiser window.

To open this window click: Allocate button in the StockMiser window

Things to remember about manual allocations The project you allocate a stock item to does not have to be a real project. An example of this

would be allocating a missing piece of stock to project “MIA.”

If you do not want to use a stock item, select Reserved for this job.

Remnants are reposted by entering a quantity and length.



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Stock Usage Report To obtain a report of the items used on a project, click on the Usage tab in the StockMiser window.

To open this window click: Materials menu > StockMiser > Usage tab

Things to remember about the Stock Usage report This report respects the stock filter.

Received materials will print a report for stored materials.

Used materials will print a report for cut materials.

Stock items with a category of On order will not appear on this report.

To use the Stock Usage report, do the following: 1. Set the date range for the report. Typically, this is either monthly or year-to-date.

2. Set the stock criteria you want to include.

Selecting Full lengths will charge full lengths to a job.

Selecting Remnants will list the items returned to stock for a job.

Selecting Both will list the net usage for a job.

3. Select whether you want to view received or used materials.

4. Select the method of reporting. Most often, this is by Job number.

5. Select a detailed or summary report.

6. Click the Print button to print the report.



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Stock Reports Because the StockMiser module contains such a wealth of information, several reports are provided to review stock data. Some of the more commonly used reports are:

Stock list by PO number

This report will give you a stock listing sorted by PO number. Because this report respects the stock filter settings, it can be used to view inventory that you have or that you expect to have.

List of changes (specify date)

This report is handy for tracking down the event history of stock by date. It yields a report telling you all that happened in stock on a specified date.

Inventory listing

Many companies from time to time perform an actual physical accounting of items in inventory. This report provides a checklist sorted by stock area.

Stock audit trail

This report yields another event log, similar to the List of Changes report. Filterable by user, action, or field names, it gives the history of all that happened in stock, relying on the filter set.

Cross allocation from job

This report will give you one way to look at the often asked question, “What stock did I steal from one project to use on another?” This report will give you an accounting of the inventory pulled from other jobs.

Cross allocation to job

This report will give you another way to answer the aforementioned question. On this report, you will see the projects that sent inventory to another project.



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The PurchaseMate module: Integrated Purchasing and More The PurchaseMate module does more than produce purchase orders. It enables you to keep all of a project’s purchases in one place.

To open this window click: Materials menu > PurchaseMate

Things to remember about the PurchaseMate module Purchase orders can be produced for anything.

PurchaseMate is also the interface to the stock system.

It should be noted that items you receive will only appear in the the StockMiser window if the material has been defined in your Unit Price File.

You can add boilerplate content to your purchase orders with ASTM Specs.

To add ASTM specs, click Tools, point to Options, then click Add/Change ASTM Specs.



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Setting Purchase Order Preferences You will want to take care of a few maintenance tasks before you use FabTrol MRP to produce purchase orders. Following is a guide to setting up the PurchaseMate module to produce purchase orders.

Setup Purchasing Preferences To properly use the PurchaseMate module, each user must have a few preference settings adjusted. These settings are grouped by the tab in which they are set:

User preferences > Specific tab

To open the user preferences window click: Tools menu > Options > Preferences

Numbering schemes

Each user must have their preferences set in accordance with your purchase order numbering schemes. Here is a brief synopsis of the preference options:

Allow multiple job purchase orders

Selecting this option will allow you to assign each item on a purchase order a different job number.

Deselecting this option will assign only one job to all items on a purchase order

Restart PO numbers for each job

Selecting this option will force each job to start purchase order numbering at 00001.

Deselecting this option will allow purchase order numbers to run consecutively for all jobs.

PurchaseMate > Defaults tab

To open purchase order defaults, click: Materials menu > PurchaseMate > Defaults tab Fill in the following items to save you some typing when you add purchase orders. Each of these items may be edited for individual purchase orders. Suggestions are in parenthesis:

Ship via (Vendor Truck)

Terms (As Agreed)

FOB (Destination)

Material test reports required ( )



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Purchasing Reports Within the flexibility and power of the PurchaseMate module, there are a number of useful reports that can be generated to help manage purchase orders.

Commonly used purchasing reports include:

Material received

This report, respecting the purchasing filter that is set, will provide an itemized accounting of all materials that have been received by the PurchaseMate module (regardless of whether they were received into stock or not).

Material due in

This report is different than the Call In Report in that it lists all items that have not been formally received. The Call In Report lists only items due in that are on a cut list.

Summary of POs by job

This report provides an accounting and summary of all POs for a given job.

Summary of POs by vendor

This report provides an accounting and summary of all POs for a given vendor.

Review POs

This report will give you a summary of the purchase orders you have issued for a given project, along with the description listed in the PO Specs tab of the PurchaseMate window. You will also see the vendor the PO was issued to and the weight and cost for each PO. At the bottom, you will see totals for weight and cost.

Material list

This report provides several ways to list or summarize the items on a purchase order. You may also set filters for material types and jobs.

Documents

Material Mgmt Workbook v2