Setting and Executing the MRP Run
Exercise 9: Simulative MRP
Exercise Objectives
After completing this exercise, you will be able to:
• Execute the MRP run in simulation mode
• In particular, analyze situations with scheduling problems due to the delay and implement measures to correct the problem in simulation mode.
Business Example
As a member of the project team, you familiarize yourself with the functions of simulative material requirements planning.
Task 1:
In the previous exercise, you created and planned a customer requirement of 60 pieces of the pump R-F1## for the date today + 1 month. This means that you fulfilled the requirement with a planned order.
Hint: If you did not carry out the previous exercise on the planning file entry, create the above mentioned customer requirement now (make sure that the requirement type is KEV) and then execute multi-level planning.
Note the change in the stock/requirements list:
1. Make a note of the customer requirement number:
______________________________________________________
2. Write down the number of the corresponding planned order:
______________________________________________________
Task 2:
Analyze the planned order as far as the dates are concerned.
1. Was the planned order for the customer requirement created on time?
______________________________________________________
(Note that the availability date of a planned order always falls on a working day, which is not necessarily the case for the customer requirements date.)
Continued on next page
2. What is the start date of this planned order?
______________________________________________________
What consequences does this have for procuring the components for this planned order?
_____________________________________________________
3. Execute the order report function from the stock/requirements list for this planned order. Based on this evaluation, do you foresee problems in fulfilling the sales order?
_____________________________________________________
Task 3:
Now execute single-item, multi-level planning in simulation mode for material R-F1## in plant 1000. To do this, select the Simulation mode indicator in the MRP initial screen.
1. Make sure that the indicator Also Plan Unchanged Components is set, and that you use planning mode 3 in this case.
Start the planning run by choosing Enter twice.
Hint: Do not exit the transaction.
Task 4:
Evaluate the planning results: After you have executed multilevel requirements planning, display the planning results on the material overview screen.
Select the planning result for finished product R-F1## by choosing the function 1st material.
1. Examine the planned order in the individual customer segment that you already analyzed above. Is a delay displayed for this planned order?
______________________________________________________
By how many working days is the planned order delayed due to the lower level assemblies and components?
____________________________________________ working days
Continued on next page
2. Select the planned order and click on the order structure button. Select the planned order and choose the Expand Subtree button. Note down the two procurement elements that cause the longest delays in the following table:
MRP element Number of MRP element
Material Delay (working days)
Return to the display of the Planning results: Individual lines for material R-F1##.
Hint: Do not leave the transaction.
Task 5:
Now reschedule the planned order into the future: Select the planned order you examined and choose the Reschedule procurement proposal button. Using the displayed (availability) date of the planned order, postpone the planned order by the number of working days that was displayed as the delay time for the planned order (see above). Enter the appropriate new order finish date for the planned order in the new field.
Hint: To help you do this, you can use F4 and the plant calendar in the ReschDate field. The new end date is calculated as previous end date + delay time of planned order, calculated in working days.
Make sure that you do not use the current date as the starting point for rescheduling by mistake.
1. Make sure that the planned order is firmed. To do this, display the detail screen for the relevant planned order by calling it from the list. Check whether the indicator is set in the Firmed field. Return to the list by choosing the Copy procurement proposal button.
Hint: Do not leave the transaction.
Continued on next page
Task 6:
Display the stock/requirements list for material R-F1## in plant 1000 in a parallel session.
1. Is the changed end date displayed for the planned order that you have just edited?
________________________________________________________
Give a reason for the result:
________________________________________________________
Task 7:
You should now execute planning for the planned order again: The assemblies and components that lie below the planned order that you have rescheduled, have not yet been planned.
Return to the session with the simulation results. Select the planned order that you have just processed and choose Execute planning run.
1. By how many working days is the planned order now delayed due to the assemblies and components?
____________________________________________ working days 2. Save the planning result (and exit the transaction).
Task 8:
Call up the stock/requirements list for material R-F1## in plant 1000 again (if necessary, refresh the list).
1. Is the modified end date now displayed for the planned order you just edited?
____________________________________________________________
Give a reason for the result:
____________________________________________________________
____________________________________________________________
Task 9:
Then call the stock/requirements list for R-F1##, plant 1000 and execute the “order report” function for this planned order.
1. Do the assemblies and components still show rescheduling messages?
____________________________________________________________
Solution 9: Simulative MRP
Task 1:
In the previous exercise, you created and planned a customer requirement of 60 pieces of the pump R-F1## for the date today + 1 month. This means that you fulfilled the requirement with a planned order.
Hint: If you did not carry out the previous exercise on the planning file entry, create the above mentioned customer requirement now (make sure that the requirement type is KEV) and then execute multi-level planning.
Note the change in the stock/requirements list:
1. Make a note of the customer requirement number:
______________________________________________________
a) Customer requirement number: Varies
2. Write down the number of the corresponding planned order:
______________________________________________________
a) Planned order number: Varies
Task 2:
Analyze the planned order as far as the dates are concerned.
1. Was the planned order for the customer requirement created on time?
______________________________________________________
(Note that the availability date of a planned order always falls on a working day, which is not necessarily the case for the customer requirements date.)
a) Planned order on time: Yes, the planned order was created on time.
If the customer requirements date lands on a holiday or a weekend, the planned order will have an availability date that is before the customer requirements date.
2. What is the start date of this planned order?
______________________________________________________
Continued on next page
What consequences does this have for procuring the components for this planned order?
_____________________________________________________
a) Planned order start date: Varies, about one week after the current date.
Consequences for procuring the components: The time available for procuring the components is very tight. If the components are not already in stock, there could be problems meeting the order date.
3. Execute the order report function from the stock/requirements list for this planned order. Based on this evaluation, do you foresee problems in fulfilling the sales order?
_____________________________________________________
a) Problems foreseen: Yes, problems can be expected.
Procurement of the subordinate components occurs with procurement elements that contain exception messages.
Task 3:
Now execute single-item, multi-level planning in simulation mode for material R-F1## in plant 1000. To do this, select the Simulation mode indicator in the MRP initial screen.
1. Make sure that the indicator Also Plan Unchanged Components is set, and that you use planning mode 3 in this case.
Start the planning run by choosing Enter twice.
Hint: Do not exit the transaction.
a) Menu path: Logistics → Production → MRP → Planning → Single-Item, Multi-Level
Continued on next page
Task 4:
Evaluate the planning results: After you have executed multilevel requirements planning, display the planning results on the material overview screen.
Select the planning result for finished product R-F1## by choosing the function 1st material.
1. Examine the planned order in the individual customer segment that you already analyzed above. Is a delay displayed for this planned order?
______________________________________________________
By how many working days is the planned order delayed due to the lower level assemblies and components?
____________________________________________ working days a) Delay: Yes, a delay is displayed.
Length of the total delay of the planned order: Varies, around 15 working days.
2. Select the planned order and click on the order structure button. Select the planned order and choose the Expand Subtree button. Note down the two procurement elements that cause the longest delays in the following table:
MRP element Number of MRP element
Material Delay (working days)
Continued on next page
Return to the display of the Planning results: Individual lines for material R-F1##.
Hint: Do not leave the transaction.
a) Longest delay:
MRP element Number of MRP element
Material Delay (working days)
PLOrd Varies R-B3## Varies, around
15 days
PLOrd Varies R-B4## Varies, around
11 days
Task 5:
Now reschedule the planned order into the future: Select the planned order you examined and choose the Reschedule procurement proposal button. Using the displayed (availability) date of the planned order, postpone the planned order by the number of working days that was displayed as the delay time for the planned order (see above). Enter the appropriate new order finish date for the planned order in the new field.
Hint: To help you do this, you can use F4 and the plant calendar in the ReschDate field. The new end date is calculated as previous end date + delay time of planned order, calculated in working days.
Make sure that you do not use the current date as the starting point for rescheduling by mistake.
1. Make sure that the planned order is firmed. To do this, display the detail screen for the relevant planned order by calling it from the list. Check whether the indicator is set in the Firmed field. Return to the list by choosing the Copy procurement proposal button.
Hint: Do not leave the transaction.
a) No solution required
Continued on next page
Task 6:
Display the stock/requirements list for material R-F1## in plant 1000 in a parallel session.
1. Is the changed end date displayed for the planned order that you have just edited?
________________________________________________________
Give a reason for the result:
________________________________________________________
a) Modified end date: No, the new date is not displayed.
Reason: Simulative requirements planning occurs in the main memory.
As long as the planning run is not saved, the data in the database remains unchanged.
Task 7:
You should now execute planning for the planned order again: The assemblies and components that lie below the planned order that you have rescheduled, have not yet been planned.
Return to the session with the simulation results. Select the planned order that you have just processed and choose Execute planning run.
1. By how many working days is the planned order now delayed due to the assemblies and components?
____________________________________________ working days a) Total delay now: 0 working days
2. Save the planning result (and exit the transaction).
a) No solution required
Task 8:
Call up the stock/requirements list for material R-F1## in plant 1000 again (if necessary, refresh the list).
1. Is the modified end date now displayed for the planned order you just edited?
____________________________________________________________
Give a reason for the result:
____________________________________________________________
Continued on next page
____________________________________________________________
a) Modified end date now displayed: Yes, the modified end date is now displayed.
Reason: When you save the planning run, the planning results are saved to the database.
Task 9:
Then call the stock/requirements list for R-F1##, plant 1000 and execute the “order report” function for this planned order.
1. Do the assemblies and components still show rescheduling messages?
____________________________________________________________
a) Rescheduling messages for assemblies and components: No (Only the exception message “Opening date in the past” appears)
Lesson Summary
You should now be able to:
• Trigger single-item planning
• Trigger total planning
• Interpret the planning file
• Execute the MRP run in simulation mode