Upon completion of almost every planning run, problems will have arisen from scheduling issues. Planners need a method to identify each problem as it relates to a material/locaton. SAP ERP uses exception messages to identify any issues with a production plan.
As a result of a planning run or simple changes to supply and demand, the plan results are monitored using exception messages. Exception messages alert you to situations that require further processing, such as start date in the past or stocks falling below the safety level. The MRP controller can then select those materials from the planning results to process them manually.
When using either the MRP List or the Stock/Requirements list, users should be aware that different exception messages could be displayed for the same material/plant combination. The MRP list shows the exception messages that were generated as a results of the planning run. The Stock/Requirements list will show exception messages in a real time environment. When dealing with make-to-stock materials, the Stock/Requirements list will show alerts based on dynamic pegging.
Pegging is the relationship between a specific requirement and the receipt that was created to supply the demand. Make-to-stock products are constantly re-pegging based on chronological order.
Exception messages indicate the following: Newly created order proposals from planning, dates in the past, problems with BOM explosion or scheduling, rescheduling proposals.
Here is a list of the current exception messages in SAP ERP:
Group No. Exception message
6 96 Stock fallen below safety stock level
8 98 Abnormal end of requirements planning
6 70 Max. release qty - quota exceeded
4 01 Newly created
1 02 New, opening date in the past
2 03 New, and start date in the past
3 04 New, and finish date in the past
4 61 Scheduling: Customizing inconsistent 4 62 Scheduling: Master data inconsistent 2 63 Production start before order start 3 64 Production finish after order finish
5 50 No BOM exists
5 52 No BOM selected
5 54 No valid run schedule
5 55 Phantom assembly not exploded
5 53 No BOM explosion due to missing config.
6 58 Uncovered reqmt after effective-out date
Group No. Exception message
6 56 No Requirements coverage
6 40 Coverage not provided by master plan
69 Recursive BOM components possible
1 05 Opening date in the past
2 06 Start date in the past
3 07 Finish date in the past
7 10 Bring process forward
7 15 Postpone process
7 20 Cancel process
7 30 Plan Process according to schedule
6 25 Excess stock
6 26 Shortage in individual segment
6 57 Disc. matl partly replaced by follow-up
6 59 Receipt after effective-out date
4 42 Order proposal has been changed
4 44 Order proposal re-exploded
4 46 Order proposal has been manually changed
4 80 Reference to retail promotion
4 82 Item is blocked
If scheduling problems occur, the system displays a corresponding exception message in the stock/requirements list and the MRP list as a rescheduling proposal.
If this proposal is to be accepted, you must adjust the dates for the receipt element manually. The automatic adjustment of these dates is possible in the planning result display or evaluation, for example, in interactive planning or when the indicator, ìDisplay results before savingî has been selected in the initial screen of the planning run. The rescheduling proposal can be accepted here using the function, ìReschedule order proposalî.
Figure 20: Old/New Exception Messages
You can differentiate between old and new exceptions in the MRP list if you work with the processing indicator.
For processed MRP lists, the system compares the exceptions with those from the old MRP list during the planning run. If the exception corresponds to an element in both lists, it is flagged as an ìoldî exception.
In the collective list display, you can specifically select the lists with new exception messages.
When using collective display of the MRP lists, you can specifically select the lists with new exceptions and even search for new and old exceptions in the individual lists.
Note: In the planning run, exceptions can be characterized as íoldí or ínewí. This function only refers to the exceptions with the highest priority During the materials planning of a material, an exception adjustment is executed for the previously available MRP list if this is characterized as processed. If there are exception messages in the MRP list that was just created, the system searches for matching exceptions in the old MRP list that is indicated as processed. If the corresponding exception is then found, it is characterized in the new list as íoldí.
If this applies to all the exceptions of the new list, the processing indicator of the MRP list is retained. In addition, the MRP list does not appear if only lists with new exceptions are selected in the collective display for MRP lists (MD06). It is possible for a line of the MRP list to have two exceptions, but the adjustment only affects the exceptions that are directly visible when displaying the MRP list, which is normally that with the higher priority.
The following exceptions can never be regarded as íoldí:
ï newly scheduled
ï new. Creation date in the past ï new. Start date in the past ï new. End date in the past
ï order proposal automatically changed ï newly exploded
ï material has no bill of material ï no valid bill of material
ï version without valid SAFK record
In contrast, the exception ìOrder proposal manually changedî must always be íoldí since a change was consciously made to the corresponding line of the list.
All remaining exceptions take part in the adjustment. In this case, the old list is first searched for the corresponding element. If this exists and has the same exception then the exception is marked as íoldí if one of the following special cases does not apply:
ï Rescheduling exception: The rescheduling date must then also agree
ï Stock material surplus: Then quantity and reduction quantity must also agree
Using Exception Messages
1. SAP ERP menu path: Logistics → Production → MRP → Evaluations → MRP List - Collective Display
2. Select using your MRP Controller 0## at plant 1000.
3. Select the Exception groups tab, and select all exception groups.
4. Press ENTER .
5. Select a material that has an exception message in group 7 and select Display selected MRP lists.
6. Select Details of element to see the exception messages for the MRP element.