Can be MRP (simplify req det), automatic create PO from PR(automatic generate PO), Determination req with source determination & Contract, GR & ERS
To create automatic PO for PR/ create automatic PO for contract ME59N, the prerequisite is, source supply has assigned in PR (info rec, contract), in material master and vendor master automatic PO is tick.Grouping some item PR can group into some of PO, can be determine in selection screen ME59N (purc group, plant/ del date).
Item error when automatic generation: can be happen when item in PR is not complete (account assignment cat U, vendor in block, tax code missing for case ERS)
When generation can choose exclude item with errors and can show the error log or using do not exclude item with errors.
Source det, also can create automatic when planning run MRP that specified in item PR (if MRP run direct to PR not PLO). Prerequisite : source is in question can be determined unique, source list has maintain.
ERS. In ERS settlement invoice represent credit memo. Vendor inform message (credit memo) about settlement delivery.Advantages : ordering transaction more quickly, minimize error entry, qty &
price variance will not happen.
Disadvantages : can not settle delivery cost, plan and unplanned del.
Vendor will not send invoice, but invoice is generate automatic by system ref PO and GR doc. If there is return goods, ERS will create credit memo.
Prerequisite : GR based IV & ERS set in vendor master, PO, maintain tax code for item, estimated price indicator in item details condition, GR is create ref PO, di info record No ERS indicator is not set.
To settle ERS MRRL, sebelum di settle dpt test run, bs juga run background program RMMR1MRS
MRP: main function to ensure mat is required in qty and right time, ensure mat availability. Can automate generate procurement proposal and prod.
Possible procurement element : PLO, PR, Sched agreement schedule line. PLO and PR :
Internal planning elements can be change, resched, delete at any time. MRP controller will check PLO that have to be convert to PR. Advantage of creating PLO is to check the execute of MRP contoller. In production planed order convert to prod order then system convert dep req in PLO into reservation in prod order.
Also can create schedule line, if scheduling agreement exist and MRP relevant in source list, shg setelah run planning bs tergenerate sched line (fix element, tdk bs diubah)
Prerequisite : Requiremen planning can be create in plant level/ MRP area.Misalnya ada sloc dlm plant itu yag tidak ingin di run, itu bs di define dlm MRP area (group together Sloc into MRP area). Using MRP are can differentiation material planning within a plant.
3 Different type MRP are : Plant, Sloc, Subcont MRP area
MRP Procedure : Consumption based(ROP, forcast based, Time phased), MRP based,
In MRP 2 -> procuremen type, if choose X (both inhouse and external prod, in house prod is applied first. Step MRP & CBP : Net req calculation, Lot size calculation, schedulling,
a.
Consumption Based planning
Based on previous mat consumption, historical value, use mat forcast and statistical procedure to determinew future req.
SO, PIR and Res not relevant with planning (not refer to prod planning. Net req not form PIR and dep req) Usually used in mat not in manuf plant but for mat with planning B & C material and operating supplies. Prerequisite : need upto date Inventory management. If working with forcast req, consumption history must be run according to certail legality
MRP type key to determine procedure to use for planning material and to determine MRP paremeter that must be enter during maintrnance mat master (MRP type tentuin master dta yg hrs dilengakpi di mat master, misal VB harus input forcast)
In scheduling, the system defines the date on which the material will be available from the date of the planning run. This procedure is called forward scheduling Schedulling => Forward sched = > start from current date (=order start date PLO, release date PR to convert to PO) Shortage qty date = date on planning run + (purch time purchasing + PDT (order finish date PLO) +GR Proc time= availability time) ROP
Cek stock available +fix receipt ( Open PO+ firm PR + firm PLO )< ROP ?
a.
Ya, case mat withdrawl -> Create PLO => Net req VB = ROP –(Wh stock + SS +firm PR, PLO + PO)b.
No, case GR, eg material return at lead time -> Delete PLOc. Ga ada planned receipt lagi coz mat return -> system suggest cancle receipt
* fix receipt = on order stock
ROP can manual VB (SS & ROP manual in mat master) & automatic VM (pake forcast, perlu ROP awal, Service level)
ROP can use with external proc (artinya SO, manual Res, Order res, MO and relese PR can be used also for determination req). using it, can decide wheater external req is used in complete periode horizon or only in replenishment lead time.
Consideration ROP : SS, LT, present Consumption / future req
SS used to cover unplanned excess consumption & req coz delay delivery. SS part ROP
ROP composed expected average material consumption during replenish lead time and.
Proses in consumption based :
1. Create planning file of material that will be planned in planning run.
2. Calculate net req, 3. Lot sizing calculation,
4.
Scheduling planning run (ROP using forward scheduling)PR -> Release date, delivery date PLO -> start date, end date
5.
Check procurement type (GR PRO/ GR PO) system determine source supply6. MRP controller check and edit new procurement proposal
Forcast based
Future req using forcast as basis consumption value to estimate future req.
Forcast is calculate at regular interval. Using backward schedulling
Time phased
Using data historical in mat forcast to determine future req. Forcast is executed according to predefined interval in rythme, example according delivery time.
Run MRP better for material with some rhytme (shifted according del time, vendor always deliver in particular week
Static Lot size : system not consider future req.Lot for lot : req based on shortage qty
Fix lot size : req brp pun, akan tetap di propose yang fixed di mat master. If not enough system generate bebereapa order proposal
Replenish max stock level : system create order proposal to the amount required to bring stock level upto max stock level in mat master.
b. MRP based
Based on current and future req. PIR trigger requirement calculation.Requirement element : SO, PIR, Res,-> create dep req that BOM explosion create.
Usually used for inhouse prod material, planning FG and assembly group such as component material A
MRP Type
MRP type is a key that controls the MRP procedures to be used for planning a material. It belongs to the plant-specific data (i.e. MRP are data of a material).
MRP type controls which planning parameters must or can be entered when maintaining the mat master
MRP type controls:
o MRP Procedures (MRP, reorder point planning, forecast-based planning, time-phased materials planning, no materials planning)
Master data for MRP
MRP view is in plant level, but also can be MRP area level. Data in material master of MRP is devided into General data, data dependent MRP procedure, Data required for scheduling, Data required for lot size calculation.MRP-relevant data is stored at plant level in MRP 1-4, forecast, and purchasing view in mat master
You can plan SLoc for MRP separately. Settings in mat master at SLoc level in MRP 4 view.
MRP profile key of mrp parameter independent of mat master , Profile MMD1:collection information for configuration material master record. MRP profile is assigned when MM01, profile that already assigned cannot be changed. If data attribute is changed in profile, system will update it to all material that has assigned using background job program RMMM0001. Can see MRP pofile usage MMD7. Di MRP profile bs fix value, dan default value
* Edit MRP profile, ketika MRP view sudah diisi lalu ingin di ubah dari MRP profile data
** Ketika MRP profile di change (sudah ada assignment ke mat) -> create background job to reassign new data/ start job profile.
Untuk lihat display change doc untuk material master bisa MM04 MRP profile specifies:
o Which fields filled with values when entering MRP data in mat master record
o What are the values entered in these fields
o Which of these values can be overwritten (default values) and which cannot (standard values)
Material status : restrict usability material determine which function in MM &PP (business usage intended to material) can contol result warning message.
Mat status can be cross plant.
Planning Run
Untuk dpt run planning MRP, maka req planning hrs di active -> SPRO -> CBP -> Planning -> Activate MRP. Also have to set plant parameter and have to maintain MRP data in material master. Planning file entry (GI, Res, ubah mat master, forcast dll), bisa juga di add manual.
1. Execute planning (online/background MDBT bisa single atau berulang regulary for 1 plant/MRP area): MD01 Total planning online , single object planning ( MD03 single level, single item (hanya level BOM yg dipilih atas 1 mat) also can single item multi level (level atas item yg dipilih dan lower BOM level), single item interactive (can detail check, for MPS item, di MD04 can see simulation run MRP)
Schedule run background depends on date specified in variant when execute background job.Result planning : Statistic of scope planning, exceptional, termination (bisa print log jika run background). Config to define scope of planning as a group, enter counter to specify sequence individual MRP unit (plant/MRP area)Sequence run planning, Plant MRP area, Sloc MRP area, Subcont MRP area. In scope of planning can restrict 1/ some MRP area or total planning run for this MRP area
2. Planning file entry, material relevant for planning run . Planning file control scope of planning and planning file entry = mat that are to be considered planned in different type of planning run are determined.Planning run type :
o
NEUPL : regenerative planning (only mat that include in planning file, if change data MRP type, lot sizing procedure/ purchasing proc time tdk muncul change indicator di planning file.o
NETCH : net change planning in total horizon.eg create PO (1 item, 1 level)o
NETPL : net change planning in planning horizon ( 1 item, 1 level) NETCH & NETPL u/ single item planningChanges relevant to planning can be :
change stock, PR-PO-PLO-sales req-forcast req,-dep req and reservation, field relevant to planning of these GR/ GI, Deletion GR GI
Define planning horizon can in plant level/ MRP group.
Display planning file MD21
Jika setelah di tandai di run, maka indicator X ini akan menjadi blank
Control parameter for the planning run creation indicator procurementproposal (direct PR or PLO) schedule line (syaratnya ada source list), creation indicator MRP list, plannin mode (specifies how non fix procurement proposal from the last planning run are tobe handled in next planning run whether the existing planning just needs to be adjusted, or whether BOM and routings need to be exploded again, or whether the planning should be recreated from scratch
)
, scheduling.The creation indicators of MRP lists, PR, and schedule lines can also be set in the MRP group.
Config exception message as a result in MRP list
Jika material master sudah ada sebelum MRP di aktifkan di plant, maka hrs generate planning file untuk material MDAB. Also need consistency check misalnya material yang sebelumnya udah ditandai untuk ikut di run MRP, kemudian ingin di exclude.
Priority MRP group to Plant => in total planning system will check mat group di assign to mat master, if yes system will read parameter in MRP group, but if No system will use parameter in plant. MRP group also can define for each with mat type
Stock req List : dynamic report to evaluate planning situation using current stock/req list MD04. Element MRP : PLO, PRO, PR, PO, Res, Plant stock, Sloc stock, SO, Forcast reqScreen area : header, item, mat tree
MRP list : tools to evaluate MRP that show result of last planning run, static.
Change after planning run can not be seen
Source det :can using info record contract, Outline agreement item Planning Result
PLO, PR, Sched agreement, MRP list (Planning result material)
Planning situation or the result of a planning run can be evaluated using the two lists; individually or collectively.
Stock/requirements list is a dynamic list. It shows the present stock,
requirements, and receipts situation. Changes become obvious as soon as you call the current list, or choose refresh to read the elements from the database in the display of the list. Change made after planning date are displayed directly. MD04
MRP lists show the result of the most recent planning run and are therefore static: Changes made after the planning run are not shown. Has header and item (MRP element). Also can show material tree in MRP list. MRP list is store in the system until delete manually/ replace by new planning run. MD05 PLO can create manual/ automatic from planning run. Char PLO :
It is a procurement proposal in MRP for requirement coverage, an internal planning element. It is not binding so does not trigger procurement directly, just helps with planning.
It can be changed or deleted at any time.
It is still undecided as to whether in-house production or external procurement.
For in-house can be used in capacity calculation.
For in-house produced materials, it determines the basic dates for the production.
Option to convert PLO : individual MD14, collective MD15. PR that already converted from PLO is fixed automatically.
Personal setting
Header data : master dan transaction data Item : MRP element
Can use filter, comparison stock req list & MRP list, can display vendor/ cust, GR date,
User specific setting : Definition of settings to access the lists Definition of user-specific transaction calls Configuration of columns in the lists
Navigation between materials with material tree Definition of the traffic light value
Saving selection parameters for collective access into the MRP list.
Planning Evaluation
Collective list
Can be seen for stock req list and MRP list. Traffic light indicator show how urgent material processing is and can setting for how to maintain traffic light.
Can using search, sort, use graphical display changes to stock situation of 1 or
several material.
Different in selection criteria, in MRP list can search for processing indicator/ new exception
Material treeStructure tree in MRP list & stock req list (maintain in user specific setting).
Matrial tree can be for worklist tree(all material in current session), order tree(all component & assembly of selected MRP element), product group (all material of product group, jk di selection criteria diinput product group)
Navigation profile
To simplify work in MRP list & stock req list (setting in user specific transaction calls). Setting navigation profile CBP > Evaluation >Define navigation profile.
Navigation profile will be assign in user specific setting
Exception message
Indicate exceptional situations that have tobe considered (start date in the past, stock level falling below safety stock. Exception message occurs during planning run, that need to be checked by MRP controller and used to control planning result MRP. Config exception message CBP > Planning > Evaluation
> Exception message > Define and group exception message. Can maintain period split for period total CBP > Planning > Period total > Define individual periods for period total. Day’s supply (number of days a material will last taking the current plant stock into account) Day’s receipt ( how many days a material will last, taking current plant stock and receipt element into account) and exception group control trafic light display. CBP > evaluation > define receipt element for receipt days supply.
You can define two receipt days’ supplies. You can determine that for the first receipt days’ supply, the less firm receipt
elements are taken into
consideration, and for the second days’ supply, only the firm receipt elements.
Can config screen element for MRP type CBP> Evaluation > Define screen sequence for header details.
Lot size Calculation
During planning run system determine shortage qty through net req calculation that must be covered by receipt element which calculate in lot size calculation. Three groups of lot-size calculation procedures:
o Static lot-sizing procedure: the lot size is calculated using only the entered qty in the material’s master record.
o Periodic lot-sizing procedure: groups together requirement qty from one or several periods to form a lot
o Optimum lot-sizing procedure: groups requirements from several periods together to form a lot, whereby an optimum cost ratio is determined between lot size independent costs and storage costs.
SPRO CBP > Planning > Lot size calculation > Define lot sizing procedure Static lot size
In here, future shortages are not taken into account; i.e. if a shortage occurs, an order proposal is created for the amount defined for the static lot size.
System doesn’t check to see when a future shortage will occur.
Types of static lot-size:
o Lot-for-lot order qty; an order proposal is created for the shortage qty.
If an issue comes up and cannot be covered, system still only creates one order proposal covering the total shortage qty on this particular day.
o Fixed lot size; an order proposal is created for the fixed lot size if a material shortage occurs. The system will create several order proposals for the same date to cover the shortage, if one proposal is not sufficient.
o Replenish to maximum stock level; an order proposal is created, if a shortage occurs, for the amount required to bring the stock level up to the maximum stock level recorded in the mat master.
Periodic Lot-Size
In here, system groups several requirement qty within a time interval together to form a lot. Period lengths can be days, weeks, months, or a period flexible length equal to posting periods, as well as freely definable periods according to a planning calendar.
Types of periodic lot-size:
o Daily lot size: All requirement qty that fall within a day or within a specific number of days (user defined) are grouped together to form a lot
o Weekly lot size: All requirement qty that fall within a week or within a specific number of weeks (user defined) are grouped together to form a lot
o Monthly lot size: All requirement qty that fall within a month or within a specific number of months (user defined) are grouped together to form a lot
o Lot size according to flexible period length (also called period lot size):
All requirement qty that fall within one flexible period length or within a specific number of flexible period lengths (user defined) are grouped together to form a lot. Period lengths are determined according to the accounting periods.
Lot Size Rounding
Lot size rounding is a set of additional restrictions (in mat master) that can group requirements to form a lot. Eg: By specifying a rounding value, system
will determine during lot size calculation that the lot size qty is a multiple of an order unit (if the material is only delivered in complete pallets)
Beside the rounding value, you can also use rounding profile. It is used to define settings for rounding up or rounding down the order proposal qty into deliverable units. It is define in Customizing CBP> Planning> Lot size cal >Maintain rounding profile.
It is contains of the threshold and the rounding value. Threshold value is the value from which the system rounds up to the value of the next deliverable
It is contains of the threshold and the rounding value. Threshold value is the value from which the system rounds up to the value of the next deliverable