68461064 sap production planning old

8/9/2019 68461064 Sap Production Planning Old

http://slidepdf.com/reader/full/68461064-sap-production-planning-old 1/100

PRODUCTION PLANNING MODULE



PPPP

PPPP

FI

FICO

CO

SD

SD

MM

MMPM

PM

QM

QM

PS

PS

HR

HR



Organizational and Master Data

Business Process for Manufacturing Planning and Execution

Reporting and Analysis



Sales Info System

COPA

!orecasting

Procurement

Sales " Oper#Planning

DemandMgmt

MPSMRPMaterial planning

ManufacturingExecutionOrderSettlement

Planning Process

Execution Process



Requirement from salesmar!eting

Pro"uction Planning

C#ec! A$aila%ilit&

Com'onents Ca'acit&

Run (c#e"ule )t&s

(c# * Ca' Le$elling

Mfg+ Execution ,ac!flus#ing

Recei't of -in Goo"s In (tores

(#ift "ates

Pro$i"e A""l+ ca'acitiesPurc#asing &es

nono

&es

REM



Requirement from salesmar!eting

Pro"uction Planning

C#ec! A$aila%ilit&

Com'onents Ca'acit&

Pro"uction Or"er

(c# * Ca' Le$elling

Mfg+ Execution Pro"uction Confirmation

Recei't of -in Goo"s In (tores

(#ift "ates

Pro$i"e A""l+ ca'acitiesPurc#asing &es

nono

&es

Discrete



(ales Info (&stemInformation contains total sales or"ers alrea"& o%taine".incoming sales or"ers. 'en"ing sales or"ers / 'ro"uct 0ise.

customer 0ise. region 0ise+

-orecasting,ase" on t#e 'ast #istor& of consum'tion. a forecast of

t#e sales figures for a 'ro"uct can %e ma"e+-uture 'ro1ections are ma"e using one of t#e (tatistical

forecasting met#o"s+

COMPONENTS



(ales * O'erations Planning2ig#er le$el 'lanning i+e+o$erall 'lanning at com'an& le$el

3earl&2alf &earl&)uarterl& Planning

Deman" Management

Management of RequirementsRequirements can %e from sales forecasts. sales or"ers.etc+

COPAPro1ections 0ill %e %ase" on t#e com'an&4s future 'ro1ection

of costing an" 'rofita%ilit& anal&sis+



MRPT#is is t#e total 'lanning of all t#e com'onents ta!ing

into consi"eration t#e existing requirements an" stoc!s+Creation of 'urc#ase requisitions. 'ro"uction or"ers.etc+-inal ste' in t#e 'lanning 'rocess+

MP(Planning of items t#at greatl& influence t#e com'an&4s 'rofits

or consume critical resources"ominate 'ro"uction 'rocesses+

After t#e 'ro"uction 'lan of t#ese critical items are firme" u'. t#e 'lanning of ot#er com'onents are ta!en u'+



Re'etiti$e Manufacturing 5Run (c#e"ule quantities are $ie0e")uantities are confirme" %& ,ac!flus#ingGoo"s are recei$e" into stoc!

MANU-ACTURING E6ECUTION

Discrete Manufacturing 5Pro"uction or"ers are release"Materials are issue"Com'letion confirmations are 'erforme"Goo"s are recei$e" into stoc!



STANDARD PRODUCTION PLANNING REPORTS

(toc!Requirements List

Lists t#e latest stoc!requirement 'osition of a materialin t#e 'lant i+e+'lanne" or"ers. 'ro"uction or"ers.etc+

Pro"uction Plan

T#is re'ort lists t#e mont#l& 'ro"uction 'lans / material

an" 'lant 0ise+

Or"ers

T#is re'ort lists t#e or"ers 'en"ingcom'lete" for a material

material 0ise or 0or! center 0ise++




)uantit& 'ro"uce"

T#is re'ort lists t#e quantit& of t#e material 'ro"uce" "uring t#e

Perio" in question+

7or! center Loa"s

T#is re'ort lists t#e a$aila%le ca'acities. require" ca'acities.

remaining a$aila%le ca'acities an" 8loa" for t#e 0or! center+

Consum'tion

Lists t#e consum'tion of a material for t#e 'erio" in question+



,ac!logs

Lists t#e %ac!log of t#e loa" at a 0or! center for t#e 'erio"

in question+

Missing 'arts

Lists t#e missing 'arts t#at are require" for t#e 'ro"uction of a material+




Production Planning Basic Data

Routings

Work CentersMaterials

CapacitiesInspection

Plans

Production

Facilities

Bills of Material

PP Basic Data Production

Resources/Tools

F06010



SAP R/3 Integration ModelSales

Distri!ution

Sales Distri!ution

ProductionPlanning

ProductionPlanning

MaterialsManage"ent

MaterialsManage"ent

Finance

Controlling

Finance

Controlling

Custo"erCusto"erSales Order

Shipment

Receivable Accounts / Cash Receipt

Credit Limit

Material Availability Chec

!rans"er o" Re#uirements

$oods %ssue to SO

$oodsReceipt

%nvoiceRecei p

t

&urchaseOrder

Accounts &ayable

%nvoice

Accountin' (ocument&roduction Cost

&roduction Order

&roduction Order Receipt

Sales Forecast / &lan

#endor#endor



Organizational Structures in R/3

Cost accounting

Accounts

Internal logistics$MRP/Production%

In&entor' "anage"ent

(roup

Controlling areas

Sales organi)ations

Co"pan' codes

#aluation areas

Plants

Storage locations/!atc*es/special stocks

+,ternal logistics Purc*asingorgani)ations

LevelsLevels#ie-s#ie-s



Material Master Data

(eneral Data St. oc. Specific DataPlant Specific Data Sales Specific Data

Material Master

(ata applicable

throu'hout the client

e)')

Material number

(escription

*nits o" measure

+ei'ht

,olume

&roduct hierarchy

(ata dependent on sales

or'ani-ation and

distribution channel

e)')(eliverin' plant

Sales te.t

Sales units

Shippin' data

(ivision

(ata relevant

"or plannin' and

production

e)')MR& pro"ile

&roduction costs

&lannin' data

,aluation

(ata re"errin' to stora'e

and inventory mana'ement

e)')

uantities

Special stoc

+arehouseattributes



Material T'pes in t*e Standard SAPMaterial T'pe

DI+0

+RSA

F+RT1AB

1AWA

1IB+

++R

0A(

R21

#+RP

W+TT

PR2D

Service

Spare &art

Finished &roductSemi"inished &roduct

!radin' $ood

Operatin' Supply

mpty Containers

2on stoc %tem

Ra3 Material

&aca'in'

Competitor &roduct

&roduction Resources/ !ools

Description



Product

Data

+ngineering

Design

Sales

Production

Stock

Finance

Purc*asing

Master data is a ey piece

o" in"ormation in the system

Master data can be seen "roma number o" vie3s

ach vie3 can correspond

to an SA& module

ach vie3 has a number

o" in"ormation screens

ach vie3 belon's to an or' unit 3ithin the

business

One product may have multiple plant and

sales vie3s4 one "or each plant or sales

area

Master Data Views



+ngineering

Design

Sales

Production Stock

Finance

Purchasing

Examples of How Data is Used

!e.ts copied

to purchase orders

Maintains stoc levels

by plant4 stora'e

location4 and batch

(ata used to

calculate MR&

lead times

Controls customer

orderin' rules

"or material

Controls 3hich

$eneral Led'er

Account is updatedMaterial description

used in reportin'

Product

Data



ills of Material

Simple BOM arian! BOM Mul!iple BOM

Simple BOM representing

single material

Similar materials

represented

by variants on one BOM

BOM representing a material

which can be made up of

multiple compositions

e.g. different

components

and quantities



ill of Material Validit! Area of Validity – The same Bill of Material can be allocated to several

plants. Before you can allocate the BOM to a dierent plant, the material

must exist at the new plant, the unit of issue on the BOM item must be

the same.

Validity Period (alid from!to dates"

Becomes eective with the valid from date

The validity date is determined by the system automatically to be

either the next eective from date, or #$!%#!#&&&.

' '

B B)

*+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++

from #!#!&- from #$!%#!&-



B2M Structure

5OM eader

%tem 10

%tem 70

%tem 80

Sub %tem 10

Sub %tem 70

Plant Assignment

Validity Period

elease !ndicator

Stoc" !tems

#on$stoc" !tems

Variable Si%e !tems

&ocument !tems

'e(t !tems

Additional component details

e.g. installation points

for components



Bill of Material (lossar' BOM Ca!eg"r# ) categori%es BOM*s to represent different ob+ects, for e(ample-

Material BOM $$ structure of products manufactured quipment BOM $$ structure of equipment for plant maintenance

&ocument BOM $$ structure of documents such as drawings /0.123BOM Gr"up ) is a collective number for all BOM*s in a group which allows for one

or several similar products to be described under one number.

All Alternatives of a multiple Bill of Material All variants of a variant Bill of Material

3BOM Usage ) special view of the BOM which represents a specific area of

the company in which the BOM is used, for e(ample4 ngineering4 Production4

5osting4 Sales4 Plant Maintenance

'he BOM 6sage allows different views to e(ist without

separate BOM*s for each usage.



I!em Ca!eg"r# ) ;hen you enter a new Bill of Material item4 an item category must be assigned. !t has important control functions such as-

Screen selectionSpecific processing4 such as material number required4 negative values supported.

'he !tem 5ategory cannot be changed once set. !t must be deleted and re$added. Si%es are maintained for variable$si%e items !tem categories include-

Stoc" !tems $$ material in stoc" as a component #on$stoc" !tems $$ material not stoc"ed $ with or without a material number Variable$si%e $$ system calculates the quantity required using formulas

PM Structure !tem $$ used with plant maintenance equipment &ocument !tem $$ used with &ocument BOM*s

Su%&I!ems ) are typically used to represent different installation points for partialquantities of an item.

!n assembling resistors on a printed circuit board4 the installation points aredescribed. 'here is no logic related to sub$items

Bill of Material (lossar' $cont.%



Asse"!l'

ine

Mac*ines

People

Production

ine

CapacityRequirementsPlanning

Scheduling,Execution Times

Costing

Work Centers

Work

Centers

Cost

Center



Work Centers and Routings

Routing

2peration 4

2peration 54

2peration 34

Work Center W

Cost Center 44

Asse"!l'

Cost Centre 544

Work Center W5 Finis*ing

Cost Center 544

Work Center W

Cost Center 44

Asse"!l'



"or# $enter $ategor! +or centers are allocated to di""erent 3or center cate'ories

!he 3or center cate'ory is used to control the "ield and screen selection

"or 3or centers durin' 3or center maintenance)

+or Center Cate'ory Screen ,ie3

Statistical +or center 5asic (ata

&roduction +or Center 5asic (ata

(e"ault ,alues

Capacity ,alues

Schedulin'

Cost Center Assi'nment



$ost $enter %ssignment to"or# $enter for Operation$osting

Cost Center

Oper 0010 Oper 0070 Oper 0080 Oper 0090

Routin' 3ith standard values

Set *p :S!;

Machine :MAC;

Labor :LA5;

+or Center

3ith Activities

durin' production

Activity Rates

Set *p <=0)00

Mach <60)00

Labor <>0)00

Overhead <=0)00



+or Center Capacity

Oper 0010 Oper 0070 Oper 0080 Oper 0090

Routin' 3ith standard values

Set up Formula

Machine !ime Formula

!eardo3n Formula

+or Center

Formulas

Set up 1)0 hrs

Machine ?)? hrs

!eardo3n )? hrs

Operation Std ,alues

+or Center Schedule

Use of &ormulas in "or# $enters



> hrs

1 hr

= hrs

1 hr

6 hrs

Working1ours

5rea

!ime

Working1ours less

Breaks

&lanned

(o3ntime

Producti&eWorking

1ours

Available Capacity at a Work Ceter



Routing Structure #ie-s

Routing

2peration 342peration 542peration 4

Work Centre6

PP7ASS+M

Control 8e'6

7 Ti"e Tkts

7 Costing

2peration Te,t6

Pre7asse"!le

fra"e

Std #alues6

a!64 "ins

Mac*64 "ins

Materials

Co"ponents

B2M

Process

Resource Tool

$PRT%



B2M(roups

B2M(roups

'roduction Master Data

Materialsand PRTs

Materialsand PRTs

Bills ofMaterial

Bills ofMaterial RoutingsRoutings Work

Centers

WorkCenters

Routing(roups

Routing(roups

CostCenters

CostCenters

ComponentsAllocated toOperations

%tem Cate'ory

Material !ype

+/C Cate'ory



2peration

2peration t'pes

$Main% operation

Su!7operation

Su!7operation

1ierarc*'Costing Co"pletion confir"ations

Sc*eduling al-a's takes place on t*e

$"ain% operation le&el

T*e control ke' defines -*et*er co"pletion confir"ations andcosting are carried out on t*e $"ain% operation le&el9 or on t*esu!7operation le&el.

Indicator6 group operation su!7operation le&elco"!ined operation $"ain% operation



Material %llocation

2p. 42p. 4

2p. 542p. 54

2p. 342p. 34

2p. 42p. 4

2p. 342p. 34

Routing

B2M

ProductProduct



Ma!erial

5

5

4

45

4

45

5

3

5

3

Routing (roup

Routing (roup

Counter

Material)Routing %llocations

A routing alterative can be allocated to several materials. A material in a plant can be allocated to several alternatives.



Routing Default Values

RoutingRoutingMaterial

Master

Material

MasterWork

Center

Work

Center

5ase *nit o" Measure

&lanner $roup

Short !e.t

Control @eyStandard ,alues

Activities

Standards !e.t @ey

R data



External 'rocessing2per 4442per 444

2per 44542per 4454

2per 44:42per 44:4

2per 44;42per 44;4

Purc* Re<nPurc* Re<n

Purc* 2rdPurc* 2rd

#endor Proc#endor Proc

(oods Rec(oods Rec

Routin' data copied to order

includin' #uantities and dates

&urchasin' creates &)O)

At 'oods receipt4 the operationis con"irmed



2peration ead Ti"e

Float 5e"ore Float A"terOper 0010 Oper 0070 Oper 0080

ueue Setup &rocess !eardo3n +ait Move

.ecution !ime%nteroperation

!ime%nteroperation

!ime

2peration ead Ti"e



Routing 2peration Se<uences

StandardRoutin' represents a standard

se#uence de"inin' production

procedure

ParallelRoutin' includes processes 3hich

can be per"ormed simultaneously

to achieve time e""iciencies

SplitRoutin' includes processes 3hich

can/must be split across a number

o" 3or centers

2&erlappedRoutin' de"ines process 3here one

operation is to overlap 3ith the

"ollo3in' operation



T*e Planning Concept inSAP

Sales

Plan

S2P

Production

Plan

MPS

&lanned

%ndependentRe#uirements

Customer %ndependent

Re#uirements

Re#uirements :Orders; "rom

S( ModuleO""set

8eep Balanced

Order &roposals

MRP

&lanned Orders

&roduction Orders

&urchase

Re#uisitions

(emand ie

Re#uirements

Order proposals4 planned orders etc are created and adBusted by runnin' the MR& or M&S pro'rams)



/O0 speci1es sales 2uantities for the lon3 andintermediate term to rou3hly assess the feasibility of

sales and operation plans

/ales and Operations 0lannin3 at the 0roduct 4roup or

5!4 level Materials may be planned to3ether in 0roduct 4roups

/ales 2uantities are determined for future periods

0roduction 2uantities are then determined on the

basis of sales

Sales and Operations 'lanning &unctions



M60 77 is concerned with inte3ratin3 individual planswithin a supply chain

0ro1tability 'nalysis – 6evenue and /ales 0lans

/ales and Operations 0lannin3 – /ales and 0roduction

0lans

Master 0lannin3 – )emand 0ro3ram and Master

/chedule

Material 6e2uirements 0lannin3 – )ependent

6e2uirements and

Sales an$ Opera!i"ns Planning ' Planning Levels



S!ep ( ) Sales Planning of <uture Sales =uantities

5opy in from Sales !nformation System or Profitability Analysis

Automatic forecast based on historical factors

Manual entry of sales quantities

S!ep ) ) Production Planning

Synchroni%e production plan with sales plan

Stoc" level equal to %ero

Specify a target days supply by period

Specify a target stoc" level by period

nter planning data manually

Sales an$ Opera!i"ns Planning ' S!eps



S!ep * ) &isaggregation of Planning Values

&etermine the sales and production quantities of product group members

Modify the disaggregated sales planning data and create a production plan

for each member

S!ep + ) 'ransfer of Planning Values to MP

Pass the planned sales and production quantities as independent

requirements to demand management

!f product group data is transferred4 the system automatically disaggregates

the planning data to the finished product level

Sales an$ Opera!i"ns Planning ' S!eps



Sales an$ Opera!i"ns Planning ' Pr"$uc! Gr"ups

A Product >roup brings together materials according to some criteria such as

similar type or manufacturing process.

?in" material master data with product groups

Materials and product groups can be members of more than one group fordifferent planning scenarios

Assignment of members from different plants to the same product group for

cross$plant planning

A product group may have a different unit of measure from its members e.g.

aggregate in cartons vs pieces

Proportional factors for disaggregation $ how the product 3roup 2uantitiy is

distributed to its members

/upports production versions for a material or 3roup

Supports multi$level product group hierarchy

>raphical support of one or more levels



Sales and Production Planning is carried out using a Planning 'able which

shows the stoc" level that results from the sales and operations planning for

both materials and product groups

'he Planning 'able is divided into-

Sales =uantities

Production =uantities

'arget &ay*s Supply and 'arget Stoc" ?evels

Sales an$ Opera!i"ns Planning ' The Planning Ta%le



Sales an$ Opera!i"ns Planning ' Crea!ing a Sales Plan

Manual &ata ntry and &istribution <unctions

ntered directly into the Planning 'able as a @ or qty

5opying &ata from Sales !nformation System

Planned order4 invoiced or delivery quantities

'he planning data is aggregated across all materials in the group

5opying from Profitability Analysis

=uantity and performance measures

5opying the <orecast

Aggregates the consumption values for all the materials in the product

group



Sales an$ Opera!i"ns Planning ' Crea!ing a Pr"$uc!i"n Plan

&etermine the quantities to produce to meet the sales plan

Synchroni%e to the Sales Plan ) the system copies the sales quantities into the

production quantities

ero Stoc" ?evel ) 6se e(isting stoc" to cover sales quantities. ;hen used up4

production quantities will synchroni%e with the sales quantities

'arget Stoc" ?evel ) 'he system determines production quantities based on

sales and target stoc" levels

'arget &ays Supply ) 5overage is e(pressed in days



Sales an$ Opera!i"ns Planning ' Disaggrega!i"n

<unctionality is based on proportionality factors of product group members

'he result of disaggregation is the sales plan of its members

Strategy parameters are used to create the production plan from the sales plan

on to a product group member

&isaggregation can be carried out for the product group or for selected members

only



Sales an$ Opera!i"ns Planning '

Trans,erring Da!a !" Deman$ Managemen!

'ransfer a single$level product group /multiple2 or individual material /single2

!ndependent equirements Parameters

Specify equirements 'ype

Version #umber

?imit scope of the time period



Cop' fro"Sales Plan

Cop' fro"Prodn Plan

Cop' fro"Forecast

Cop' fro"2rig Plan

De"and Manage"ent=De"and Progra">

Manual &lanned%ndependent

Re#uirements

Sales

(emand "romSales Orders

MRP/MPS

Sales and 2perations Planning



Ma"e product for stoc" in e(pectation of customer sales

Plan using planned independent requirements for anonymousC ma"e$to$stoc"

production.

6se #et or >ross equirements Planning

#et equirements $$ includes warehouse stoc"4 planned issues and receipts

>ross equirements $$ e(cludes warehouse stoc". Dust includes planned

and open orders

(ample is a shelf stoc" item such as a bi"e accessory light

Planning equirement 'ype is ?S< $ ma"e to stoc" which is used in the planned independent requirements transaction

Sales Order equirement is ES? $ which is sale from stoc"

Planning S!ra!eg# ' Ma-e&!" S!"c-



Sale rom stoc$ Planning

Production Push

Ware*ouse Stock

Finis*ed Product

S!ra!eg#. Ma-e&T"&S!"c- Pr"$uc!i"n

.ample Common shel" items such as a bie accessory :li'ht;



Ma"e product in e(pectation of customer sales

Plan using planned independent requirements at finished goods level to drive

demand to long lead time components

'ypically there is a longer lead time to produce than the customer is

willing to wait for

Sales orders consume the planned independent requirement quantities

Planned quantities that are not consumed by sales orders result in e(cess stoc"

(ample is a long lead time custom product

Planning equirement 'ype is VS< ) planning with final assembly

Sales Order equirement is ESV ) which is sales order with consumption

Planning S!ra!eg# ' Planning /i!h 0inal Assem%l#



Sales Order &lannin'

&roduction &ush

Ware*ouse Stock

Finis*ed Product

.ample Custom "urniture such as a cherry table

Final

Assembly

to Sales Order

Purchase Produce

MR& 3ithout re"erence to sales order

&lanned %ndependent

Re#uirements

S!ra!eg#. Planning /i!h 0inal Assem%l#



Planning S!ra!eg# ' Planning 1i!h"u! 0inal Assem%l#

<inal assembly is initiated by the customer sales order

Stop production at sub$assembly level

<inal assembly pull

(ample is automobile assembled with unique combination of features /sub$

assemblies2

Planning equirement 'ype is VS $$ planning without final assembly

Sales Order equirement is EV $$ independent customer order with

consumption



Sales Order

&lannin'

&roduction &ushFinal Assembly &ull

Ware*ouse StockFinis*ed Product

Ware*ouse Stock

Asse"!l' 4

Ware*ouse Stock

Asse"!l' 45

.ample Option oriented product such as a car

Stop at level

&lanned %ndependentRe#uirements

Assembly 3henSales OrderScheduled

&urchase &roduce

S!ra!eg#. Planning 1i!h"u! 0inal Assem%l#



Planning S!ra!eg# ' Planning /i!h Planning Ma!erial

Planned independent requirements of Planning Material initiate procurement of

the planning bill components

Sales orders for the final assembly create planned orders of the finished productand reduce planning quantities for the planning material

Possible to plan a family of products from forecast placed on the planning bill.

'he planning bill details4 through percentages4 the quantity required for common

parts

(ample is a bi"e with common sub$assemblies used in many finished items

Planning equirement 'ype is VS< $$ planning with planning material

Sales Order equirement is EVV $$ independent customer order with planning

material



Sales Order

&lannin'

&roduction &ushFinal Assembly &ull

Custo"er StockFinis*ed Product

PlanningMaterial

Ware*ouse StockAsse"!l' 4

Ware*ouse StockAsse"!l' 45

.ample 5ies 3ith the same "eatures e.cept "or the color

&urchase &roduce 'ote( Percentages drive lo!er level

demands or su& assem&lies

S!ra!eg#. Planning /i!h Planning Ma!erial

&lanned %ndependentRe#uirements



Sales Order

&roduction by Lot Si-e &ull

Ware*ouse Stock

Finis*ed Product

.ample Combine customer orders "or the same item

S!ra!eg#. Pr"$uc!i"n %# L"! Si2e



Planning S!ra!eg# ' Ma-e !" Or$er Pr"$uc!i"n

Sales orders are planned according to sales order number

Produced quantities for each sales order are managed individually

Production and procurement costs are managed in either a settlement order or

a pro+ect

(ample is a custom product with a unique structure such that it only applies to

a particular customers order

Sales equirement 'ype is E $$ independent customer order without

consumption



MRP 0ea!ures

MRP

Lot si-in'

Order schedulin'

and 'eneration

%nternal production

and e.ternal purchasin'

2et re#uirements

calculation

5ill o" Material

.plosion

Forecastin'



MR' O*er*iew



Overvie/Purchase$ I!ems MRP

Purc*asing

Accounting

+arehousemana'ement

system

$oods receipt

%nventory mana'ement,aluation

$oods !rans"er issue postin'

%nvoice receipt

%nvoice veri"ication

Master data

Material5atches,endors

Customers



MRP6 Reorder Point Planning

Reorder &oint

Sa"ety Stoc

Order (ate (elivery (ate

'ime

Stoc"



Purc*asingProcess Ti"e

#endor Planned Deli&er'Ti"e

Desired Deli&er' DateRelease

2rder Date

0"r/ar$ Sche$uling ,"r E3!ernal Pr"curemen!

Toda'

(oods ReceiptProcess Ti"e

For-ard sc*eduling used for reorder point "aterial



Dail# Accumula!i"n.

Sales 2rders

Planned Indi&idual

Re<uire"ents

Reser&ations

+ntries

fro"

Planning

File

Ware*ouse

Stock

?

2pen 2rder Proposals

S*ortages

2rder

Proposal

0et C*ange Planning

Co&erage calculation per re<uire"ent date



MRP Prere<uisites

Activated "or MR&PA0T +#+

MAT+RIA +#+ ,alid MR& !ype

,alid Material Status

Material MR& ,ie3s Maintained MR& Controller

&lanned Lead !ime MR& $roup Lot Si-e (ata



Ma!erial Mas!er ' MRP (4e# 0iel$s

Sche$uling Parame!ers

Planning Time 0ence. defines a period during which MP9MPS will not automaticallyadd or reschedule orders

Sche$uling Margin. controls therelease period, opening period

for a materialand scheduling floats for production

Release period is the number of wor"ing days in the release period

Opening period is the number of wor"ing days between the order creation andplanned start date

Order floats allows for safety margin before and after production

Planne$ Deliver#. lead$time for purchased material

In&h"use Pr"$uc!i"n. lead$time for manufactured material

GR Pr"cessing Time. goods receipt processing time

(ample- doc"$to$stoc" time



Ma!erial Mas!er ' MRP ) 4e# 0iel$s

Availa%ili!# Chec- indicates whether the system generates individual or summari%ed

requirements for sales orders for this material and for planning4 which MP items the

system includes in the availability chec".

Ma!67PPC S!a!us is used to limit the usability of materials for certain activities such

as4 purchasing4 bills of material



Ma!erial Mas!er MRP * 4e# 0iel$s

In$epen$en! Re8uiremen!s

C"nsump!i"n M"$e. controls consumption of planned independentrequirements by customer requirements

Selections- bac"ward4 forward4 or both

C"nsump!i"n Peri"$s Bac-/ar$70"r/ar$. specifies the number ofperiods of forward or bac"ward consumption

6sed in con+unction with consumption mode

S!"rage L"ca!i"n MRP MRP In$ica!"r. determines whether or not requirements4 for a specific

storage location4 are planned separately from the overall plan

Re"r$er Level. used for storage location MP

Replenishmen! 9uan!i!#. used for storage location MP



ot Si)ing

Static Periodic 2pti"u" $Cost %

Lot "or Lot

Fi.ed Lot si-e

Replenish up to

ma.imum stoclevel

(aily Lot si-e

+eely Lot si-e

Monthly Lot si-e

Fle.ible period

Lot si-e accordin'

to plannin' calen)

&art period balancin'

Least unit cost procedure

(ynamic Lot si-e creation

$ro"" reorder procedure



MRP. S!a!ic L"! Si2ing

ot for ot 2rder @uantit'6 S*ortage @uantit' 2rdered @uantit'

Replenis*"ent up to Ma,i"u" Stock e&el6

Stock re<uired to ac*ie&e

"a,i"u" stock le&el set in

t*e "aterial "aster

2rder

@uantit'

Material

Fi,ed 2rder

@uantit'

S*ortage

@uantit'

2rder

Fi,ed 2rder

@uantit'If

2rder

2rder

2rderFi,ed ot Si)e6S*ortage @uantit'

Fi,ed 2rder @uantit'

If



Carr#ing Ou! !he Planning Run

Total Planning All materials in a 'iven plant

All materials are revie3ed by MR& re'ardless o" activity

Only the materials in a plant that have undergone a change relevantto planning since the last plannin' run :net chan'e plannin';

Planning Inter&al Limitin' the MR& &lannin' %nterval

Ti"e

Planned requirements and

supply order receipts

example(#"" days

MRP Planning 1ori)on



Planning Run Op!i"ns ,"r Au!"ma!icCrea!i"n ", Re8uisi!i"ns an$ Deliver# Sche$ules

MRP C"n!r"l Parame!er. determine whether or not MP will

automatically create requisitions or delivery schedules

Op!i"ns are.

&o not automatically create. Only create planned order

Automatically create within the opening period

Automatically create for the entire planning hori%on

Opening Peri"$ Parame!er. allows the user to ta"e advantage of

MP*s automatic creation features while retaining control over the

number of open purchasing documents



MRP Lis!

MR& Controller

$roup o" Materials"or 3hich controller

is responsible

ControllerGs MR&

Listin'

$oods Receipt$oods %ssues

MRP 2rder Proposals

and Planner Messages

fro" MRP Planning run.

Planner can drill do-n to re&ie- "aterial

"o&e"ent acti&it'



S!"c- Re8uiremen!s Lis!

Date MRP +le"ent Suppl'/De"and Ref +M @uantit' A&aila!le

01/01 S!OC@ 10001/0> OR(R Sales Order 7? =?

01/1? &L OR( 1000 170 0? 100 1=?

07/01 H &lannin' !ime Fence

Stoc" equirements ?ist brings together all the supply orders4 independent

and dependent demands and stoc" balances for the material. MP ma"es

order proposals to balance the supply9demand position for the material



MR&

&lannin'Result

MRP Lis! vs S!"c- Re8uiremen!s Lis!

'he MP ?ist displays the result of the last planning run

'he Stoc" equirements ?ist displays the most up$to$date stoc" and

requirements situation

MRP

PlanningProcess

MRP

Planning

Process

Last planningrun results

Stock RequirementsList uses current data

Current Stoc4

R#mts4 5alances4

planned Receipts4

%ssues



2rder ReleaseProcess Ti"e In7*ouseProduction Ti"e

2rderFinis*Date

2rderStartDate

Bac-/ar$ Sche$uling ,"r In&h"use Pr"$uc!i"n

FutureRe<uire"ent

Date

(oods ReceiptProcess Ti"e

MP determines the basic scheduling dates using bac"ward scheduling

!f the release date lies in the past4 the system automatically

swithches to forward scheduling

MRP PlanningDate 77 toda'

MRP Planning ead Ti"e

2rderRelease

Date



+

Independent Re<uire"entsCusto"er Re<uire"ents

Planned 2rders

Dependent Re<uire"ents

B5B

R R5 R3

Planned 2rders

DependentRe<uire"ents

DependentRe<uire"ents

Level 0

Level 2

Level 1

Planned 2rders

Planned 2rdersPlanned 2rdersPlanned 2rders

I (emandI Supply

Planning S!ruc!ure

Mul!i&Level



Or$er Pr"p"sals. Planne$ Or$ers

Procure"ent T'pe isIn7*ouse Production

MRPMRP

Controller

&lanned OrderOrder ty

Order (ate

Capacity Re#ts)

Resource Re#ts)

&lanned OrderOrder ty

Order (ate

Capacity Re#ts)

Resource Re#ts)

&roduction

Order



Planning ,"r In&h"use Pr"$uc!i"n

Planned2rder

Planned2rder

Production

2rder

Auto Chan'e/ (elete

i" situation chan'es

AutoCreation

Collective Conversioninto &roduction Order

Manual chan'es/deletion

ManualCreation

Planning Run MRP Controller

%ndividual Conversioninto &roduction Order

&roduction

Order Release



T*e Production C'cle

Issue

Ma!erials

!" Or$er

Select

BOM

Select

outing

Schedule

'imes F &ates

5alculate

5apacity

Purchase

equisitions

>oods

!ssue

&roduction

Order

5alculate

Planned 5osts

Release

2rder ChecAvailability

Print Shop

<loor

Papers

Crea!e

Or$er

5reate

equired

Purchases

Confir"

Co"pletion

Receive c"mple!e

g""$s in!" s!"c-

>oods

eceipt

5onfirmation Slip

CalculateActual Costs

Actual

Labor



Pr"$uc!i"n Or$er Release

Production 2rderRead' for Release

Material A&aila!ilit'C*eck

2rder or2peration Release

S*op PaperPrinting Possi!le

MaterialWit*dra-als Possi!le

Order release is carried out manually

*ses checin' rules de"ined in con"i'uration

Online or in bac'round &ic List4 Con"irmation Slips4)))



Ma!erial Availa%ili!# Chec-

Stock on

1and

1?0 *nits

Reser&ation

for

?0 *nitsNe!

Availa%le 7G1 711 011

711

Planned 2rder

for

700 *nits

Dependent

Re<uire"ent

for 700 *nits

Re<uire"ent

for ;4 nits

are A&aila!le



G""$s M"vemen! ,"r a Pr"$uc!i"n Or$er

Material 1

Material 7

Production

$oods

receipt o"

Material 8

$oods %ssue

Consumption o"

Material 1 and 7

Reservation

&lanned $oods %ssue

*nplanned $oods %ssue

$oods issues only apply to stoc items



G""$s Issue Resul!s

$oods %ssue&ostin'

*pdateReservations

$/L Account

*pdate

Accountin'

Material (ocument

Material

*sa'eStatistics

Cost ObBect

Allocation



C"mple!i"n C"n,irma!i"ns

Production 2rder

2perations

0010 Assemble 5oard

0070 Assemble Case

0080 Assemble unit

0090 Final !est

Production 2rder

2perations

0010 Assemble 5oard

0070 Assemble Case

0080 Assemble unit

0090 Final !est

C

Con"irmOperation 0010

Activities


Activities

Con"irm

Operation 0070Activities


Activities


Activities


Activities


Activities


Activities

&artial or Final Con"irmation Sin'le or Collective Con"irmation Milestone Con"irmation Reduction o" Capacity Re#uirements (etermination o" Actual Costs

Milestone



C"n,irma!i"n Da!a

@uantit'

Dates

a!or

Jield Scrap uantity Scrap Reason

Start date Finish date

+or Center &ersonnel 2umber uali"ication +a'e $roup +a'e !ype

68461064 sap production planning old

Documents