Sap Production Planning (Old)

8/3/2019 Sap Production Planning (Old)

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PRODUCTION PLANNING MODULE


2/100

PPPP

PPPP

FI

FICO

CO

SD

SD

MM

MM

PM

PM

QM

QM

PS

PS

HR

HR


3/100

Organizational and Master Data

Business Process for ManufacturingPlanning and Execution

Reporting and Analysis


4/100

Sales InfoSystem

CO/PA

Forecasting

Procurement

Sales & Oper.Planning

DemandMgmt

MPS/MRPMaterial planning

ManufacturingExecutionOrderSettlement

Planning Process

Execution Process


5/100

Requirement from sales/marketing

Production Planning

Check Availability

Components Capacity

Run Schedule Qtys

Sch & Cap Levelling

Mfg. Execution Backflushing

Receipt of Fin Goods In Stores

Shift dates /

Provide Addl. capacitiesPurchasing yes

nono

yes

REM


6/100

Requirement from sales/marketing

Production Planning

Check Availability

Components Capacity

Production Order

Sch & Cap Levelling

Mfg. Execution Production Confirmation

Receipt of Fin Goods In Stores

Shift dates /

Provide Addl. capacitiesPurchasing yes

nono

yes

Discrete


7/100

Sales Info SystemInformation contains total sales orders already obtained,incoming sales orders, pending sales orders product wise,

customer wise, region wise.

ForecastingBased on the past history of consumption, a forecast of

the sales figures for a product can be made.Future projections are made using one of the Statistical

forecasting methods.

COMPONENTS


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Sales & Operations PlanningHigher level planning i.e.overall planning at company level

Yearly/Half yearly/Quarterly Planning

Demand Management

Management of RequirementsRequirements can be from sales forecasts, sales orders,etc.

CO/PAProjections will be based on the companys future projection

of costing and profitability analysis.


9/100

MRPThis is the total planning of all the components taking into

consideration the existing requirements and stocks.Creation of purchase requisitions, production orders,etc.Final step in the planning process.

MPSPlanning of items that greatly influence the companys profits

or consume critical resources/dominate production processes.

After the production plan of these critical items are firmed up,the planning of other components are taken up.


10/100

Repetitive Manufacturing -Run Schedule quantities are viewedQuantities are confirmed by BackflushingGoods are received into stock

MANUFACTURING EXECUTION

Discrete Manufacturing -Production orders are releasedMaterials are issuedCompletion confirmations are performedGoods are received into stock


11/100

ORDER SETTLEMENTCosts accrued to an order are debited to one or several

allocation receivers belonging to financial or managerial

accounting.


12/100

STANDARD PRODUCTION PLANNING REPORTS

Stock/Requirements List

Lists the latest stock/requirement position of a materialin the plant i.e. planned orders, production orders,etc.

Production Plan

This report lists the monthly production plans material

and plant wise.

Orders

This report lists the orders pending/completed for a material

material wise or work center wise..


13/100


Quantity produced

This report lists the quantity of the material produced during the

Period in question.

Work center Loads

This report lists the available capacities, required capacities,

remaining available capacities and %load for the work center.

Consumption

Lists the consumption of a material for the period in question.


14/100

Backlogs

Lists the backlog of the load at a work center for the period

in question.

Missing parts

Lists the missing parts that are required for the production ofa material.



15/100

Production Planning Basic Data

Routings

Work CentersMaterials

CapacitiesInspectionPlans

ProductionFacilities

Bills of Material

PP Basic DataProductionResources/Tools

F06010


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SAP R/3 Integration ModelSales &

Distribution

Sales &Distribution

ProductionPlanning

ProductionPlanning

MaterialsManagement

MaterialsManagement

Finance &

Controlling

Finance &

Controlling

CustomerCustomerSales Order

Shipment

Receivable Accounts / Cash Receipt

Credit Limit

Material Availability Check

Transfer of Requirements

Goods Issue to SO

Goods

Receipt

Invoice

Receipt

Purchase

Order

Accounts Payable

Invoice

Accounting DocumentProduction Cost

Production Order

Production Order Receipt

Sales Forecast / Plan

VendorVendor


17/100

Organizational Structures in R/3

Cost accounting

Accounts

Internal logistics(MRP/Production

)

Inventorymanagement

Group

Controlling areas

Salesorganizations

Company codes

Valuation areas

Plants

Storage locations/batches/special stocks

External logistics Purchasingorganizations

LevelsLevelsViewsViews


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Material Master Data

General Data St. Loc. Specific DataPlant Specific DataSales Specific Data

Material Master

Data applicablethroughout theclient

e.g.Material number

Description

Units of measure

Weight

Volume

Producthierarchy

Data dependent onsales organizationand distributionchannel

e.g.

Delivering plant

Sales text

Sales units

Shipping data

Division

Data relevantfor planning andproduction

e.g.MRP profile

Production costs

Planning data

Valuation

Data referring tostorage andinventorymanagement

e.g.

Quantities

Special stock

Warehouseattributes


19/100

Material Types in the Standard SAPMaterial Type

DIEN

ERSA

FERTHALB

HAWA

HIBE

LEER

NLAG

ROH

VERP

WETT

PROD

Service

Spare Part

Finished ProductSemi-finished Product

Trading Good

Operating Supply

Empty Containers

Non stock Item

Raw Material

Packaging

Competitor Product

Production Resources/ Tools

Description


20/100

Product

Data

EngineeringDesign

Sales

Production

Stock

Finance

Purchasing

s Master data is a key pieceof information in the system

s

Master data can be seen froma number of views

s Each view can correspondto an SAP module

s Each view has a number

of information screens

s Each view belongs to an orgunit within the business

s One product may have multipleplant and sales views, one foreach plant or sales area

Master Data Views


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EngineeringDesign

Sales

Production Stock

Finance

Purchasing

Examples of How Data is Used

Texts copiedto purchase orders

Maintains stocklevels by plant,

storage location,and batch

Data used tocalculate MRP

lead times

Controlscustomer

ordering rules

for material

Controls whichGeneral Ledger

Account is updatedMaterial descriptionused in reporting

ProductData


22/100

Bills of Material

Simple BOM Variant BOM Multiple 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


23/100

Bill of Material Validity Area of Val idity The same Bill of Material can be allocated to several plants.

Before you can allocate the BOM to a different plant, the material must exist at the

new plant, the unit of issue on the BOM item must be the same.

Validity Period (Valid from/to dates) Becomes effective with the valid from date

The validity date is determined by the system automatically to be either the

next effective from date, or 12/31/1999.

A A

B C B D

X----------------------------------------------------------->>>>

from 1/1/95 from 12/31/95

to 12/30/95 to 12/31/99


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BOM Structure

BOM Header

Item 10

Item 20

Item 30

Sub Item 10

Sub Item 20

Plant Assignment

Validity Period

Release Indicator

Stock Items

Non-stock Items

Variable Size Items

Document Items

Text Items

Additional component details

e.g. installation points

for components


25/100

Bill of Material Glossary

BOM Category categorizes BOMs to represent different objects; for example:

Material BOM -- structure ofproducts manufacturedEquipment BOM -- structure ofequipment for plant maintenance

Document BOM -- structure ofdocuments such as drawings (3.0)BOM Group is a collective number for all BOMs in a group which allows for one

or several similar products to be described under one number.

AllAlternatives of a multiple Bill of MaterialAll variants of a variant Bill of Material

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

the company in which the BOM is used; for example, Engineering, Production,

Costing, Sales, Plant Maintenance

The BOM Usage allows different views to exist without


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Technical Type the system distinguishes BOMs according to whether they

represent product variants or production alternatives. If you create a variant

for the BOM,the system marks it as a Variant Bill. If there is more than one

alternative for a material, the system marks the BOM as a Multiple Bill.

Bill of Material Glossary(cont.)

BOM Validity Bills of Material are valid over an area and effectivity period.

Area of Validity -- identifies which plants the BOM has been allocated to Validity Period -- identifies the from and to effectivity dates.

The default to date is 12/31/9999


27/100

Item Category When you enter a new Bill of Material item, an item category must be assigned.

It has important control functions such as:

Screen selection Specific processing, such as material number required, negative values supported. The Item Category cannot be changed once set. It must be deleted and re-added. Sizes are maintained for variable-size items Item categories include:

Stock Items -- material in stock as a componentNon-stock Items -- material not stocked - with or without a material numberVariable-size -- system calculates the quantity required using formulasPM Structure Item -- used with plant maintenance equipmentDocument Item -- used with Document BOMs

Sub-Items are typically used to represent different installation points for partial

quantities of an item.

In assembling resistors on a printed circuit board, the installation points are

described.

There is no logic related to sub-items

ill of Material Glossary (cont.)


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29/100

AssemblyLine

Machines

People

Production

Line

CapacityRequirementsPlanning

Scheduling,Execution Tim

Costing

Work Centers

WorkCenters

CostCenter


30/100

Work Centers and Routings

Routing

Operation 10

Operation 20

Operation 30

Work Center W1

Cost Center 100

Assembly

Cost Centre 200

Work Center W2Finishing

Cost Center 200

Work Center W1

Cost Center 100

Assembly


31/100

Work Center CategoryWork centers are allocated to different work center categories

The work center category is used to control the field and screen selectionfor work centers during work center maintenance.

Work Center Category Screen View

Statistical Work center Basic Data

Production Work Center Basic DataDefault ValuesCapacity ValuesSchedulingCost Center Assignment


32/100

Cost Center Assignment toWork Center for Operation

Costing

Cost Center

Oper 0010 Oper 0020 Oper 0030 Oper 0040

Routing with standard values

Set Up (SET)

Machine (MACH)

Labor (LAB)

Work Centerwith Activities

duringproduction

Activity Rates

Set Up $70.00

Mach $60.00Labor $80.00

Overhead $70.00


33/100

Work Center Capacity

Oper 0010 Oper 0020 Oper 0030 Oper 0040

Routing with standard values

Set up Formula

Machine Time Formula

Teardown Formula

Work CenterFormulas

Set up 1.0 hrs

Machine 5.5 hrs

Teardown .5 hrs

Operation Std Values

Work Center Schedule

Use of Formulas in Work Centers


34/100

8 hrs

1 hr

7 hrs

1 hr

6 hrs

WorkingHours

BreakTime

WorkingHours less

Breaks

PlannedDowntime

ProductiveWorkingHours

Available Capacity at a Work Center


35/100

Routing Structure Views

Routing

Operation 30Operation 20Operation 10

Work Centre:PP-ASSEM

Control Key:- Time Tkts- Costing

Operation Text:Pre-assemble

frame

Std Values:Lab:10 mins

Mach:10 mins

MaterialsComponents

BOM

ProcessResourceTool (PRT)


36/100

BOMGroups

BOMGroups

Production Master Data

Materialsand PRTs

Materialsand PRTs

Bills ofMaterial

Bills ofMaterial Routings

Routings WorkCenters

WorkCenters

RoutingGroups

RoutingGroups

CostCenters

CostCenters

ComponentsAllocated toOperations

Item Category

Material Type

W/C Category


37/100

Operation

Operation types

(Main)

operation

Sub-operation

Sub-operation HierarchyCosting

Completion confirmations Scheduling always takes place

on the

(main) operation level

The control key defines whether completion confirmations andcosting are carried out on the (main) operation level, or on thesub-operation level.

Indicator: group operation sub-operation levelcombined operation (main) operation


38/100

Operation / Sub-operation

Operation0010

Operation0010

Operation

0020

Operation0020

Sub Operation0010 / 10

at Work Center A1


at Work Center A1


at Work Center A2


at Work Center A2


at Work Center A3


at Work Center A3

Schedule at Operation Level

Useful when processing for operation 0010

occurs over multiple work centers

Capacity Planning & Costingpossible at Sub Operation Level Level


39/100

Material Allocation

Op. 10Op. 10

Op. 20Op. 20

Op. 30Op. 30

Op. 10Op. 10

Op. 30Op. 30

Routing

BOM

ProductProduct


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Material

1

1

2

2

01

02

01

02

1

1

1

2

3

1

2

3

1

1

RoutingGroup

RoutingGroup

Counter

Material-Routing Allocations

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


41/100

Routing Default Values

RoutingRoutingMaterialMaster

MaterialMaster

WorkCenter

WorkCenter

Base Unit of MeasurePlanner GroupShort Text

Control KeyStandard ValuesActivitiesStandards Text KeyHR data


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External ProcessingOper 0010Oper 0010

Oper 0020Oper 0020

Oper 0040Oper 0040

Oper 0050Oper 0050

Purch ReqnPurch Reqn

Purch OrdPurch Ord

Vendor ProcVendor Proc

Goods RecGoods Rec

Routing data copied to order

including quantities and dates

Purchasing creates P.O.

At goods receipt, the operationis confirmed


44/100

Routing Operation SequencesStandard

Routing represents a standardsequence defining productionprocedure

ParallelRouting includes processes whichcan be performed simultaneouslyto achieve time efficiencies

SplitRouting includes processes whichcan/must be split across a numbe

of work centers

OverlappedRouting defines process where onoperation is to overlap with thefollowing operation


45/100

The PlanningConcept in SAP

Sales

Plan

SOP

Production

Plan

MPS

PlannedIndependentRequiremen

ts

CustomerIndependent

Requirements

Requirements(Orders) from SD

Module

Offset

Keep Balanced

Order Proposals

MRP

PlannedOrders

ProductionOrders

PurchaseRequisitions

Demand ieRequirements

Order proposals, planned orders etc are created and adjusted by running theMRP or MPS programs.


46/100

SOP specifies sales quantities for the long and intermediateterm to roughly assess the feasibility of sales and operation

plans

Sales and Operations Planning at the Product Group or F/G level

Materials may be planned together in Product Groups

Sales quantities are determined for future periods

Production quantities are then determined on the basis ofsales

Sales and Operations Planning Functions


47/100

MRP II is concerned with integrating individual plans within asupply chain

Profitability Analysis Revenue and Sales Plans

Sales and Operations Planning Sales and Production Plans

Master Planning Demand Program and Master Schedule

Material Requirements Planning Dependent Requirementsand

Procurement Plan

Sales and Operations Planning Planning Levels


48/100

Step 1 Sales Planning of Future Sales Quantities

Copy in from Sales Information System or Profitability Analysis

Automatic forecast based on historical factors

Manual entry of sales quantities

Step 2 Production Planning

Synchronize production plan with sales plan

Stock level equal to zero

Specify a target days supply by period

Specify a target stock level by period

Enter planning data manually

Sales and Operations Planning Steps


49/100

Step 3 Disaggregation of Planning Values

Determine the sales and production quantities of product group members

Modify the disaggregated sales planning data and create a production plan

for each member

Step 4 Transfer of Planning Values to MRP

Pass the planned sales and production quantities as independent

requirements to demand management

If product group data is transferred, the system automatically disaggregates

the planning data to the finished product level

Sales and Operations Planning Steps


50/100

Sales and Operations Planning Product Groups

A Product Group brings together materials according to some criteria such as

similar type or manufacturing process.

Link 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 group quantitiy is

distributed to its members

Supports production versions for a material or group

Supports multi-level product group hierarchy

Graphical support of one or more levels


51/100

Sales and Production Planning is carried out using a Planning Table which

shows the stock level that results from the sales and operations planning for

both materials and product groups

The Planning Table is divided into:

Sales Quantities

Production Quantities

Target Days Supply and Target Stock Levels

Sales and Operations Planning The Planning Table


52/100

Sales and Operations Planning Creating a Sales Plan

Manual Data Entry and Distribution Functions

Entered directly into the Planning Table as a % or qty

Copying Data from Sales Information System

Planned order, invoiced or delivery quantities

The planning data is aggregated across all materials in the group

Copying from Profitability Analysis

Quantity and performance measures

Copying the Forecast

Aggregates the consumption values for all the materials in the product

group


53/100

Sales and Operations Planning Creating a Production Plan

Determine the quantities to produce to meet the sales plan

Synchronize to the Sales Plan the system copies the sales quantities into the

production quantities

Zero Stock Level Use existing stock to cover sales quantities. When used up,

production quantities will synchronize with the sales quantities

Target Stock Level The system determines production quantities based on

sales and target stock levels

Target Days Supply Coverage is expressed in days


54/100

Sales and Operations Planning Disaggregation

Functionality is based on proportionality factors of product group members

The 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

Disaggregation can be carried out for the product group or for selected members

only


55/100

Sales and Operations Planning

Transferring Data to Demand Management

Transfer a single-level product group (multiple) or individual material (single)

Independent Requirements Parameters

Specify Requirements Type

Version Number

Limit scope of the time period


56/100

Master Planning

Demand Management

Planning and Consumption Strategies

Specification of Requirement Quantities

and Delivery Dates

Master Production Scheduling

Planning for Master Schedule Items

Planning Time Fence

Interactive MPS


57/100

Copy fromSales Plan

Copy fromProdn Plan

Copy fromForecast

Copy fromOrig Plan

Demand ManagementDemand Program

Manual Planned

IndependentRequirements

Sales

Demand fromSales Orders

MRP/MPS

Sales and Operations Planning


58/100

Make product for stock in expectation of customer sales

Plan using planned independent requirements for anonymous make-to-stock

production.

Use Net or Gross Requirements Planning

Net Requirements -- includes warehouse stock, planned issues and receipts

Gross Requirements -- excludes warehouse stock. Just includes planned

and open orders

Example is a shelf stock item such as a bike accessory light

Planning Requirement Type is LSF - make to stock which is used in theplanned independent requirements transaction

Sales Order Re uirement is KSL - which is sale from stock

Planning Strategy Make-to Stock


59/100

Sale from stock Planning

Production Push

WarehouseStock

FinishedProduct

Strategy: Make-To-Stock Production

Example: Common shelf items such as a bike accessory (light)


60/100

Make product in expectation of customer sales

Plan using planned independent requirements at finished goods level to drive

demand to long lead time components

Typically 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 excess stock

Example is a long lead time custom product

Planning Requirement Type is VSF planning with final assembly

Sales Order Requirement is KSV which is sales order with consumption

Planning Strategy Planning with Final Assembly


61/100

Sales Order Planning

Production Push

Warehouse StockFinished Product

Example: Custom furniture such as a cherry table

FinalAssembly

to Sales Order

Purchase Produce

MRP without reference to sales order

Planned IndependentRequirements

Strategy: Planning with Final Assembly


62/100

Planning Strategy Planning Without Final Assembly

Final assembly is initiated by the customer sales order

Stop production at sub-assembly level

Final assembly pull

Example is automobile assembled with unique combination of features (sub-

assemblies)

Planning Requirement Type is VSE -- planning without final assembly

Sales Order Requirement is KEV -- independent customer order with

consumption


63/100

Sales Order

Planning

Production PushFinal Assembly Pull


Warehouse Stock

Assembly 01

Warehouse Stock

Assembly 02

Example: Option oriented product such as a car

Stop at leve


Assembly whenSales OrderScheduled

Purchase Produce

Strategy: Planning Without Final Assembly


64/100


65/100

Sales Order

Planning

Production PushFinal Assembly Pull

Customer StockFinished Product

PlanningMaterial

Warehouse StockAssembly 01

Warehouse StockAssembly 02

Example: Bikes with the same features except for the color

Purchase Produce Note: Percentages drivelower level demands for subassemblies

Strategy: Planning with Planning Material



66/100

Sales Order

Production by Lot Size Pull

WarehouseStockFinished Product

Example: Combine customer orders for the same item

Strategy: Production by Lot Size


67/100

Planning Strategy Make to Order Production

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 project

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

a particular customers order

Sales Requirement Type is KE -- independent customer order without

consumption


68/100

Sales Order

Production by Lot Size Pull


Example: New machinery

Strategy: Make-To-Order Production


69/100

MRP Features

MRP

Lot sizing

Order schedulingand generation

Internal productionand externalpurchasing

Net requirementscalculation

Bill of MaterialExplosion

Forecasting


70/100

MRP Overview


71/100

OverviewPurchased Items MRP

Purchasing

Accounting

Warehousemanageme

ntsystem

Goods receipt

Inventorymanagement

Valuation

Goods Transferissue posting

Invoice receipt

Invoiceverification

Master data

MaterialBatchesVendors

Customers:


72/100

MRP: Reorder PointPlanning

Reorder Point

Safety Stock

Order Date Delivery Date

Time

Stock


73/100

PurchasingProcess Time

Vendor PlannedDelivery Time

Desired DeliveryDate

ReleaseOrder Date

Forward Scheduling for External Procurement

Today

Goods ReceiptProcess Time

Forward scheduling used for reorder point material


74/100

Daily Accumulation:

Sales Orders

PlannedIndividual

Requirements

Reservations

Entriesfrom

PlanningFile

WarehouseStock

+

Open Order Proposals

Shortages

OrderProposal

Net ChangePlanning

Coverage calculation per requirement date


75/100

MRPPrerequisites

s Activated for MRPPLANT LEVEL

MATERIAL LEVEL s Valid MRP Type

s Valid Material Status

s Material MRP Views Maintainedw MRP Controller

w Planned Lead Timew MRP Groupw Lot Size Data


76/100

Material Master MRP I Key Fields

Basic, General, and Lot Size Data

s Procurement Type indicates if the material is externally procured, or produced

internally or both.

s Special Procurementidentifies special planning rules which may be used for in-

house production or external procurement

s MRP Type determines how the material is planned such as MRP, MPS, or

consumption based planning

s Material Lead Timeidentifies for material planning the planned delivery days or

in-house production days

s Lot Size determines which lot-sizing procedure the system uses to

calculate order quantities


77/100

Material Master MRP 1Key Fields

Scheduling Parameters

Planning Time Fence: defines a period during which MRP/MPS will notautomatically add or reschedule orders

Scheduling Margin: controls the release period, opening periodfor a material

and scheduling floats for production

Release periodis thenumber of working days in the release period

Opening period is the number of working days between the order creation andplanned start date

Order floats allows for safety margin before and after production

Planned Delivery: lead-time for purchased material

In-house Production: lead-time for manufactured material

GR Processing Time: goods receipt processing time

Example: dock-to-stock time


78/100

Material Master MRP 2 Key Fields

s Availability Check indicates whether the system generates individual orsummarized requirements for sales orders for this material and for planning, which

MRP items the system includes in the availability check.

s Mat./PPC Status is used to limit the usability of materials for certain activities such as,

purchasing, bills of material


79/100

Material Master MRP 3 Key FieldsIndependent Requirements

Consumption Mode: controls consumption of planned independentrequirements by customer requirements

Selections: backward, forward, or both

Consumption Periods Backward/Forward: specifies the number ofperiods of forward or backward consumption

Used in conjunction with consumption mode

Storage Location MRP MRP Indicator: determines whether or not requirements, for a specific

storage location, are planned separately from the overall plan

Reorder Level: used for storage location MRP

Replenishment Quantity: used for storage location MRP


80/100

MRPTypesVB

VM

VV

PD

M0

Manual Reorder Point Planning:MRP produces order proposals when stock falls below a reorderpoint. The reorder point and safety stock levels are entered

manually

Automatic Reorder Point Planning:The reorder point and safety stock level are calculated based onthe forecast results

Forecast PlanningThe latest forecast is copied as requirements which are used tocreate order proposals

Deterministic PlanningMRP produces order proposal(s) to match the exact quantity ofthe requirements based on independent and dependent demands


81/100

Lot Sizing

Static Periodic Optimum (Cost )

Lot for Lot

Fixed Lot size

Replenish up to

maximum stocklevel

Daily Lot size

Weekly Lot size

Monthly Lot size

Flexible period

Lot size accordingto planning calen.

Part period balancing

Least unit cost procedure

Dynamic Lot size creation

Groff reorder procedure


82/100

MRP: Static Lot Sizing

Lot for Lot Order Quantity:Shortage Quantity = Ordered Quantity

Replenishment up to Maximum Stock Level:

Stock required to achievemaximum stock level set in

the material master

OrderQuantity =

MaterialFixed Order

Quantity

=ShortageQuantity

Order =Fixed Order

QuantityIf Order

Order

OrderFixed Lot Size:Shortage Quantity

>Fixed Order Quantity

If


83/100

Carrying Out the Planning Run

Total Planning All materials in a given plant

s All materials are reviewed by MRP regardless of activity

s Only the materials in a plant that have undergone a change relevantto planning since the last planning run (net change planning)

Planning Interval Limiting the MRP Planning Interval

Time

Planned requirements andsupply order receipts

example:100 days

MRP Planning Horizon


84/100

Planning Run Options for AutomaticCreation of Requisitions and Delivery Schedules

MRP Control Parameter:determine whether or not MRP will

automatically create requisitions or delivery schedules

Options are:

Do not automatically create. Only create planned order

Automatically create within the opening period

Automatically create for the entire planning horizon

Opening Period Parameter:allows the user to take advantage of

MRPs automatic creation features while retaining control over the

number of open purchasing documents


85/100

MRP List

MRP Controller

Group of Materialsfor which controller

is responsible

Controllers MRPListing

Goods ReceiptGoods Issues

MRP Order Proposalsand Planner Messages

from MRP Planning run.

Planner can drill downto review materialmovement activity


86/100

Stock Requirements List

RP Element Supply/Demand Ref EM Quantity Av

STOCK 100ORDER Sales Order 25 75PL ORD 1000 120 05 100 175

-----------------------------------------------> Planning Time Fence

ments List brings together all the supply orders, independent

nt demands and stock balances for the material. MRP makes

ls to balance the supply/demand position for the material


87/100

MRP

PlanningResult

MRP List vs Stock Requirements List

The MRP List displays the result of the last planning run

The Stock Requirements List displays the most up-to-date stock and

requirements situation

MRP

PlanningProcess

MRPPlanningProcess

Last planningrun results

Stock RequirementsList uses current data

Current Stock,Rqmts,Balances,plannedReceipts,Issues


88/100

PurchasingProcess Time

Vendor PlannedDelivery Time

Desired DeliveryDate

CalculatedOrder

Release Date

Backward Scheduling for External Procurement

FutureRequirement

DateGoods ReceiptProcess Time

s MRP determines the basic scheduling dates using backward scheduling

s If the release date lies in the past, the system automatically switches toforward scheduling

MRP PlanningDate -- today

MRP Planning Lead Time


89/100

Order ReleaseProcess Time In-houseProduction Time

Order

Finish

Date

Order

StartDate

Backward Scheduling for In-house Production

FutureRequiremen

t

Date

Goods ReceiptProcess Time

s MRP determines the basic scheduling dates using backward scheduling

s If the release date lies in the past, the system automatically

swithches to forward scheduling

MRP PlanningDate -- today

MRP Planning Lead Time

OrderRelease

Date


90/100

E1

Independent RequirementsCustomer Requirements

Planned Orders

Dependent Requirements

B2B1

R1 R2 R3

Planned Orders

DependentRequirements

DependentRequirements

Level 0

Level 2

Level 1

Planned Orders

Planned OrdersPlanned OrdersPlanned Orders

= Demand= Supply

Planning Structure

Multi-Level


91/100

Order Proposals: Planned Orders

Procurement Type isIn-house Production

MRPMRP

Controller

Planned OrderOrder QtyOrder DateCapacity Reqts.Resource Reqts.

Planned OrderOrder QtyOrder DateCapacity Reqts.Resource Reqts.

ProductionOrder


92/100

Planning for In-house Production

PlannedOrder

PlannedOrder

Production

Order

Auto Change/ Deleteif situation changes

AutoCreation

Collective Conversioninto Production Order

Manual changes/deletion

ManualCreation

Planning Run MRP Controller

Individual Conversioninto Production Order

Production

Order Release


93/100

The Production Cycle

Issue

Materials to

Order

Select

BOM

Select

Routing

Schedule

Times & Dates

Calculate

Capacity

Purchase

Requisitions

Goods

Issue

ProductionOrder

Calculate

Planned Costs

Release

Order

CheckAvailability

Print Shop

Floor

Papers

Create

Order

Create

Required

Purchases

ConfirmCompleti

on

Receive complete

goods into stock

Goods

Receipt

Confirmation Slip

CalculateActual Costs

ActualLabor

OAK BROOK TECHNOLOGIES


94/100

Production Order CreationManual

Order CreationOrder Proposal

MRP Conversion

Determine

Order Type

RoutingSelection

Lead TimeScheduling

Bill of MaterialSelection

s Enter start or finish datedepending on scheduling direction

s Component Overridess Material Reservationss Item Categories

s Alternate Sequence Assignmentss One operation is required

Changes are allowedbeforeorder release

OAK BROOK TECHNOLOGIES


95/100

Production Order Release

Production OrderReady for Release

Material AvailabilityCheck

Order orOperation Release

Shop PaperPrinting Possible

MaterialWithdrawals Possible

s Order release is carried out manually

s Uses checking rules defined in configuration

s On-line or in backgrounds Pick List, Confirmation Slips,...


96/100

Material Availability Check

Stockon

Hand

150Units

Reservation

for

50 UnitsNet

Available 150 100 300

100

PlannedOrder

for

200 Units

Dependent

Requirementfor

200 Units

Requirement

for 50Units

are


97/100

Goods Movement for a Production Order

Material 1

Material 2

Production

Goodsreceipt

ofMaterial

3

Goods Issue

Consumption of

Material 1 and 2

Reservation

Planned Goods Issue

Unplanned Goods Issue

Goods issues only apply to stock items


98/100

Goods Issue Results

Goods IssuePosting

UpdateReservations

G/L AccountUpdate

Accounting

MaterialDocument

MaterialUsage

Statistics

Cost ObjectAllocation


99/100

Completion Confirmations

Production OrderOperations

0010 - Assemble Board

0020 - Assemble Case

0030 - Assemble unit

0040 - Final Test

Production OrderOperations

0010 - Assemble Board

0020 - Assemble Case

0030 - Assemble unit

0040 - Final Test

C

ConfirmOperation 0010

Activities


Activities

Confirm

Operation 0020Activities

Confirm

Operation 0020Activities


Activities


Activities


Activities


Activities

s Partial or Final Confirmations Single or Collective Confirmations Milestone Confirmations Reduction of Capacity Requirementss Determination of Actual Costs

Milestone


100/100

Confirmation Data

Quantity

Dates

Labor

s Yields Scrap Quantitys Scrap Reason

s Start dates Finish date

s Work Centers Personnel Numbers Qualifications Wage Groups Wage Type

Documents

Sap Production Planning (Old)