SCM240 Production Planning

Full text

(1)SCM240 Production Planning (ERP). Date Training Center Instructors Education Website. Participant Handbook Course Version: 81 Course Duration: 5 Day(s) Material Number: 50086866. An SAP course - use it to learn, reference it for work.

(2) Copyright Copyright © 2008 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors.. Trademarks •. Microsoft®, WINDOWS®, NT®, EXCEL®, Word®, PowerPoint® and SQL Server® are registered trademarks of Microsoft Corporation.. •. IBM®, DB2®, OS/2®, DB2/6000®, Parallel Sysplex®, MVS/ESA®, RS/6000®, AIX®, S/390®, AS/400®, OS/390®, and OS/400® are registered trademarks of IBM Corporation.. •. ORACLE® is a registered trademark of ORACLE Corporation.. •. INFORMIX®-OnLine for SAP and INFORMIX® Dynamic ServerTM are registered trademarks of Informix Software Incorporated.. •. UNIX®, X/Open®, OSF/1®, and Motif® are registered trademarks of the Open Group.. •. Citrix®, the Citrix logo, ICA®, Program Neighborhood®, MetaFrame®, WinFrame®, VideoFrame®, MultiWin® and other Citrix product names referenced herein are trademarks of Citrix Systems, Inc.. •. HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C®, World Wide Web Consortium, Massachusetts Institute of Technology.. •. JAVA® is a registered trademark of Sun Microsystems, Inc.. •. JAVASCRIPT® is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape.. •. SAP, SAP Logo, R/2, RIVA, R/3, SAP ArchiveLink, SAP Business Workflow, WebFlow, SAP EarlyWatch, BAPI, SAPPHIRE, Management Cockpit, mySAP.com Logo and mySAP.com are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other products mentioned are trademarks or registered trademarks of their respective companies.. Disclaimer THESE MATERIALS ARE PROVIDED BY SAP ON AN "AS IS" BASIS, AND SAP EXPRESSLY DISCLAIMS ANY AND ALL WARRANTIES, EXPRESS OR APPLIED, INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECT TO THESE MATERIALS AND THE SERVICE, INFORMATION, TEXT, GRAPHICS, LINKS, OR ANY OTHER MATERIALS AND PRODUCTS CONTAINED HEREIN. IN NO EVENT SHALL SAP BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR PUNITIVE DAMAGES OF ANY KIND WHATSOEVER, INCLUDING WITHOUT LIMITATION LOST REVENUES OR LOST PROFITS, WHICH MAY RESULT FROM THE USE OF THESE MATERIALS OR INCLUDED SOFTWARE COMPONENTS.. g20081434910.

(3) About This Handbook This handbook is intended to complement the instructor-led presentation of this course, and serve as a source of reference. It is not suitable for self-study.. Typographic Conventions American English is the standard used in this handbook. The following typographic conventions are also used. Type Style. Description. Example text. Words or characters that appear on the screen. These include field names, screen titles, pushbuttons as well as menu names, paths, and options. Also used for cross-references to other documentation both internal (in this documentation) and external (in other locations, such as SAPNet).. 2007. Example text. Emphasized words or phrases in body text, titles of graphics, and tables. EXAMPLE TEXT. Names of elements in the system. These include report names, program names, transaction codes, table names, and individual key words of a programming language, when surrounded by body text, for example SELECT and INCLUDE.. Example text. Screen output. This includes file and directory names and their paths, messages, names of variables and parameters, and passages of the source text of a program.. Example text. Exact user entry. These are words and characters that you enter in the system exactly as they appear in the documentation.. <Example text>. Variable user entry. Pointed brackets indicate that you replace these words and characters with appropriate entries.. © 2008 SAP AG. All rights reserved.. iii.

(4) About This Handbook. SCM240. Icons in Body Text The following icons are used in this handbook. Icon. Meaning For more information, tips, or background Note or further explanation of previous point Exception or caution Procedures. Indicates that the item is displayed in the instructor's presentation.. iv. © 2008 SAP AG. All rights reserved.. 2007.

(5) Contents Course Overview ............................................................................. vii Course Goals.................................................................................vii Course Objectives ...........................................................................vii. Unit 1: Overview of Production Planning in SAP ERP .................................1 Overview of Supply Chain Planning........................................................ 2. Unit 2: Demand management.............................................................. 21 Overview of Demand Management ...................................................... 23 Planning Make-to-Stock Production...................................................... 28 Planning Make-to-Order Production...................................................... 66 Enhancements for Demand Management............................................... 87 Basics of the Availability Check.......................................................... 103. Unit 3: Executing Material Requirements Planning .................................121 Overview and Concept of MRP .......................................................... 123 Prerequisites for MRP..................................................................... 127 Setting and Executing the MRP Run.................................................... 132 Firming ...................................................................................... 170. Unit 4: Technical Processes of Requirements Planning ...........................191 Net Requirements Calculation ........................................................... 193 Lot-Size Calculation ....................................................................... 216 Procurement Types........................................................................ 234 Scheduling.................................................................................. 245 BOM and Routing Selection.............................................................. 267. Unit 5: Evaluating and Processing the MRP Results ...............................287 MRP List and Stock/Requirements List................................................. 289 Planning Table ............................................................................. 313 Exception Messages ...................................................................... 318 Additional Evaluation Aids ................................................................ 323. Unit 6: Additional MRP processes.......................................................345 Master Production Scheduling ........................................................... 347. 2007. © 2008 SAP AG. All rights reserved.. v.

(6) Contents. SCM240. Long-Term Planning ....................................................................... 358 Multi-Site Planning......................................................................... 389 MRP Areas ................................................................................. 404. Appendix 1:. vi. ...............................................................................435. © 2008 SAP AG. All rights reserved.. 2007.

(7) Course Overview This course teaches you how to use the production planning functions in ERP (SAP ECC).. Target Audience This course is intended for the following audiences: •. This course is aimed at project team members and key users responsible for the implementation of production planning with SAP ERP using SAP ECC.. Course Prerequisites Required Knowledge • •. PLM110 – Basic Data Part 1 SCM100 – Planning Overview (ERP). Recommended Knowledge •. SAPSCM - SAP SCM overview. Course Goals This course will prepare you to: • • • •. Explain the various functions and uses of consumption-based planning and material requirements planning Explain the processes and implementation options of important planning strategies for non-configurable products Make the most important Customizing settings for material requirements planning and evaluate the planning results Introduce and classify further aspects of requirements planning. Course Objectives After completing this course, you will be able to: •. 2007. Explain the differences between consumption-based planning and material requirements planning. © 2008 SAP AG. All rights reserved.. vii.

(8) Course Overview. • • • •. SCM240. Set up and use important planning strategies and Customizing for non-configurable products Execute material requirements planning and evaluate the results Configure the technical processes and related Customizing Use the additional functions of material requirements planning. SAP Software Component Information The information in this course pertains to the following SAP Software Components and releases:. viii. © 2008 SAP AG. All rights reserved.. 2007.

(9) Unit 1 Overview of Production Planning in SAP ERP Unit Overview Place the course in context in terms of both content and organizational aspects. It is important to show where the course belongs in the SCM curriculum. The course operates exclusively within SAP ECC as far as content, demonstrations, and exercises are concerned, dealing with the production planning process in the system. The course builds on the basics covered in SCM100. As an introduction, put the production planning process into context: Talk about the entire planning chain from (optional) sales and operations planning to shop floor control. Do not go into detail about the functions. Instead, show how the contents of the course relate to the neighboring business processes.. Unit Objectives After completing this unit, you will be able to: • • •. Place the course content in the overall context Outline the business scenario used Give an overview of Supply Chain Planning in ECC. Unit Contents Lesson: Overview of Supply Chain Planning....................................... 2 Exercise 1: Production Planning Process with ECC .......................... 9. 2007. © 2008 SAP AG. All rights reserved.. 1.

(10) Unit 1: Overview of Production Planning in SAP ERP. SCM240. Lesson: Overview of Supply Chain Planning Lesson Overview Welcome the participants and introduce the course content and objectives. Familiarize the participants with the course schedule. Get the participants to introduce themselves.. Lesson Objectives After completing this lesson, you will be able to: • • •. Place the course content in the overall context Outline the business scenario used Give an overview of Supply Chain Planning in ECC. Business Example Your company is implementing production planning and detailed scheduling using ECC MRP. You use the example of the Precision Pump Company to familiarize yourself with the functions of MRP. The Precision Pump Company offers various standard pumps. After you have entered future requirement quantities in demand management, you plan production in the production plant. Externally procured or low value materials should, if necessary, be planned using consumption-based planning.. 2. © 2008 SAP AG. All rights reserved.. 2007.

(11) SCM240. Lesson: Overview of Supply Chain Planning. Figure 1: Possible SAP Components of Supply Chain Planning. SC planning primarily uses the following SAP components: SAP ECC (ERP Central Component), SAP SCM (including APO, Advanced Planning and Optimization), and SAP BW (Business Information Warehouse). The SAP SCM system contains many components that constituted separate systems in earlier releases. As well as APO, SCM 4.1 also includes Supply Chain Event Management (EM) and Inventory Collaboration Hub (ICH). The interfaces responsible for integrating ECC with BW or SCM APO are made available using a corresponding Plug-In. The interface between ECC and SCM APO is called the Core Interface (CIF).. 2007. © 2008 SAP AG. All rights reserved.. 3.

(12) Unit 1: Overview of Production Planning in SAP ERP. SCM240. Figure 2: Supply Chain Planning in ECC. Supply Chain Planning in SAP ECC can be divided into several steps: Planning takes place in demand management. Consumption of the forecast with sales orders is possible. Long-term planning is simulative planning. You can use it to analyze a demand program to see how feasible it is, for example. Master production scheduling is requirements planning for master schedule items. Non-master schedule items are planned in material requirements planning.. 4. © 2008 SAP AG. All rights reserved.. 2007.

(13) SCM240. Lesson: Overview of Supply Chain Planning. Figure 3: Production Planning and Control. Figure 4: Demand Management. Demand Management is the management of independent requirements. The behavior of independent requirements in material requirements planning (for example, whether they are effective, or whether they consume other requirements) is determined by their requirements type or by the planning strategy.. 2007. © 2008 SAP AG. All rights reserved.. 5.

(14) Unit 1: Overview of Production Planning in SAP ERP. SCM240. Planned independent requirements are stock requirements that can be derived from a forecast of future demand. In make-to-stock production, you want to start procurement of the affected materials without waiting for specific sales orders. On the one hand, this kind of procedure allows you to reduce delivery times, while on the other hand, you can use forecast planning to spread the burden as evenly as possible across your production resources. Sales orders (customer independent requirements) are created in Sales and Distribution. Customer requirements can enter Material Requirements Planning directly, depending on their requirement type. This is always desirable if you want to plan for specific customers. Sales orders can be used either as exclusive requirement sources, for which procurement is then specifically triggered (make-to-order production), or they can be grouped with planned independent requirements to create the total requirements. Consumption is also possible with planned independent requirements.. Figure 5: MRP Procedures. If you want to plan material requirements automatically, you must define suitable MRP and lot-sizing procedures in the material master. To do this, use the MRP type and lot size indicators. Depending on the procedure you choose, you then have to maintain further data in the material master. You can define different MRP procedures for a material in different plants. The two main planning procedures are consumption-based planning and material requirements planning.. 6. © 2008 SAP AG. All rights reserved.. 2007.

(15) SCM240. Lesson: Overview of Supply Chain Planning. Consumption-based planning is based on historical consumption values and uses forecasting or statistical procedures to determine future requirements. Consumption-based planning is characterized by its simplicity and is mainly used for B and C parts with a low value. One prerequisite of consumption-based planning is efficient and constantly up-to-date inventory management. In contrast to consumption-based planning, material requirements planning takes current and future sales as a reference point and is executed for the whole BOM structure. The planned requirement quantities trigger the MRP calculation. It produces better planning results than consumption-based planning.. Figure 6: The principle of MRP. In the first step for detailed planning in MRP, the procurement dates and quantities for the required assemblies and components are determined based on the requirements dates and quantities for the finished product (for example, a sales order). Bills of material and routings must be exploded to do this. Scheduling of procurement for in-house products is carried out using the routing. The production operations to be executed and the length of the individual operations are specified in the routing. The assemblies (from the BOM) required for production must be available when production of the finished product is started. Procurement of these assemblies must therefore be initiated earlier. In this way, assuming the dependent. 2007. © 2008 SAP AG. All rights reserved.. 7.

(16) Unit 1: Overview of Production Planning in SAP ERP. SCM240. requirements date is the availability date, the system determines the order dates of the components by means of backward scheduling using the in-house production time or planned delivery time.. 8. © 2008 SAP AG. All rights reserved.. 2007.

(17) SCM240. Lesson: Overview of Supply Chain Planning. Exercise 1: Production Planning Process with ECC Exercise Objectives After completing this exercise, you will be able to: • Execute the main steps required for the production planning process in SAP ECC.. Business Example Precision Pumps Inc uses the make-to-stock production strategy. The make-to-stock production strategy is used. Pumps are manufactured, put away, and then sold.. Task 1: In plant 1000, enter a demand program (planned independent requirements) for material R-F1## (replace ## with your group number). Select make-to-stock production (LSF requirements) for the first 8 weeks of your planning period. To do this, proceed as follows: 1.. Maintain the material master: In the material master for pump R-F1##, enter strategy group 10 for plant 1000 in the MRP 3 view and save the change.. 2.. In Demand Management, enter the planned independent requirements (requirement type LSF) for material R-F1## in plant 1000 (version 00). Set the planning period to week format by entering the indicator W in the planning period field in the initial screen for the transaction. Enter the following planned independent requirements for pump R-F1## in plant 1000: Current. Current. Current. Week + 5. Week + 6. Week + 7. 25. 25. 25. .... Current Week + 12. ...25. (Total quantity: 200 pieces, the first column on the left-hand side in transaction MD61 is the current week) Save your entries. 3.. From the MRP menu, display the stock/requirements list for material R-F1## in plant 1000. Continued on next page. 2007. © 2008 SAP AG. All rights reserved.. 9.

(18) Unit 1: Overview of Production Planning in SAP ERP. SCM240. Note down the exact date of the second LSF requirement:______________________. Task 2: From the MRP menu, carry out multilevel, single-item planning for pump R-F1##. In the initial screen of the planning run, use the following creation indicators: Processing key. NETCH. Purchase req. purchase req.. 2. Scheduling agreement schedule lines. 3. Create MRP list. 1. Planning mode. 1. Scheduling. 1. Also plan unchanged components. Select. Display results. Do not select. Display material list. Select. Simulation mode. Do not select. 1.. In the initial screen for single-item, multilevel MRP, save the creation indicator setting you have made for the MRP run by selecting the menu path Settings → Save.. 2.. Start the MRP run by choosing Enter and confirm the system warning by choosing Enter again.. Task 3: Once the MRP run has been carried out successfully, the system displays the statistics. 1.. Choose the Material List pushbutton and select the row containing your pump R-F1## by clicking on the button at the beginning of the row. Goto the display for the current stock-/requirements list for the material and refresh the screen (F6).You can now see the planned orders created for the requirements. Continued on next page. 10. © 2008 SAP AG. All rights reserved.. 2007.

(19) SCM240. Lesson: Overview of Supply Chain Planning. 2.. Display one of the planned orders by double-clicking it and choosing Display Element. Select the Component Overview pushbutton and compare the order start date of the end product R-F1## with the requirements date for the assemblies R-B1##, R-B2## and R-B3##. How do you explain the date? __________________________________________________________________ __________________________________________________________________ Then exit the display for the planned order and the stock-/requirements list (understand that you navigated in the stock-/requirements list in display mode).. Task 4: Call the current stock/requirements list again and convert the first two planned orders into production orders. Then release each production order. 1.. From the MRP menu, display the current stock/requirements list for material R-F1## in plant 1000.. 2.. Click on the Details of Element icon to display the statistics for the first planned order in the list. Choose the Convert planned order into production order function. Release the production order and save the order. 3.. Repeat the operation for the second planned order.. 4.. Refresh the display by selecting Refresh. Make a note of the production order numbers. Production order number 1 _______________________________________ Production order number 2 _______________________________________ Hint: You may have to wait a few seconds for the asynchronous update to read the data from the queue and update it to the database. You can call the refresh function several times until you see the production orders.. Continued on next page. 2007. © 2008 SAP AG. All rights reserved.. 11.

(20) Unit 1: Overview of Production Planning in SAP ERP. SCM240. Task 5: Now assume that you have produced the product, and can post the end product, the pump, to stock. (We will skip completion confirmation for the purposes of this training example) 1.. Execute the goods movement (more precisely: the Goods receipt for the order MIGO with the transaction MIGO_GO) from the Inventory Management menu. In this transaction, use Goods Receipt and Order, not Display, to make your selections. Enter the order number and choose Enter to confirm your entry. Select the Item OK field. You may have to scroll down to see this. Take a look at the Where tab page to make sure that the movement type 101 has been defined (order to stock). Post the goods movement. Repeat the operation for the second order number.. 2.. Check the stock situation in the stock/requirements list and make a note of the quantity of the oldest planned independent requirement: _____________________ the date of the oldest planned independent requirement: _____________________ the quantity available today: _____________________. 12. © 2008 SAP AG. All rights reserved.. 2007.

(21) SCM240. Lesson: Overview of Supply Chain Planning. Solution 1: Production Planning Process with ECC Task 1: In plant 1000, enter a demand program (planned independent requirements) for material R-F1## (replace ## with your group number). Select make-to-stock production (LSF requirements) for the first 8 weeks of your planning period. To do this, proceed as follows: 1.. Maintain the material master: In the material master for pump R-F1##, enter strategy group 10 for plant 1000 in the MRP 3 view and save the change. a). 2.. Menu path: Logistics → Production → Master Data → Material Master → Material → Change → Immediately. In Demand Management, enter the planned independent requirements (requirement type LSF) for material R-F1## in plant 1000 (version 00). Set the planning period to week format by entering the indicator W in the planning period field in the initial screen for the transaction. Enter the following planned independent requirements for pump R-F1## in plant 1000: Current. Current. Current. Week + 5. Week + 6. Week + 7. 25. 25. 25. .... Current Week + 12. ...25. (Total quantity: 200 pieces, the first column on the left-hand side in transaction MD61 is the current week) Save your entries. a) 3.. Menu path: Logistics → Production → Production Planning → Demand Management → Planned Independent Requirements → Create. From the MRP menu, display the stock/requirements list for material R-F1## in plant 1000. Note down the exact date of the second LSF requirement:______________________ a). Menu path: Logistics → Production → Production Planning → Demand Management → Environment → Stock/Requirements List Date of second LSF requirement: Varies Continued on next page. 2007. © 2008 SAP AG. All rights reserved.. 13.

(22) Unit 1: Overview of Production Planning in SAP ERP. SCM240. Task 2: From the MRP menu, carry out multilevel, single-item planning for pump R-F1##. In the initial screen of the planning run, use the following creation indicators: Processing key. NETCH. Purchase req. purchase req.. 2. Scheduling agreement schedule lines. 3. Create MRP list. 1. Planning mode. 1. Scheduling. 1. Also plan unchanged components. Select. Display results. Do not select. Display material list. Select. Simulation mode. Do not select. 1.. In the initial screen for single-item, multilevel MRP, save the creation indicator setting you have made for the MRP run by selecting the menu path Settings → Save. a). 2.. Menu path: Logistics → Production → MRP → Planning → Single-Item, Multi-Level. Start the MRP run by choosing Enter and confirm the system warning by choosing Enter again. a). Menu path: Logistics → Production → MRP → Planning → Single-Item, Multi-Level. Continued on next page. 14. © 2008 SAP AG. All rights reserved.. 2007.

(23) SCM240. Lesson: Overview of Supply Chain Planning. Task 3: Once the MRP run has been carried out successfully, the system displays the statistics. 1.. Choose the Material List pushbutton and select the row containing your pump R-F1## by clicking on the button at the beginning of the row. Goto the display for the current stock-/requirements list for the material and refresh the screen (F6).You can now see the planned orders created for the requirements. a). 2.. No solution required.. Display one of the planned orders by double-clicking it and choosing Display Element. Select the Component Overview pushbutton and compare the order start date of the end product R-F1## with the requirements date for the assemblies R-B1##, R-B2## and R-B3##. How do you explain the date? __________________________________________________________________ __________________________________________________________________ Then exit the display for the planned order and the stock-/requirements list (understand that you navigated in the stock-/requirements list in display mode). a). How do you explain the date? The requirements dates for the assemblies coincide with the order start date of the planned order for the finished product. The assemblies are therefore available at the start of production for the finished product.. Task 4: Call the current stock/requirements list again and convert the first two planned orders into production orders. Then release each production order. 1.. From the MRP menu, display the current stock/requirements list for material R-F1## in plant 1000. a). 2.. Menu path: Logistics → Production → Production Planning → Demand Management → Environment → Stock/Requirements List. Click on the Details of Element icon to display the statistics for the first planned order in the list. Choose the Convert planned order into production order function. Release the production order and save the order a). No solution required.. Continued on next page. 2007. © 2008 SAP AG. All rights reserved.. 15.

(24) Unit 1: Overview of Production Planning in SAP ERP. 3.. Repeat the operation for the second planned order. a). 4.. SCM240. No solution required.. Refresh the display by selecting Refresh. Make a note of the production order numbers. Production order number 1 _______________________________________ Production order number 2 _______________________________________ Hint: You may have to wait a few seconds for the asynchronous update to read the data from the queue and update it to the database. You can call the refresh function several times until you see the production orders. a). Production order number 1: Varies Production order number 2: Varies. Task 5: Now assume that you have produced the product, and can post the end product, the pump, to stock. (We will skip completion confirmation for the purposes of this training example) 1.. Execute the goods movement (more precisely: the Goods receipt for the order MIGO with the transaction MIGO_GO) from the Inventory Management menu. In this transaction, use Goods Receipt and Order, not Display, to make your selections. Enter the order number and choose Enter to confirm your entry. Select the Item OK field. You may have to scroll down to see this. Take a look at the Where tab page to make sure that the movement type 101 has been defined (order to stock). Post the goods movement. Repeat the operation for the second order number. a). Menu path: Logistics → Materials Management → Inventory Management → Goods Movement → Goods Receipt → GR for Order (MIGO) Alternatively, you can also use transaction MIGO (goods movement MIGO). Continued on next page. 16. © 2008 SAP AG. All rights reserved.. 2007.

(25) SCM240. Lesson: Overview of Supply Chain Planning. 2.. Check the stock situation in the stock/requirements list and make a note of the quantity of the oldest planned independent requirement: _____________________ the date of the oldest planned independent requirement: _____________________ the quantity available today: _____________________ a). the quantity of the oldest planned independent requirement: 25 the date of the oldest planned independent requirement: Varies the quantity available today: 50. 2007. © 2008 SAP AG. All rights reserved.. 17.

(26) Unit 1: Overview of Production Planning in SAP ERP. SCM240. Lesson Summary You should now be able to: • Place the course content in the overall context • Outline the business scenario used • Give an overview of Supply Chain Planning in ECC. 18. © 2008 SAP AG. All rights reserved.. 2007.

(27) SCM240. Unit Summary. Unit Summary You should now be able to: • Place the course content in the overall context • Outline the business scenario used • Give an overview of Supply Chain Planning in ECC. 2007. © 2008 SAP AG. All rights reserved.. 19.

(28) Unit Summary. 20. SCM240. © 2008 SAP AG. All rights reserved.. 2007.

(29) Unit 2 Demand management Unit Overview Demand management represents the first step in the planning process, as it is considered in this course. This unit (and course) does not cover determination of the actual level of the planned independent requirements – this is the task of preliminary demand planning, realized in the SAP system by executing Sales and Operations Planning (or alternatively in SAP SCM (APO DP = Demand Planning)). Normally, the forecasting technique is used here. Assuming that the planning figures are known, this unit deals with the issue of the requirements type for planned independent requirements. The requirements type is determined (or rather, can be determined) by the strategy entered in the material master. Point out that a strategy is usually defined as a result of the planned independent requirement type and a customer requirement type, and how these interact. In this course, sales orders are simulated by customer requirements (a sales order creates a customer requirement), since you have to create a delivery in order to cancel out a sales order (for which there is not enough time in this course). Otherwise customer requirements behave in the same manner as sales orders. Introduce the various strategies in detail and explain their functions. There are strategies that take effect at finished product level, and assembly strategies that are used for planning an assembly. The functions of planned independent requirement consumption with customer requirements or dependent requirements and the functions of planned independent requirement reduction are important in understanding how the strategies work. Furthermore, this unit will look explicitly at the availability check against planning and the availability check with ATP logic, although both these issues really come under the area of Sales. Nevertheless, this integrated whole must be dealt with from two perspectives: Availability checks can also play a role in production planning (checking for available components from planned orders or production orders). You should also point out the difference between the net requirements calculation and the availability check.. 2007. © 2008 SAP AG. All rights reserved.. 21.

(30) Unit 2: Demand management. SCM240. Unit Objectives After completing this unit, you will be able to: • • • • • • • •. Use the planning strategy Explain the interplay between planned independent requirements and customer requirements Use planning strategies for make-to-stock production Use planning strategies for make-to-order production Explain assembly processing Make demand management settings Make an adjustment and reduce requirements Carry out ATP checks for sales orders. Unit Contents Lesson: Overview of Demand Management ..................................... 23 Lesson: Planning Make-to-Stock Production..................................... 28 Exercise 2: Sales Orders in Make-to-Stock Production .................... 43 Exercise 3: Planning with Final Assembly ................................... 49 Exercise 4: Subassembly Planning ........................................... 59 Lesson: Planning Make-to-Order Production .................................... 66 Exercise 5: Planning Without Final Assembly ............................... 79 Lesson: Enhancements for Demand Management ............................. 87 Exercise 6: Customizing........................................................ 97 Lesson: Basics of the Availability Check......................................... 103 Exercise 7: Availability Check for Sales Order ............................. 109. 22. © 2008 SAP AG. All rights reserved.. 2007.

(31) SCM240. Lesson: Overview of Demand Management. Lesson: Overview of Demand Management Lesson Overview The fundamental concepts of demand management and the terms specific to this area will be explained.. Lesson Objectives After completing this lesson, you will be able to: • •. Use the planning strategy Explain the interplay between planned independent requirements and customer requirements. Business Example You are a member of a project team in a company that manufactures pumps. The team is responsible for the implementation of production planning, from demand management to material requirements planning. The pumps are not configurable. You want to use planning strategies for the procurement of non-configurable pumps in Demand Management.. Figure 7: Overview: Requirements Calculation. With regard to later procurement and therefore requirement coverage, it is first useful to take an overview of the net requirements calculation for material requirements planning. A procurement is generally necessary only if the requirements situation. 2007. © 2008 SAP AG. All rights reserved.. 23.

(32) Unit 2: Demand management. SCM240. exceeds the stock/receipt situation at the time of the comparison. Here, it is important which requirements are included in the requirements situation and how the requirements affect each other (for example, whether they are MRP-relevant and whether they offset each other). The respective requirements volume (and therefore the production program) also depends on the default settings maintained in the planning or requirement strategy. Note that, from a technical point of view, this behavior is not the same as an availability check . The above comparison is a net requirements calculation. This unit deals with the properties of the important ECC planning strategies and how to use them to generate a relevant production program.. Figure 8: Reasons for using planning strategies. A requirement is the quantity of a material that is required at a certain time in a plant. Planned independent requirements have no relation to the requirements of other materials. In particular, planned independent requirements can be attained using flexible planning or manual planning in the ECC system. They can also be characterized under the general term “planning”. Together with sales orders they form dependent requirements. A planning strategy specifies one of a number of possible material planning procedures. Some planning strategies support make-to-stock production. You could, for example, plan production or purchasing based on a forecast and then cover the sales orders from the stock.. 24. © 2008 SAP AG. All rights reserved.. 2007.

(33) SCM240. Lesson: Overview of Demand Management. Some planning strategies support make-to-order production. In this case, you may not start production or purchasing, for example, until a sales order has been received. Some requirements strategies support a combination of make-to-stock and make-to-order production. You could produce the subordinate assembly based on a forecast, for example. You would not start the final assembly until a sales order is received.. Figure 9: Spectrum of Planning Strategies. A number of options are available for planning production with the help of planned independent requirements. The different effects that planned independent requirements can have is controlled in ECC by the planning strategy. If you use make-to-stock production strategies, production usually takes place without there being sales orders for the respective material. If sales orders are then received, these can be met by warehouse stock so that short delivery times can be realized. With make-to-stock production, it is also possible to implement a steady production process, independent of the current demand. Make-to-stock production can also be executed for assemblies. In this case, the finished products themselves are not produced to stock, but rather the necessary assemblies are procured. A sales order for a finished product can usually be fulfilled quickly because only final assembly remains to be carried out and the assemblies required for this already exist.. 2007. © 2008 SAP AG. All rights reserved.. 25.

(34) Unit 2: Demand management. SCM240. Sales-order based production is not based on planning in the real sense; rather a product is procured for an existing sales order. Make-to-order production is often used in connection with subassembly planning for the components, to keep delivery times as short as possible.. Figure 10: Overview: Important Planning Strategies in ECC. The make-to-stock production strategies plan production or procurement using planned independent requirements, which can be created from sales or forecast figures. Sales orders are fulfilled by warehouse stock. Make-to-stock production strategies are used in industries where demand and sales fluctuate but where production should be kept at full capacity. Fluctuations in demand and sales are balanced out by warehouse stock. When working with the strategies for make-to-order production, the sales order is the only pegged requirement. In addition to standard make-to-order production, planning without final assembly is also possible. Various strategies for assembly processing are also available.. 26. © 2008 SAP AG. All rights reserved.. 2007.

(35) SCM240. Lesson: Overview of Demand Management. Lesson Summary You should now be able to: • Use the planning strategy • Explain the interplay between planned independent requirements and customer requirements. 2007. © 2008 SAP AG. All rights reserved.. 27.

(36) Unit 2: Demand management. SCM240. Lesson: Planning Make-to-Stock Production Lesson Overview Planning make-to-stock production is mainly done using planned independent requirements. Sales orders can be taken into account too, without the need for sales order-specific planning.. Lesson Objectives After completing this lesson, you will be able to: •. Use planning strategies for make-to-stock production. Business Example Pump production is planned independently of sales orders using planned independent requirements.. Figure 11: Important Make-to-Stock Production Strategies. 28. © 2008 SAP AG. All rights reserved.. 2007.

(37) SCM240. Lesson: Planning Make-to-Stock Production. Figure 12: Make-to-Stock: Overview. Areas where used: Make-to-stock strategies are aimed at planning the procurement of components (production or purchasing) by planning the finished product. If it is easier for you to plan at component level, you can use planning at assembly level. Choose a make-to-stock production strategy if a) the materials do not have to be stored separately or are assigned to a specific sales order; b) the costs have to be visible at material level, in other words not at sales order level. You use make-to-stock production when you produce stock independently of an order, because you want to supply your customers with goods from this stock later. You may want to produce goods without a sales order if you expect a demand for them in the future. Make-to-stock strategies thus support very close customer-supplier relationships, since their purpose is to supply the customer with goods from stock as quickly as possible. Returns that have been through a quality check as well as other unplanned goods receipts can be used for other sales orders. You can avoid increased warehouse stock in a make-to-stock environment by creating planned independent requirements in advance to plan your stock. If you do this, you can also decide whether sales orders that exceed your plan can influence production. In addition, sales orders should be known at a relatively early stage (for example, using scheduling agreements). Make-to-stock production strategies generally consist of four phases: Generation of planned independent requirements, procurement, receipt of sales order, goods issue for delivery and reduction of planned independent requirements.. 2007. © 2008 SAP AG. All rights reserved.. 29.

(38) Unit 2: Demand management. SCM240. Figure 13: Make-to-Stock Production (10). In pure make-to-stock production (“net requirements planning” according to strategy 10), the demand program is determined without reference to sales orders. Sales orders are not relevant for MRP, but you can display them for information purposes. You can make this setting in the No MRP field in Customizing for the relevant requirements class (work step, “Define Requirements Classes” in Customizing for Sales and Distribution). Sales orders are fulfilled from stock. No consumption with planned independent requirements occurs. You can carry out the availability check with ATP logic in Sales and Distribution. Goods withdrawals against a sales order reduce the respective sales order. Reduction of the demand program, that is, of the planned independent requirements, is carried out at goods issue (the PIR reduction indicator must be set in Customizing for customer requirements class 30 if you want to reduce the demand program by delivering to a sales order). The oldest planned independent requirement is reduced first, in accordance with the FIFO (first in first out) principle using the requirement date. Future planned independent requirements are also reduced by goods issues, providing this is allowed by the “forward consumption period” in the material master.. 30. © 2008 SAP AG. All rights reserved.. 2007.

(39) SCM240. Lesson: Planning Make-to-Stock Production. Figure 14: Make-to-Stock Production (10): Master Data. Maintain the strategy group 10 in the material master (MRP 3) for the finished product.. Figure 15: Make-to-Stock Production/Net Requirements Planning (10). The demand program is defined without reference to sales orders.. 2007. © 2008 SAP AG. All rights reserved.. 31.

(40) Unit 2: Demand management. SCM240. Sales orders are not relevant for MRP, but you can display them for information purposes. You make this setting in the No MRP field in Customizing for the relevant requirements class (work step, “Define Requirements Classes” in Customizing for Sales and Distribution). Sales orders are fulfilled from stock. You can carry out the availability check with ATP logic in Sales and Distribution. Goods withdrawals against a sales order reduce the respective sales order. Reduction of the demand program, that is, of the planned independent requirements, is carried out at goods issue (the PIR reduction indicator must be set in Customizing for requirements class 30 if you want to reduce the demand program when delivering to a sales order). The oldest planned independent requirement is reduced first, in accordance with the FIFO (first in first out) principle and using the requirement date. Future planned independent requirements are also reduced by goods issues, providing the forward consumption period in the material master allows this.. Figure 16: Production by Lot Size (30). In production by lot size (strategy 30), the requirements for the finished product are transferred to MRP when a sales order is processed. You can also plan additional warehouse requirements in Demand Management. This means that in production by lot size, sales orders as well as planned independent requirements are included in Material Requirements Planning. Planned independent requirements are not consumed by sales orders, however. Both requirements can then be procured in common lot using a suitable lot-sizing procedure (for example, period lot-sizing) with a common procurement element (such as a planned order).. 32. © 2008 SAP AG. All rights reserved.. 2007.

(41) SCM240. Lesson: Planning Make-to-Stock Production. Sales orders are fulfilled from stock. The customer requirement is reduced by the goods issue to the customer. You can carry out the availability check with ATP logic in Sales and Distribution. The warehouse orders created additionally in demand management are reduced by the goods issue to the warehouse order, for example, to a cost center (the reduction is carried out according to the FIFO principle, just as for planning strategy 10). You can apply this strategy when you need to map orders for major customers and factory sales from the warehouse simultaneously, for example.. Figure 17: Production by Lot Size (30): Master Data. 2007. © 2008 SAP AG. All rights reserved.. 33.

(42) Unit 2: Demand management. SCM240. Figure 18: Production by Lot Size (30) for Sales and Stock Orders. In production by lot size, the system groups the procurement quantities for customer requirements and planned independent requirements into lots. To do this, it uses the lot-sizing procedure defined in the material master record.. Figure 19: Planning with Final Assembly (40). 34. © 2008 SAP AG. All rights reserved.. 2007.

(43) SCM240. Lesson: Planning Make-to-Stock Production. Planning with final assembly (planning strategy 40) allows you to focus on flexible and fast reaction to customer demand, whilst also aiming for a production process that is as smooth as possible. The procurement and production of all components and assemblies including their final assembly should be triggered by planned independent requirements before sales orders arrive. You set the planned independent requirements for the finished product in Demand Management. Incoming sales orders consume these planned independent requirements. Planned independent requirements that have not been consumed can - periodically, for example - be set to zero (transaction MD74). If customer requirements exceed planned independent requirements, the system automatically creates a planned order for the sales order, including the unplanned quantity, in the next MRP run (sales orders that affect requirements). The availability check can be executed from the sales order. The consumption of planned independent requirements by customer requirements depends on the consumption mode and the consumption periods.. Figure 20: Planning with Final Assembly (40): Master Data. Maintain the strategy group 40 in the material master (MRP 3) for the finished product.. 2007. © 2008 SAP AG. All rights reserved.. 35.

(44) Unit 2: Demand management. SCM240. The settings for the consumption of sales orders and planned independent requirements from the material master are included in this strategy. In the material master, an MRP group can also be used to assign the consumption to the material. If consumption values are found both directly using the strategy group and indirectly using the MRP group, the values from the strategy group are taken.. Figure 21: Consumption. You can use consumption mode to determine the direction on the time axis in which incoming sales orders are to consume planned independent requirements. In backward consumption (consumption mode 1), the sales order consumes planned independent requirements from before the customer requirement. In forward consumption (consumption mode 3), the sales order consumes planned independent requirements from after the customer requirement. You can combine backward and forward consumption provided that you take the consumption periods into account (consumption modes 2 or 4).. 36. © 2008 SAP AG. All rights reserved.. 2007.

(45) SCM240. Lesson: Planning Make-to-Stock Production. You can define the consumption mode and the consumption periods either in the material master or for each plant and MRP group. If no values have been entered, the system uses the default setting with backward consumption for 999 days Hint: If you use mode 1 and do not maintain the backward consumption interval, this means that only the requirements on the current day are consumed. The consumption indicator (consumption type) is important in addition to the consumption mode and consumption periods. The consumption indicator controls whether the planned independent requirements are consumed with customer requirements or with dependent requirements and order reservations, for example. It is defined as a default value for each planned independent requirement class in Customizing for Demand Management. The indicator can be overridden in the item detail screen for planned independent requirements management.. Figure 22: Consumption Mode 1: Backward Consumption (I). 2007. © 2008 SAP AG. All rights reserved.. 37.

(46) Unit 2: Demand management. SCM240. Figure 23: Consumption Mode 1: Backward Consumption (II). Figure 24: Consumption Mode 2: Backward/Forward. 38. © 2008 SAP AG. All rights reserved.. 2007.

(47) SCM240. Lesson: Planning Make-to-Stock Production. Figure 25: Planning at Assembly Level (70). It makes sense to plan at assembly level (strategy 70 + set mixed MRP indicator) when processing variants if it is easier to specify a requirements forecast for certain assemblies than it is for the variant diversity of the finished product. With this planning strategy, planning for an assembly is considered separately. The planned independent requirement is entered at assembly level and triggers the production of the assembly. If sales orders are received for the finished product, the BOM is exploded for the finished product. Dependent requirements or reservations are also created for the assembly as a result of planned orders or production orders for the finished product. These consume the planned independent requirements of the assembly. If, due to sales orders, planned orders, or production orders at finished product level, the dependent requirements or reservations exceed the assembly's planned independent requirements, a planned order is created for the assembly during the next planning run. In Sales and Distribution, the system does not perform a check of the assembly planning quantities. In the strategy group of the material master record, you must enter strategy 70 and the mixed MRP indicator must be set for assembly planning. The consumption indicator in the item screen of the planned independent requirements must allow consumption with reservations and dependent requirements.. 2007. © 2008 SAP AG. All rights reserved.. 39.

(48) Unit 2: Demand management. SCM240. Figure 26: Planning at Assembly Level (70): Master Data. You make the strategy setting in the material master for the assembly or assemblies. Maintain the planning strategy 70 together with the set mixed MRP indicator in the ECC material master (MRP 3) for the assembly or assemblies. In principle, the finished product can show any strategy. Maintain the consumption parameters (consumption mode, forward and backward consumption periods) in the material master. The consumption indicator in the item screen for the planned independent requirements must allow consumption with reservations and dependent requirements. If you map this strategy together with a final assembly that takes place in make-to-order production, you must also set the individual/collective indicator to “collective” in the material master of the assemblies.. 40. © 2008 SAP AG. All rights reserved.. 2007.

(49) SCM240. Lesson: Planning Make-to-Stock Production. Figure 27: Consumption in Subassembly Planning (70). In the first step, you create the requirement quantities expected in the future for the assembly. You do this in Demand Management. Sales orders at finished product level are created and planned or production orders generated. The resulting dependent requirements or reservations (for the assembly) consume the planned independent requirements of the assembly.. 2007. © 2008 SAP AG. All rights reserved.. 41.

(50) Unit 2: Demand management. SCM240. Figure 28: Subassembly Planning (70): Consumption Periods. Similar to ECC strategy 40, the consumption logic is determined by the consumption mode and the backward and forward consumption periods. These are defined in the material master for the assembly, or per plant and MRP group. With this strategy, the consumption periods are calculated on the basis of the dependent requirements or reservations.. 42. © 2008 SAP AG. All rights reserved.. 2007.

(51) SCM240. Lesson: Planning Make-to-Stock Production. Exercise 2: Sales Orders in Make-to-Stock Production Exercise Objectives After completing this exercise, you will be able to: • Describe the effect of a sales order in make-to-stock production.. Business Example Precision Pumps Inc. has produced pumps to stock using make-to-stock production. A sales order is received. The sales order should have no influence on planning, but should be available for information purposes. The sales order is delivered.. Task 1: You have executed planning strategy 10 from the start. Now create a customer requirement in make-to-stock production and examine its effect in planning. 1.. In the Demand Management menu, create a customer requirement of 10 pieces for pump R-F1##. The date should appear 4 days after the second planned independent requirements date in the stock/requirements list. Use the following data: Delivering plant:. 1000. Required delivery date:. 4 calendar days after the second planned independent requirements date in the stock/requirements list. Material:. R-F1##. Quantity:. 10 pieces. Confirm your entry by choosing Enter and make sure that the system automatically defines the customer requirement type KSL in the item. Save the customer requirement.. Continued on next page. 2007. © 2008 SAP AG. All rights reserved.. 43.

(52) Unit 2: Demand management. 2.. SCM240. Call the current stock/requirements list for material R-F1## in plant 1000 (you can access the current stock/requirements list directly from the Demand Management environment). You can see that the sales order is displayed for information purposes only but it is not relevant to planning (that is, it has no effect on the available quantity). a) Note the customer requirement number/item number: __________________ / __________________________________ b) and the customer requirement quantity: ______________________________________________________. Task 2: Now reduce the planned independent requirements by withdrawing stock for the customer requirement. 1.. The customer appears at the sales desk and wants to collect the 10 pumps ordered. The customer placed the order by telephone quite a while ago. You created the sales order in the system and it is displayed in the evaluation for information purposes, although the material ordered is from make-to-stock production. From the Inventory Management menu, post the withdrawal to the customer in the form of an other goods issue (transaction Goods Issue MIGO). Carry out the goods movement using the following parameters: Material number:. R-F1##. Quantity:. 10 pieces. Movement Type:. 231 (Consumption to sales order from warehouse). Plant:. 1000. Storage Location:. 0002. Confirm the data with Enter and then enter the customer requirement number and item you noted above on the Account Assignment tab page. Save your entries. 2.. Call the stock/requirements list and examine the stock situation. a) How has the stock situation changed? ______________________________________________________ b) Which independent requirements and sales orders have been reduced? Continued on next page. 44. © 2008 SAP AG. All rights reserved.. 2007.

(53) SCM240. Lesson: Planning Make-to-Stock Production. ______________________________________________________ ______________________________________________________. 2007. © 2008 SAP AG. All rights reserved.. 45.

(54) Unit 2: Demand management. SCM240. Solution 2: Sales Orders in Make-to-Stock Production Task 1: You have executed planning strategy 10 from the start. Now create a customer requirement in make-to-stock production and examine its effect in planning. 1.. In the Demand Management menu, create a customer requirement of 10 pieces for pump R-F1##. The date should appear 4 days after the second planned independent requirements date in the stock/requirements list. Use the following data: Delivering plant:. 1000. Required delivery date:. 4 calendar days after the second planned independent requirements date in the stock/requirements list. Material:. R-F1##. Quantity:. 10 pieces. Confirm your entry by choosing Enter and make sure that the system automatically defines the customer requirement type KSL in the item. Save the customer requirement. a) 2.. Menu path: Logistics → Production → Production Planning → Demand Management → Customer Requirements → Create. Call the current stock/requirements list for material R-F1## in plant 1000 (you can access the current stock/requirements list directly from the Demand Management environment). You can see that the sales order is displayed for information purposes only but it is not relevant to planning (that is, it has no effect on the available quantity). a) Note the customer requirement number/item number: __________________ / __________________________________ b) and the customer requirement quantity:. Continued on next page. 46. © 2008 SAP AG. All rights reserved.. 2007.

(55) SCM240. Lesson: Planning Make-to-Stock Production. ______________________________________________________ a). Sales order number/item number: Varies/10. b). Sales order quantity: 10 PC. Task 2: Now reduce the planned independent requirements by withdrawing stock for the customer requirement. 1.. The customer appears at the sales desk and wants to collect the 10 pumps ordered. The customer placed the order by telephone quite a while ago. You created the sales order in the system and it is displayed in the evaluation for information purposes, although the material ordered is from make-to-stock production. From the Inventory Management menu, post the withdrawal to the customer in the form of an other goods issue (transaction Goods Issue MIGO). Carry out the goods movement using the following parameters: Material number:. R-F1##. Quantity:. 10 pieces. Movement Type:. 231 (Consumption to sales order from warehouse). Plant:. 1000. Storage Location:. 0002. Confirm the data with Enter and then enter the customer requirement number and item you noted above on the Account Assignment tab page. Save your entries. a). Menu path: Logistics → Materials Management → Inventory Management → Goods Movement → Goods Issue (MIGO) Alternatively, you can also use the transaction MIGO (goods movement MIGO).. 2.. Call the stock/requirements list and examine the stock situation. a) How has the stock situation changed? ______________________________________________________ b) Which independent requirements and sales orders have been reduced? ______________________________________________________ Continued on next page. 2007. © 2008 SAP AG. All rights reserved.. 47.

(56) Unit 2: Demand management. SCM240. ______________________________________________________. 48. a). Stock reduced from 50 pieces to 40 pieces.. b). The oldest planned independent requirement has been reduced from 25 pc to 15 pc. At the same time, the customer requirement was reduced (from 10 pieces to 0 pieces) and no longer appears.. © 2008 SAP AG. All rights reserved.. 2007.

(57) SCM240. Lesson: Planning Make-to-Stock Production. Exercise 3: Planning with Final Assembly Exercise Objectives After completing this exercise, you will be able to: • Describe how planning with final assembly strategy works • Describe the effects of a sales order when using planning with final assembly strategy. Business Example Precision Pumps Inc. has produced pumps to stock. It now wants to change its strategy to planning with final assembly.. Task 1: In plant 1000, you want to enter a demand program (planned independent requirements) beginning in six months time and distributed over a period of six months. For these 6 months of your planning, choose the planning with final assembly (VSF requirements) strategy to plan the production of 1200 pumps. To do this, follow the two steps described below: 1.. Maintain the material master: In the material master for pump R-F1## enter the strategy group 40 (planning with final assembly). To do this, call the transaction Change material immediately from the production master data with the following parameters: Select view(s):. MRP 3. Organizational levels:. Plant 1000. In the strategy group field, enter the value 40 and save the material master. 2.. Maintain planned independent requirements: From the Demand Management menu create planned independent requirements for material R-F1## in plant 1000. Set the planning period to month format by entering the indicator M and Version 00 in the planning period field on the initial screen for the transaction. Start the transaction. Enter material number R-F1## and plant 1000 (field MPR area) on the table screen in a new empty row. Select this row and go to the Schedule lines tab page to access the schedule lines screen. Make sure the requirements type VSF, which belongs to strategy 40, is set automatically by the system. Continued on next page. 2007. © 2008 SAP AG. All rights reserved.. 49.

(58) Unit 2: Demand management. SCM240. Call the Split period online function from the edit menu to instruct the system to automatically split the production quantity of 1200 pieces over the 6 month period. Use the following data: From:. M, current month + 6 months. To:. Current month + 11 months. Planned quantity:. 1200 pieces. Period indicator for automatic distribution of requirements quantity: M. Confirm (including any potential warnings) with Enter and save the requirements.. Task 2: 1.. Display the stock/requirements list for material R-F1## in plant 1000 and note a) the second VSF requirements date: _________________________________ b) and the requirement quantity: _________________________________. Task 3: From the MRP menu, carry out multilevel, single-item planning for pump R-F1##. Use the same creation indicators as in the previous exercises. Make sure the “Display Material List” indicator is selected. Start the planning by choosing Enter twice. Once the MRP run has been carried out, the system displays the statistics. 1.. Choose the Material List function, select the row with pump R-F1## and goto to the stock/requirements list of the material. You now see the planned orders that have been created for the requirements (refresh the list if necessary).. 2.. What is the available quantity for the second VSF requirement date? _________________________________. 3.. What is the planned independent requirements quantity for the second VSF requirements date? Continued on next page. 50. © 2008 SAP AG. All rights reserved.. 2007.

(59) SCM240. Lesson: Planning Make-to-Stock Production. _________________________________. Task 4: Now enter a customer requirement of 10 pieces from the Demand Management menu for material R-F1## in plant 1000. 1.. Use the second VSF planned independent requirement date + 4 calendar days (that is, the date you noted above + 4 days) as requirement date for the customer requirement. Make sure the requirements type is KSV (sales order with consumption) and save your entries.. Task 5: Call the current stock/requirements list again (If necessary choose the Refresh pushbutton after having called up the list) and analyze the behavior of the customer requirement that you have just entered. 1.. What difference do you see compared to the customer requirement you created in make-to-stock production (previous exercise)? ______________________________________________________. 2.. What is the planned independent requirement quantity for the second VSF requirements date in the stock/requirements list now? ______________________________________________________. Task 6: In the stock/requirements list, select the second VSF planned independent requirement and call the Details of element and Display element functions. In the planned independent requirements table, select the row with the requirements that were created last and examine the VSF planned independent requirement quantities (as they appear on the database) on the schedule lines screen. 1.. Note the requirements quantity on the date above: ______________________________________________________. 2.. Do the two quantities (i.e., the quantity in this question and the quantity in the previous question) differ? If so, by how much? ______________________________________________________. Continued on next page. 2007. © 2008 SAP AG. All rights reserved.. 51.

(60) Unit 2: Demand management. SCM240. Task 7: Analyze the total planned independent requirements situation. To do this, access the Display Total Requirements function in the evaluations for Demand Management. 1.. Which VSF requirements quantities were consumed by which customer requirements quantities? ______________________________________________________. 2.. Which planned independent requirements quantities are displayed in the stock/requirements list? ______________________________________________________. Task 8: 10 pumps from stock are delivered to the customer. Post the other goods issue. You must enter the customer requirement number and the item number here. You can find this number in the stock/requirements list in the VSF planning customer requirement (planning with final assembly). You will recognize the process of this goods movement posting from the exercise “sales orders in make-to-stock production”, task 2. 1.. How has the stock situation changed? ______________________________________________________. 2.. Which planned independent requirements (customer requirements/planned independent requirements) were reduced by the goods issue from warehouse? (From the current stock/requirements list, look at the schedule lines of the VSF requirements on the database.) ______________________________________________________. 52. © 2008 SAP AG. All rights reserved.. 2007.

(61) SCM240. Lesson: Planning Make-to-Stock Production. Solution 3: Planning with Final Assembly Task 1: In plant 1000, you want to enter a demand program (planned independent requirements) beginning in six months time and distributed over a period of six months. For these 6 months of your planning, choose the planning with final assembly (VSF requirements) strategy to plan the production of 1200 pumps. To do this, follow the two steps described below: 1.. Maintain the material master: In the material master for pump R-F1## enter the strategy group 40 (planning with final assembly). To do this, call the transaction Change material immediately from the production master data with the following parameters: Select view(s):. MRP 3. Organizational levels:. Plant 1000. In the strategy group field, enter the value 40 and save the material master. a) 2.. Menu path: Logistics → Production → Master Data → Material Master → Material → Change → Immediately. Maintain planned independent requirements: From the Demand Management menu create planned independent requirements for material R-F1## in plant 1000. Set the planning period to month format by entering the indicator M and Version 00 in the planning period field on the initial screen for the transaction. Start the transaction. Enter material number R-F1## and plant 1000 (field MPR area) on the table screen in a new empty row. Select this row and go to the Schedule lines tab page to access the schedule lines screen. Make sure the requirements type VSF, which belongs to strategy 40, is set automatically by the system. Call the Split period online function from the edit menu to instruct the system to automatically split the production quantity of 1200 pieces over the 6 month period. Use the following data:. Continued on next page. 2007. © 2008 SAP AG. All rights reserved.. 53.

(62) Unit 2: Demand management. SCM240. From:. M, current month + 6 months. To:. Current month + 11 months. Planned quantity:. 1200 pieces. Period indicator for automatic distribution of requirements quantity: M. Confirm (including any potential warnings) with Enter and save the requirements. a). Menu path: Logistics → Production → Production Planning → Demand Management → Planned Independent Requirements → Create. Task 2: 1.. Display the stock/requirements list for material R-F1## in plant 1000 and note a) the second VSF requirements date: _________________________________ b) and the requirement quantity: _________________________________ a). Varies. b). Varies. Task 3: From the MRP menu, carry out multilevel, single-item planning for pump R-F1##. Use the same creation indicators as in the previous exercises. Make sure the “Display Material List” indicator is selected. Start the planning by choosing Enter twice. Once the MRP run has been carried out, the system displays the statistics. 1.. Choose the Material List function, select the row with pump R-F1## and goto to the stock/requirements list of the material. You now see the planned orders that have been created for the requirements (refresh the list if necessary). a). 2.. No solution required. What is the available quantity for the second VSF requirement date? Continued on next page. 54. © 2008 SAP AG. All rights reserved.. 2007.

(63) SCM240. Lesson: Planning Make-to-Stock Production. _________________________________ a) 3.. Available quantity on the second VSF requirements date: 0 pc. What is the planned independent requirements quantity for the second VSF requirements date? _________________________________ a). Planned independent requirements quantity on the second VSF requirements date: As above (see task 2). Task 4: Now enter a customer requirement of 10 pieces from the Demand Management menu for material R-F1## in plant 1000. 1.. Use the second VSF planned independent requirement date + 4 calendar days (that is, the date you noted above + 4 days) as requirement date for the customer requirement. Make sure the requirements type is KSV (sales order with consumption) and save your entries. a). Menu path: Logistics → Production → Production Planning → Demand Management → Customer Requirements → Create. Task 5: Call the current stock/requirements list again (If necessary choose the Refresh pushbutton after having called up the list) and analyze the behavior of the customer requirement that you have just entered. 1.. What difference do you see compared to the customer requirement you created in make-to-stock production (previous exercise)? ______________________________________________________ a). 2.. The sales order with requirements type KSV is relevant to requirements. This means it affects the available quantity.. What is the planned independent requirement quantity for the second VSF requirements date in the stock/requirements list now? ______________________________________________________ a). The planned independent requirements displayed in the current stock/requirements list is 10 less than the original requirement you noted above. The procurement element remains unaffected by this for the time being; no new planning run was triggered. Continued on next page. 2007. © 2008 SAP AG. All rights reserved.. 55.

(64) Unit 2: Demand management. SCM240. Task 6: In the stock/requirements list, select the second VSF planned independent requirement and call the Details of element and Display element functions. In the planned independent requirements table, select the row with the requirements that were created last and examine the VSF planned independent requirement quantities (as they appear on the database) on the schedule lines screen. 1.. Note the requirements quantity on the date above: ______________________________________________________ a). 2.. Varies (original quantity). Do the two quantities (i.e., the quantity in this question and the quantity in the previous question) differ? If so, by how much? ______________________________________________________ a). Yes, by 10 pc.. Task 7: Analyze the total planned independent requirements situation. To do this, access the Display Total Requirements function in the evaluations for Demand Management. 1.. Which VSF requirements quantities were consumed by which customer requirements quantities? ______________________________________________________ a). Menu path: Logistics → Production → Production Planning → Demand Management → Evaluations → Display Total Reqmts Consumed VSF requirements quantities: The second VSF planned independent requirement quantity is consumed by the KSV customer requirement.. 2.. Which planned independent requirements quantities are displayed in the stock/requirements list? ______________________________________________________ a). Displayed independent requirements quantities: In the current stock/requirements list, the system displays the planned independent requirements quantities that have not been consumed (that is, the planned independent requirements that still exist after consumption).. Continued on next page. 56. © 2008 SAP AG. All rights reserved.. 2007.

No results found