SCM 240 Production Planning

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SCM240

Production Planning (SAP R/3)

mySAP Supply Chain Management

Date Training Center Instructors Education Website

Instructor Handbook

Course Version: 2004 Q3 Course Duration: 5 Day(s) Material Number: 50066127 Owner: Bill Welch (i008505)

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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.

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Course Overview

[Enter a brief overview of the course.]

Target Audience

This course is intended for the following audiences: • Consultants Implementing MRP/MPS in SAP ERP

• Customers or Users who will be using MRP/MPS on a daily basis

Course Prerequisites

Required Knowledge

• Working knowledge of the following master data objects in SAP ERP – Material Masters – Bills of material – Task Lists/Routings – Work Centers/Resources – Master Recipes Recommended Knowledge

• General understanding of Production Planning process and industry terms • General understanding of SAP ERP applications and the integration to

Production Planning (PP)

Course Duration Details

Unit 1:

Overview of Production Planning in SAP ERP

SAP ERP Supply Chain Planning Overview 45 Minutes Exercise 1: Overview of SAP ERP Supply Chain

Planning 25 Minutes

Unit 2: Evaluation the Planning Results

Using the MRP and Stock/Requirements List 30 Minutes

Exercise 2: Using the MRP Lists 10 Minutes

Exception Messages in SAP ERP 30 Minutes

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Unit 3: MRP Basics

Concept of MRP 20 Minutes

MRP Types 40 Minutes

Prerequisites for Running MRP 20 Minutes

Methods for Executing a planning run 30 Minutes Exercise 3: Executing a planning run in SAP ERP 30 Minutes

Settings in the Planning Run 30 Minutes

Exercise 4: Settings in the planning run 20 Minutes Unit 4: Demand Management in SAP ERP

Overview of Demand Management 30 Minutes

Exercise 5: Managing your Planned Independent

Requirements Minutes

Make to Stock versus Make to Order 10 Minutes

Make to Stock Planning Strategies 45 Minutes

Exercise 6: Using Make to Stock planning strategies 30 Minutes

Make to Order Planning Strategies 45 Minutes

Exercise 7: Make to Order in SAP ERP Minutes

Settings and Customizing 50 Minutes

Unit 5: Master Production Scheduling

Master Production Scheduling 25 Minutes

Exercise 8: Master production scheduling (MPS)

and material requirements planning (MRP) 25 Minutes Unit 6: Influencing the Planning Run

Net Requirements Calculation 20 Minutes

Using Buffers in Planning 30 Minutes

Exercise 9: Dynamic Safety Stock 25 Minutes Controlling order quantities in the planning run 45 Minutes

Exercise 10: Controlling Order Quantities in the

Planning Run 25 Minutes

Multi-Site Planning 30 Minutes

Exercise 11: Multi-Site Planning 30 Minutes

Continuous Input/Output 35 Minutes

Exercise 12: Continuous Input/Output in the

Planning Run (OPTIONAL) 25 Minutes

Unit 7: Technical Process of the Planning Run

Basic Dates Scheduling in the Planning Run 30 Minutes Exercise 13: Basic DateScheduling in the Planning

Run Minutes

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Exercise 14: Lead Time Scheduling in the Planning

Run 15 Minutes

Master Data Selection during the Planning Run 20 Minutes Unit 8: Multiple Sources of Supply in Planning

Source Determination Overview 30 Minutes

Source Determination in Manufacturing 30 Minutes Exercise 15: Source Determination in

Manufacturing Minutes

Quota Arrangements 30 Minutes

Exercise 16: Production Versions and Quota

Arrangements Minutes

Source Determination in Procurement 30 Minutes Exercise 17: Source Determination in Procurement Minutes Unit 9: Life Cycle Planning

Discontinuation in Production Planning 45 Minutes Exercise 18: Discontinuation in production planning 25 Minutes Unit 10: Effects of Inventory in the Planning Run

Stock Types in Production Planning 30 Minutes Modeling Quality Inspection in Production planning 30 Minutes

Exercise 19: QM lots in Production Planning Minutes Unit 11: Component Availability

ATP in the Planned order 45 Minutes

Exercise 20: Availability Checking in the Planned

order 25 Minutes

Configuration of ATP 30 Minutes

Unit 12: Simulating the Production Plan

Long-term planning requirements 50 Minutes

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Course Goals

This course will prepare you to:

• Gain an overview of the basic principals of SAP ERP Production Planning • Demonstrate the tools that a production planner would use on a daily basis • Demonstrate how Planning strategies are used to control the planning and

inventory process

• Gain detailed working knowledge of: – Demand Managements (DM)

– Materials Requirements Planning (MRP) – Master Production Scheduling (MPS) – Long Term Planning (LTP)

• Demonstrate how to configure MRP in SAP ERP

Course Objectives

After completing this course, you will be able to:

• Gain an overview of the basic principals of SAP ERP Production Planning • Demonstrate the tools that a production planner would use on a daily basis • Demonstrate how Planning strategies are used to control the planning and

inventory process

• Gain detailed working knowledge of MRP/MPS in SAP ERP • Demonstrate how to configure MRP in SAP ERP

SAP Software Component Information

The information in this course pertains to the following SAP Software Components and releases:

Several of the Tasklists for the R-F##, and R-B## at plant 1000 are in German. Use T-Code ZPSL or YILA to translate tasklists from English to German.

Prior to the start of this class CATT ZT_SCM240 must be run in order to generate the following data:

Configuration

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Master Data:

Create the Following Material Masters: • R-F3##/1000

• R-F4##/1000 • R-F5##/1000 • R-F1##/2400

Create BOM and Routings for the Following materiasl copying from the R-F1##/1000 • R-F3##/1000

• R-F4##/1000 • R-F5##/1000

Chage the following settings to the the mateiral master records • R-F1##/1000: Strategy 10 • R-F2##/1000: Strategy 40 • R-F3##/1000: Strategy 50 • R-F4##/1000: Strategy 52 • R-F5##/1000: Strategy 20 • R-F1##/2400: Strategy 40

Creat Product groups Pump-00 thru Pump-30, Include the following settings:

Material Plant Agg Factor Proportion

R-F1## 1000 1 20

R-F2## 1000 1 20

R-F3## 1000 1 20

R-F4## 1000 1 20

R-F1## 2400 1 20

Create Rough Cut Planning Profile for Pump-## Plant at 1000 Time Span: 20 Days

Base Qty: 1 pc

Status: 4 – Release General Usage: 1- Production

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From Lot Size: 1 To Lot Size: 999,999,999 work center: R-L## /1000

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Unit 1

1

Overview of Production Planning in

SAP ERP

Unit Overview

This unit will give you an overview of some of the steps that be performed by a supply chain planner using SAP ERP.

Unit Objectives

After completing this unit, you will be able to:

• Outline the steps in the SAP ERP Supply Chain Planning process

• Demonstrate knowledge of the different planning techniques in SAP ERP

Unit Contents

Lesson: SAP ERP Supply Chain Planning Overview ... 2

Demonstration: Sales and Operations Planning ... 5

Demonstration: Display Requirement in Demand Planning ... 8

Demonstration: Materials Requirements Planning... 11

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Lesson:

2

SAP ERP Supply Chain Planning Overview

Lesson Duration: 45 Minutes

Lesson Overview

In this lesson you will get an overview of supply chain planning as it could be implemented with SAP ERP. This will involve understanding the different steps in the process and how they are interrelated.

Lesson Objectives

After completing this lesson, you will be able to:

• Demonstrate knowledge of the different planning techniques in SAP ERP

The idea of this unit is to give students a high level overview of the entire process. An exercise will be done at the end of the lesson to setup the evaluation unit and demand management unit.

Business Example

The Precision Pump company manufactures and sells pumps. Some manufactured goods are produced in-house and the rest are externally procured. As a planning manager, you need to plan and manage the requirement, sales, and manufacture of pumps. To do so, you need to evaluate and analyze the SAP ERP solution for Supply Chain Planning. To do this you will identify the different step in the process and compare them to the functionality in the Production Planning (PP) module of SAP ERP.

SAP ERP Supply Chain Planning Process

Any business that sell products or services typically needs to perform some sort of planning process to ensure enough supply is available to support demand. Depending upon the types of products or services a company offers, or the industry in which they may compete, the process might be altered slightly.

The overall goal of production planning is to maintain high customer service levels while minimizing costs. The process may be adapted based on certain characteristics of the material during the sales, inventory management or production process.

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Figure 1: The Production Planning Process

In the graphic above you can see the different steps that can be used in SAP ERP to start what is often referred to as the Plan to Inventory process. This process is typical in a make to stock type of environment, where a forecast, sales plan, or demand plan is required to triggered procurement of some nature. This demand can be at the finished good, semi finished good, or raw material level.

Sales and Operations Planning (S&OP)

The first step in any make to stock process is to derive some type of demand at the plant with a forecast. This demand plan will be the basis or input in the operational process. S&OP is a strategic process. This typically entails developing a sales plan from any where between six to eighteen months or longer, depending upon the industry.

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Figure 2: Sales and Operation Planning (S&OP)

The S&OP process is typically made up of a minimum of three steps: 1. Sales Plan

2. Production Plan

3. Rough Cut Capacity Planning

The sales plan is typically generated using historical consumption (sales) data then applied to a statistical model in order to generate a “forecast”. During the first pass at creating sales plans, they should be developed without regards to operational constraints. This will give the operations team a look at the “true”demand.

The process it self is rough in nature due to the fact the demand is typically created at aggregate levels than what is typically executed. This means that the sales plan may be created at the regional, division, or product group level. In addition it is often developed in weekly or monthly buckets of time, compared to the operations team that will plan at material and daily level.

When demand is created at a higher level than which inventory is stored, a

disaggregation process is required. Disaggregation will require proportional factors or percentages to ultimately get a “high-level” plan down to the material level.

The first time the production plan is generated, it is typically equivalent to that of the sales plan. This assumes that the operations team will attempt to meet demand as it is planned by sales. Once the initial production plan is generated, it will be evaluated using rough cut capacity planning.

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In rough cut capacity planning, planners will identify one or more bottleneck work centers, and/or several critical materials for which supply is tight. If the capacity check identifies overloads then planners will typically adjust the production plan in accordance with the work centers capabilities. This might typically involve moving production forward of the demand in order to build inventory ahead of the capacity constrained period.

Demonstration: Sales and Operations Planning

Purpose

System Data

System: SAP ERP

Client: 8XX

User ID: Password:

Set up instructions:

1. SAP ERP menu path: Logistics → Production → SOP → Product Group → Display (MC85)

2. Enter Product group Pump-## at plant 1000

3. The product group should contain the following data:

Material Plant Agg Factor Proportion

R-F1## 1000 1 20 R-F1## 2400 1 20 R-F2## 1000 1 20 R-F3## 1000 1 20 R-F4## 1000 1 20 4. Exit Transaction

5. SAP ERP menu path: Logistics → Production → SOP → Planning → For Product Group → Change (MC82)

6. Enter Product Group PUMP-## at plant 1000 and select the Active version. 7. Enter the following demand starting in the third period:

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Period Month 3 Month 4 Month 5 Month 6 Month 7 Month 8

Sales 1000 800 1000 900 1000 1100

8. Edit → Create productn plan → Synchronous to sales 9. Views → Capacity situation → Rough-cut planning → Show 10. Select Save

11. SAP ERP menu path: Logistics → Production → SOP → Disaggregation→ Break Down PG Plan (MC76)

12. Enter Product Group PUMP-## at plant 1000 and select the Active version.

13. Select Create Sales Plan and select Continue

14. Scroll to review the details of the disaggregated sales plan

15. SAP ERP menu path: Logistics → Production → SOP → Planning → For Product Group→ Transfer Product Group to Planning (MC75) enter the following:

Field Value

Product Group Pump-##

Plant 1000

Version A00

Transfer strategy and period

Prod.plan for mat. or PG members as proportion of PG

From/To Leave defaults

Invisible Transfer Leave Selected

Rqmts type Leave Blank

Version 00

Active Select

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Demand Management

Demand management is the link between top-level requirements planning (S&OP) and materials planning (MPS and/or MRP).

Figure 3: Demand Management in Production Planning

Demand management may contain one or more demand programs or versions that will help drive the production planning process. Input for the demand programs can come from one or more sources:

• The Sales Plan or Production Plan from S&OP • A Material Forecast

• Manual Entry

• Another program Plan • Transferred from SAP SCM

The result of the demand programs are called Planned Independent Requirements (PIRs). Demand management determines the requirements dates and quantities of the materials we are planning. Planning strategies are used to determine how these PIRs will be used during the MPS/MRP planning runs.

Demand Management can be tied into the Sales and Distribution module to ingrate sales orders with the planning run. Sales orders can serve as a sole requirements source, for which procurement is then triggered specifically (make-to-order), or together with planned independent requirements, they can create the “total” demand.

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Demonstration: Display Requirement in Demand

Planning

Purpose

System Data

System: SAP ERP

Client: 8XX

1. SAP ERP menu Path: Logistics → Production → Production Planning → Demand Management → Planned Independent Requirements → Change (MD62) 2. Select Product Group and enter Pump-## at plant 1000.

3. SAP ERP menu Path: Logistics → Production → Production Planning → Demand Management → Environment → Stock/Requirements List (MD04) 4. Enter R-F1## at Plant 1000

Long Term Planning

Over the course of normal business, planners will often be presented with “What if...”. Whether the situation be a shift in demand patterns, extensions of existing product lines or the creating of new product lines, each situation could present a problem with available capacity or material availability.

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Figure 4: Long Term Planning

In SAP ERP, simulation planning can be obtained through the use of the Long Term Planning (LTP) module. Long term planning is an optional tool that will allow planners to simulate demand changes and run a full Materials Planning and Capacity Planning analysis. These analyses allow planners to identify possible work center overloads or issues obtaining semi-finished or raw materials. Long term planning will have the same capabilities and analysis tools that the operational planners will use to constantly evaluate the production plan.

Production Planning Procedures

When deciding how to use SAP ERP for planing you will need to identify how materials behave over the course of time. Certain characteristics will decide how materials are going to be handled in SAP ERP Planning runs.

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Figure 5: Planning Procedures in SAP ERP

Planning procedures will be typically made at the material/plant level. Therefore planners can group products that behave similarly together so that they can use common planning techniques.

In SAP ERP there are three main techniques that planners can use to drive the production planning process:

• Master Production Scheduling (MPS) • Material Requirements Planning (MRP) • Consumption Based Planning

MPS and MRP will be discussed at great length in this course. MPS/MRP take into account current inventory and any frozen production as a starting point. Then using future planned demand (PIRs) or actual demand (sales orders), trigger a calculation process to predict future procurement or need.

In contrast Consumption Based Planning is based on past usage values and uses a forecast to statistical procedure to determine future requirements. Consumption based planning is characterized by its simplicity and is mainly used for B and C parts with low value.

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Demonstration: Materials Requirements Planning

Purpose

Describe at an overview level the purpose of MRP

System Data

System: SAP ERP

Client: 8XX

1. From the system menu at the top: System → Create Session

2. SAP ERP menu path: Logistics → Production → MRP → Planning → Single-Item, Multi-Level Planning (MD02)

3. Use the following parameters for the planning run for product groupPump-## at plant 1000:

Field Value

Product Group Selected

Processing Key NETCH

Create Purchase Req. 1 - Purchase requisitions Delivery Schedules 3 - Schedule lines

Create MRP List MRP List

Planning Mode 1 - Adapt Planning Data

Scheduling 2 - Lead time scheduling

Also plan unchanged components Select

4. SAP ERP menu path: Logistics → Production → MRP → Evaluations → Stock/Requirements List (MD04)

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Capacity planning

The economic use of resources is an objective for many areas of a company. In recent years many companies have consolidated facilities in order to obtain a higher rate of utilization on resources. This trend has caused many companies to place more focus on the creation of a detail plan or a shop floor schedule

Figure 6: Capacity Planning

In SAP ERP this process is called Capacity Requirements Planning (CRP). This process typically consists of two steps:

• Capacity Evaluation • Capacity Leveling

With capacity evaluation, schedulers are reviewing the results of MPS/MRP and are looking for any time periods in which certain work centers may have more production planned than can be actually executed. This is called an overload.

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When and overload has been identified the production scheduler begins rescheduling the orders based on additional planning criteria. This may include performing finite scheduling to ensure that the resource is not overloaded, or performing an optimization run to improve the schedule by grouping like production runs together to reduce the amount of setup time between jobs.

Note: Capacity planning in SAP ERP can occur in:

• SOP

• After MPS • After MRP

• With Production and Process orders • Long Term Planning

The result of CRP will be a detailed schedule that will be issued to the shop floor. This schedule will instruct production management of the sequence and priorities of the production.

Shop Floor Control

Once a shop floor scheduled has been created and issued, the next step is execution, or shop floor control. In SAP ERP, companies will have several options to choose from on how they wish to execute and track production.

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The graphic above identifies four types of execution process in SAP ERP: • Repetitive Mfg (REM)

• Production Orders • Process orders. • Project systems

Repetitive Manufacturing is the simplest form of execution. This is often used for less complicated products that are made several times a week/month, or endure long production runs while receiving production continuously. This type of execution is often used in consumer products or the chemical industry. With this type of execution process communication between scheduling and execution must remain tight, but the control of the process remains simple. The shop floor will use planned orders to communicate production runs, and production will be tracked on a material basis not an order basis.

Production orders are typically used in a more complicated manufacturing process. Complex products typically require a higher degree of control on the production floor. With production orders, companies can control and track the production process through the uses of order status. The production orders also act as a cost and data collector for each production run. This allows management to review each production run if necessary, for efficiency and profitability.

Process orders are used more often in regulated industries. Process orders are very similar to production orders in that they act as a cost and data collector for each production run. However, industries like pharmaceuticals and food require tighter controls and tracability. Process orders have a tighter integration with Engineering Change Management (ECM) and can develop electronic batch records of each production run to give details of every step of the production process.

Project Systems (PS) is often used in Engineer-to-Order industries. This would be applicable in construction and aero space and defense to name a few. Project systems provides tight control and accounting for long extremely complex manufacturing. Using a Work Break down structure and activities tied to production orders, allows companies to tie several levels of production or services together for better supervision and cost control.

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Exercise 1: Overview of SAP ERP Supply

Chain Planning

Exercise Duration: 25 Minutes

Exercise Objectives

After completing this exercise, you will be able to:

• Create a high level sales and production plan for your Product group Pump-## • Transfer a production plan at the product group level to the material level • Execute MRP to initiate a procurement plan

Business Example

As a senior planner, you must be able to explain how SAP ERP will be used to model your entire production planning process. Enter a simple sales plan in S&OP and run it through a simplified production planning process to get a basic overview of the functionality.

System Data

System: SAP ERP

Client: 8XX

CATT: Z_SCM240

1. CAT ZSCM240 Must be run prior to executing this exercise

Task 1: Create a Sales and Operations Plan in SAP ERP

To better understand the SAP ERP production planning process, we will create a sales plan for one of your pump product groups. You will then release the sales plan to demand management as the demand plan, which will drive the MRP/MPS process for IDES.

1. A product group Pump-## has been created for you at plant 1000 to represent the materials that you will be responsible for planning. Display your product group and fill in the table below:

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Material Number Plant Proportion

2. Create /Change a sales plan for your product group PUMP-## at plant 1000 in the active version (A00). Enter the following demand starting in the third period:

Sales 1000 700 800 900 1000 1100

3. Create a production plan that equals the sales plan

4. View the rough cut capacity to see if your demand is going to cause any potential capacity overloads, at work center R-L##, at any point within the planning horizon.

5. Save your plan

Task 2: Planned Independent Requirements

Once a sales and production plan is complete at the strategic level, it must be transferred to the operations level were it can be viewed at the material level. Once demand is active in demand management, it can be used to drive the MPS/MRP process.

1. Now that you have created a high level or rough production plan for your product group, PUMP-## at plant 1000 for version A00, disaggregate and release the plan, to the locations, at the material level using the product group’s proportions. 2. Now that demand has been disaggregated and transferred to the material level,

review the planned independent requirements in demand management. Fill out the following table based on the results of your transfer:

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Mat. Plant Ver. P1 P2 P3 P4 P5 P6

3. Now that you have transferred demand from the strategic high-level plan, down to a tactical material level, use the stock requirements list to review what the transfer has actually accomplished for your material R-F1## at plant 1000:

4. What is your current planning situation?

Task 3: Material Requirements Planning

After releasing the production plan from the S&OP process, you have populated demand management with planned independent requirements. These requirements are causing negative inventory. Using material requirements planning, you will create a procurement plan for product R-F1## .

1. After reviewing the stock/requirements list, it is obvious that demand is exceeding supply. In a second session, run a single-item, multi-level MRP run for R-F1## at plant 1000. Use the following parameters for the planning run:

Field Value

Processing key NETCH

Create purchase req. 1 - Purchase Requisitions

Delivery schedules 3 - Schedule lines

Create MRP list MRP List

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Field Value

Planning mode 1 - Adapt Planning Data

Scheduling 2 - Lead time scheduling

and capacity planning Also plan unchanged components Select

2. Now that a MRP run has been executed, review the stock requirements list, for R-F1## at plant 1000, to determine if the planning situation has changed.

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Solution 1: Overview of SAP ERP Supply

Chain Planning

Task 1: Create a Sales and Operations Plan in SAP ERP

To better understand the SAP ERP production planning process, we will create a sales plan for one of your pump product groups. You will then release the sales plan to demand management as the demand plan, which will drive the MRP/MPS process for IDES.

1. A product group Pump-## has been created for you at plant 1000 to represent the materials that you will be responsible for planning. Display your product group and fill in the table below:

Material Number Plant Proportion

R-F1## 1000 20

R-F1## 2400 20

R-F2## 1000 20

R-F3## 1000 20

R-F4## 1000 20

a) SAP ERP menu path: Logistics → Production → SOP → Product Group → Display (MC85)

b) Enter Product group Pump-## at plant 1000

2. Create /Change a sales plan for your product group PUMP-## at plant 1000 in the active version (A00). Enter the following demand starting in the third period:

Sales 1000 700 800 900 1000 1100

a) SAP ERP menu path: Logistics → Production → SOP → Planning → For Product Group → Change (MC82)

b) Enter Product Group PUMP-## at plant 1000 and select Active version. c) Enter the demand as indicated in the table above.

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3. Create a production plan that equals the sales plan

a) Edit → Create productn plan → Synchronous to sales

4. View the rough cut capacity to see if your demand is going to cause any potential capacity overloads, at work center R-L##, at any point within the planning horizon.

a) Views → Capacity situation → Rough-cut planning → Show

Note: Any production overloads would manually be addressed by decreasing or increasing production to keep the capacity load under 100%.

5. Save your plan a) Select Save

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Task 2: Planned Independent Requirements

Once a sales and production plan is complete at the strategic level, it must be transferred to the operations level were it can be viewed at the material level. Once demand is active in demand management, it can be used to drive the MPS/MRP process.

1. Now that you have created a high level or rough production plan for your product group, PUMP-## at plant 1000 for version A00, disaggregate and release the plan, to the locations, at the material level using the product group’s proportions. a) SAP ERP menu path: Logistics → Production → SOP → Planning For

Product Group→ Transfer Product Group to Planning (MC75) enter the following:

Field Value

Product group Pump-##

Plant 1000

Version A00

Transfer strategy and period Prod.plan for mat. or PG members as proportion of PG

From/To Leave defaults

Invisible Transfer Leave Selected

Rqmts type Leave Blank

Version 00

Active Select

b) Select Transfer Now, to transfer the product group’s production plan to the material level in Demand Management.

2. Now that demand has been disaggregated and transferred to the material level, review the planned independent requirements in demand management. Fill out the following table based on the results of your transfer:

R-F1## 1000 00 200 140 160 180 200 220

R-F1## 2400 00 200 140 160 180 200 220

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R-F2## 1000 00 200 140 160 180 200 220

R-F3## 1000 00 200 140 160 180 200 220

R-F4## 1000 00 200 140 160 180 200 220

a) SAP ERP menu Path: Logistics → Production → Production Planning → Demand Management → Planned Independent Requirements → Change (MD62)

b) Select Product Group and enter Pump-## at plant 1000. Select Enter. c) Select the Table tab to review the period details of all materials. d) Exit the Planning Table.

3. Now that you have transferred demand from the strategic high-level plan, down to a tactical material level, use the stock requirements list to review what the transfer has actually accomplished for your material R-F1## at plant 1000: a) SAP ERP menu Path: Logistics → Production → Production Planning →

Demand Management → Environment → Stock/Requirements List (MD04) 4. What is your current planning situation?

Answer: Current inventory balance is Zero (0). The independent requirements, from the production plan, are causing a negative available balance. These requirements which are acting like a demand plan, will drive production planning at the material level.

Task 3: Material Requirements Planning

After releasing the production plan from the S&OP process, you have populated demand management with planned independent requirements. These requirements are causing negative inventory. Using material requirements planning, you will create a procurement plan for product R-F1## .

1. After reviewing the stock/requirements list, it is obvious that demand is exceeding supply. In a second session, run a single-item, multi-level MRP run for R-F1## at plant 1000. Use the following parameters for the planning run:

Field Value

Processing key NETCH

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Field Value

Delivery schedules 3 - Schedule lines

Create MRP list MRP List

Planning mode 1 - Adapt Planning Data

Scheduling 2 - Lead time scheduling

and capacity planning Also plan unchanged components Select

a) From the system menu at the top: System → Create Session

b) SAP ERP menu path: Logistics → Production → MRP → Planning → Single-Item, Multi-Level Planning (MD02)

c) Select Enter twice to execute the run.

d) Select Back twice to return to the main menu

2. Now that a MRP run has been executed, review the stock requirements list, for R-F1## at plant 1000, to determine if the planning situation has changed. a) SAP ERP menu path: Logistics → Production → MRP → Evaluations →

Stock/Requirements List (MD04)

3. What has changed as a result of the MRP run?

Answer: As a result of MRP, a planned order has been created to cover each planned independent requirement. This results in a zero inventory balance after each requirement.

NOTE: due to different working days in each month, during some teaches the first planned order may be late.

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Lesson Summary

You should now be able to:

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Unit Summary

You should now be able to:

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21

Test Your Knowledge

1. Define Sales and Operations Planning?

2. Standard SOP is the only functionality provided to support this process.

Determine whether this statement is true or false.

□ True □ False

3. How may demand be provided to the SOP tool?

Choose the correct answer(s).

□ A Statistical forecast □ B Manually entered □ C Copy from COPA

□ D Copy from Sales info System □ E All of the above

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22

Answers

1. Define Sales and Operations Planning?

Answer: SOP is typically a monthy process where representatives from various areas of the company meet and review the supply and demand situation from a very high level (typically at the product group level).

2. Standard SOP is the only functionality provided to support this process.

Answer: False

Flexible planning may also be used.

3. How may demand be provided to the SOP tool?

Answer: E

All of the above are valid.

4. Why is shop floor control important in the planning process?

Answer: It provides the latest information to the planning tools as to what has actually occured.

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Unit 2

23

Evaluation the Planning Results

Unit Overview

This unit will introduce you to the tools that would be used on a day to day basis during the planning process. You will customize some of the views that speed up tasks in later units.

Unit Objectives

After completing this unit, you will be able to:

• Demonstrate how to use the MRP and Stock Requirements List for use in day to day planning.

• Describe the differences between the MRP List and Stock Requirements (S/R) list

• Explain how exception messages are used in the production planning process • Demonstrate how to configure exception messages.

• Interpret day’s supply and receipt day’s supply

Unit Contents

Lesson: Using the MRP and Stock/Requirements List ... 31 Demonstration: Navigating the Stock Requirements list ... 35 Procedure: Navigating the Stock Requirements list ... 37 Demonstration: Changing MRP Elements in the Stock Requirements list... 38 Demonstration: Navigate the Overview Tree ... 42

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Demonstration: Order Report ... 44 Demonstration: Pegged Requirements... 45 Demonstration: Navigation Profiles ... 51 Demonstration: Collective Access to MRP Lists and Stock/Requirements Lists ... 54 Exercise 2: Using the MRP Lists ... 57 Lesson: Exception Messages in SAP ERP... 71 Demonstration: Use of Exception messages ... 76 Procedure: Using Exception Messages ... 78 Demonstration: Exception Message Configuration ... 79 Lesson: Days’ Supply ... 83 Demonstration: Days’ Supply and Receipt Days’ Supply ... 86

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Lesson:

24

Using the MRP and Stock/Requirements List

Lesson Duration: 30 Minutes

Lesson Overview

In this lesson, you will learn about the usage of Material requirements planning (MRP) List and Stock/Requirements List and it’s functions. In addition, you will learn how to collectively access the both result lists.

Lesson Objectives

After completing this lesson, you will be able to:

• Demonstrate how to use the MRP and Stock Requirements List for use in day to day planning.

• Describe the differences between the MRP List and Stock Requirements (S/R) list

Processing the MRP results usually follows a total planning run. The aim is to manually process problem situations, which have led to the creation of exception messages. The typical tools for this manual processing are the stock/requirements list and the MRP list with their respective collective accesses. Alongside the exception messages, these lists offer a range of functions for processing the planning results: Rescheduling data, firming, evaluation functions such as order report or pegged requirements, days’ supply and receipt days’ supply.

Business Example

As a production planner, you need to ensure that the production plan generated by the SAP ERP system, meets the demand requirements. In order to do this you need a tool that will help you manage problems with the production plan, and give detailed information as to the supply and demand situation. Explore the MRP List and Stock/Requirements (S/R) List as an option for managing the production plan.

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Planning Run List Evaluations

As a result of a planning run in SAP ERP, a production and procurement schedule will have been created. The planning run will have generated the following items:

• Planned orders • Purchase requisitions • Schedule Lines

• Stock Transfer Requests • Material Transfers • Dependent Requirements • Exception messages

Planners will require a tool that will allow them to view the results and to identify if any problems have occurred. Prior to the initiating the planning run a planner can decide if they want an MRP list to be generated to display the results of the planning run. The MRP list will be created at the Material/MRP Area/Plant level. The MRP list always displays the supply and demand situation at the time of the last planning run and it also provides a work basis for the MRP controller. Changes that are made after the planning date are not taken into consideration, so the list is static. MRP lists are stored in the system until they are either deleted manually or replaced by new lists from a subsequent planning run.

While the MRP list is a result of the planning run, a real evaluation tool is available in the Stock/Requirements (S/R) list. The structure of the lists are very similar in nature. Each list will have it’s own unique attribute to display the relevant information for which it was designed; Static or Real time.

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Figure 8: MRP List and Stock/Requirements (S/R) List Layout

The MRP list and S/R lists are made up of several different components to which the user can navigate to at any time:

• Material Header

• Material Header Details (Dynamic) • Material Tree (Dynamic)

• MRP Elements

• Period Totals (Dynamic)

The material header will identify which material/location is being viewed as well as the unit of measure. The header details are dynamic, and can be turned on or off. These details refer to information about the material master or planning statistics that were a result of the last planning run.

The overview tree is used for toggling between various material numbers selected by the user. If users access the the collective list and select several materials, all materials will appear in the tree. If a user access’s the MRP list using a product group, the list will contain all the members of the product group.

The MRP Elements section will give the details about the supply and demand situation. An MRP Element is a term for all objects displayed as items in the MRP list or in the S/R list. Such objects include planned orders, purchase orders, reservations, and sales orders. The MRP Elements are listed individually by day. By selecting any

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MRP element and pressing the F1 key, users can get a list of all the MRP elements used by SAP ERP. MRP Elements are created on the basis of the supporting master data. Not all MRP Elements will be applicable for a material.

The period totals display will aggregate the MRP elements to a larger bucket of time, by summarizing the same MRP elements for the same day/week/month or user defined period.

The basic structure of both lists is the same:

Figure 9: Planning Segments

The MRP and S/R list is divided into various planning segments. This means that related MRP elements are also displayed together. Depending upon which planning strategy(s) are being used the list reports might be broken down into several segments. For example in a make-to-order scenario, each order and its associated inventory will be planned separately from any other inventory or order. The individual stocks, receipts, and issues are displayed and planned within the appropriate segment. The MRP calculation takes place within the individual segments.

Within each segment, the system will display the receipt first, followed by the requirement. If a receipt will be late then it will show up after the requirement, and typically, exception messages will appear describing any issues with the plan.

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Variable Headers

The header details of the List reports contain additional data for the planning run. In particular, they contain the number of exception messages that have occurred during the planning of a material (MRP List Only). You define the display of the header details for the MRP evaluations in the Customizing IMG activity “Define screen sequence for header details”. Using the IMG menu path Production → MRP → Evaluation → Define Screen Sequence for Header details , companies can create there own sequence of headers.

The header details show an overview of master data and transaction data for each material. This data is grouped together according to topic in individual screens. The MRP type controls the screens that are displayed in the requirements planning evaluations. For this, the screen sequences have a key that is assigned to the MRP type. Therefore, you can display different master data for the evaluation of consumption-based materials than for planning-based materials.

Demonstration: Navigating the Stock Requirements list

Purpose System Data System: Client: User ID: Password:

Set up instructions: Exercise from Lesson Production Planning overview must be complete.

CATT Z_SCM240 should be run to generate master data.

1. SAP ERP menu path: Logistics → Production → MRP → Evaluations → Stock/ Requirements List

2. Enter Material R-F1## at plant 1000 and press ENTER 3.

Caution: To show the Material header information select Expand Header details.

4. To show the MRP elements in an Aggregated time bucket select Switch to period totals and select the tab with the correct period of aggregation.

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28

Navigating the Stock Requirements list

2. Enter Material R-F1## at plant 1000 and press ENTER

3. To show the Material header information select Expand Header details. 4. To show the MRP elements in an Aggregated time bucket select Switch to

period totalsand select the tab with the correct period of aggregation. 5. Select Switch to individual lines.

Functions of the MRP list

Once in the MRP list a planner can use the data displayed to make intelligent business decisions. In addition to displaying information, the MRP list is interactive and can carry out several functions.

Figure 10: Functions of the MRP List

Once inside the List reports, users can create/change the material memo. This is a working script of notes regarding the material. In the List reports, the material memo will be marked with whom ever has updated the memo last and the date it was last changed.

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Each MRP element can be viewed in more detail. By selecting Details of Element, users can view more summary information about the specific MRP element. In addition it will give the user additional options to possibly Change or Display the element. Depending upon which element is chosen other options are available such as converting a planned order to a production order, partially converting to a production order, convert to a process order, or convert to a purchase requisition. Over time planners will make changes to the plan that should be documented. This may be required to adhere to company wide accountability standards. By selecting the

Material Memo icon, users can leave long text notes, which will be cumulated over time. After saving the material memo, the icon will show who and when last changed the long text on the material memo.

Users can also access the following functions: • Change/Display Material master

• Display ATP Quantities • View Stock/Sales Statistics

• Compare results to Long Term Planning

Demonstration: Changing MRP Elements in the Stock

Requirements list

Purpose System Data System: Client: User ID: Password: Set up instructions:

3. Select the first Planned order and Double click or select Details of element then select Change element

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4. Select the first planned independent requirement and select Details of elementthen select Change element

5. In the material field, replace R-F1## with R-B1## and press ENTER

6. Select Details of element, for the first dependent demand and display the parent planned order number

7. In the material field, replace R-B1## with R-T1## and press ENTER 8. Select Details of element, for the first purchase Requisition.

9. Demonstrate changing the material master. From S/R List Menu Path: Environment → Change Material

List Report Display Structure

Throughout the course of a day planners will have to review the supply and demand situation as it relates to several materials. Depending upon how the user enters the list reports, they may have access to a tree structure on the left side of the screen that will make navigating between materials easier.

Displaying the material tree is optional. Upon entering either list report, the overview tree can be accessed by selecting Show Overview tree button.

You can change the layout of the tree and display the following: • Worklist tree

• Order tree

• Product group tree

After accessing one of the lists, each user can set the overview tree to appear automatically. To set the overview tree to appear automatically, users must select Save Settings, and in the Display tab select Overview Tree Displayed option.

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Figure 11: Overview Tree

The worklist tree displays all materials in the current session. When accessing the list through the collective process, all materials that were selected are displayed. Otherwise as you type over the material number, the new product will be added to the worklist. The work list can be customized by each user. You can set in which order the fields are to be displayed. User-specific definitions for the traffic lights are also possible. User-specific sortings and groupings, such as according to the processing indicator, are possible. You can search for specific materials according to exception messages.

You can display the stock/requirements list or MRP list for a material by double-clicking on the material in the tree.

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Figure 12: Order Tree

The order tree will display the individual component requirements for the selected order or requirement are displayed on several levels. By selecting the planned order in the MRP Elements section, and selecting Order Tree, the multi level order will be displayed. In addition to the order details, exception messages and information will appear to the right of the material number. By selecting the line dividing the tree from the MRP elements a user can re-size the window and see more order information.

Note: As of SAP ERP release 4.7, it is possible to now view order network exceptions. These messages are generated and placed at the top assembly if there is an exception at a lower level.

When you navigate in the order tree, by selecting a material the correct

stock/requirements list or MRP list is displayed in the MRP Element area, and the element involved in the order report is highlighted. This way, you can quickly get an overview of the stock situations at all levels of the order structure.

The product group tree will only appear if users have accessed the collective lists and used Product group as the selection criteria. By selecting a particular material, the MRP Elements section will display the supply and demand situation.

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Demonstration: Navigate the Overview Tree

Purpose System Data System: Client: User ID: Password: Set up instructions:

1. SAP ERP menu path: Logistics → Production → MRP → Evaluations → Stock/Requirements List

3. Display the order tree, by selecting the first planned order and then select Set Up Order Structure.

4. Double click on several of the components, in the tree structure, to show the MRP elements changing and the element being highlighted in blue.

5. Show students the MRP exceptions. Move your cursor just to the right of the “alert” icons to get the quick info on the exceptions.

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Order Report

Figure 13: Order Report

The evaluation “Order report” enables you to gain an overview of the status of all BOM levels from the list of MRP elements: Sales order, production order including collective and process order, and planned order. In doing so, you can recognize problems in the production and procurement of assemblies and components at an early stage.

You access the transaction directly from the stock/requirements list or the MRP list. The system determines the receipt elements that are planned for each MRP element. The MRP controller checks how the production of a certain sales order is progressing or if there are missing parts or scheduling problems on a certain BOM level or for certain components.

The receipt elements are color coded. This enables the MRP controller to foresee possible future problems on subordinate BOM levels:

• Red: There are exception situations on subordinate BOM levels.

• White: The requirement is covered by warehouse stock on the subordinate BOM levels.

• Green: Receipt elements have been created on subordinate BOM levels, yet no exception situations exist.

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Demonstration: Order Report

Purpose

To demonstrate Order Report/Order Tree/Pegged Requirements

System Data System: Client: User ID: Password: Set up instructions:

3. Display the order tree for the first planned order. Select the first planned order, and select Order Report.

4. Drill down to show the details of the report by selecting Open all lines. 5. Double Click on the planned order to see the dependent requirements.

6. Call the list of the component R-T1##. Call the pegged requirements for the first requirement in the list and reproduce the path to the order.

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Pegged Requirements Report

Figure 14: Pegged Requirements

You can use the evaluation “Pegged requirements” ( you can access this directly from the stock/requirements list and MRP list) to trace from any BOM level on a multilevel basis which requirements have caused an order proposal and which independent requirements (particularly sales orders) are affected by the change in date or quantity of an order proposal on a lower level.

In SAP ERP 4, you can navigate from the requirements element directly to the pegged requirement on the level above in the stock/requirements or MRP list. The system displays the stock/requirements or MRP list of the superordinate level and automatically positions the cursor on the correct line of the pegged requirement. This makes it much easier to find pegged requirements on different MRP levels. You can call up this function from the details display of the requirements element. The function is available for the requirements, such as dependent requirements, order reservations, stock transfer requirements, and stock transfer reservations.

Demonstration: Pegged Requirements

Purpose

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System Data System: Client: User ID: Password: Set up instructions:

2. Enter Material R-T1## at plant 1000 and press ENTER

3. Display the pegged requirements report for the first purchase req/planned order. Select the first purchase requisition or planned order, and select Pegged Requirements.

4. This report shows the origin of the requirement at the top of the order structure. 5. Select Order Route to see the trail of requirements as it blew through the bill

of material.

6. To see and order graphic chart, select Back, then select Graphic.

Advanced Functions of MRP and Stock/Requirements

List

Navigation profile

The navigation profile function is enhanced by the possibility of defining your own favorites. See notes : Changeability of Customizing Tables in the Production System and Authorization for Maintenance of Own Favorites, for maintaining favorites. Customizing: Production → Material Requirements Planning → Evaluation → Define Navigation Profiles

Over time Planners will find the stock requirements list invaluable due to the amount of information that it contains as it relates to supply and demand. However, planners are often put into a situation where others in the business will asked for data related to certain MRP elements. As of SAP ERP release 4.6, users can now filter and select which MRP elements can be viewed and used in the available quantity calculation.

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Figure 15: Display Filter and Selection Rule

Display filters are used in the Stock/Requirements list and in the MRP list. This is a display function, and display filters have no influence on the MRP elements that are used in the calculation of the available quantity. You define display filters in the Customizing IMG: Production → MRP → Evaluations → Filter → Define Display Filter . In the configuration of the display filter users can choose:

• which MRP elements are displayed

• of the MRP elements that you select, and that are procurement proposals (planned order, purchase requisitions, schedule lines), whether only the firmed elements are displayed

• which MRP segments are displayed

• which period (display horizon) is displayed You either directly define the display horizon or allow the user to make the setting in the respective transaction. • whether the MRP elements selected should be further limited using certain

additional selections (for example, customer, vendor, storage location) You either define these additional selections directly or allow the user to define them in the respective transaction

The filters can be accessed in either of the lists by selecting Filter On. This will allow users to choose the selection filter that fits the particular requirements. To turn the filter off users can select a “blank” filter with no limitations or select Filter off to remove the filter.

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Selection rules apply to the stock/requirements list only. You define which MRP elements are displayed and which of these elements are used in the calculation of the available quantity. Selection rules enable the analysis in the stock/requirements list of various planning situations that are different with regard to the MRP elements taken into account. Selection rules have no influence on the requirements calculation. You define these in the Customizing: IMG Production → MRP → Evaluations → Filter → Define Selection Rules.

In detail, you define

• which MRP elements are selected to set up the respective evaluation list and/or to calculate the quantity available and the ranges of coverage

– do not consider: the element is not displayed and is not used to calculate the quantity available and the ranges of coverage

– display: the element is displayed but is not used in the calculation – show affecting availability: the element is displayed and is used in the

calculation

• which stocks are used to calculate the stock available

• whether schedule lines in the display are replaced by the more current forecast delivery schedules or JIT delivery schedules

• whether dependent requirements and dependent reservations for bulk materials are displayed and, if necessary, also calculated

• which period (selection horizon) should be represented. You determine the selection horizon either directly or allow the user to make this setting in the respective transaction

You define whether selection rules and display filters are to be used when accessing the list. This is done by choosing the indicator “With filter” in the initial screen, or by choosing the “Filter on” icon in the list, or in the user-specific settings.

Due to its important content planners will use the List reports several times a day. Due to it’s frequency of use, as of SAP ERP release 4.6, the list reports can be customized by each user. Through users settings, planners will be able to add their own icon buttons to jump to the most well used transactions for certain types of materials.

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Figure 16: Navigation profile

Each user can be assigned a navigation profile. A navigation profile contains

transaction calls for transactions that can be called directly from the stock/requirements list or the MRP list. The transactions are either general, which means actions at the material level, or they refer to a particular MRP element (planned order, dependent requirement).

A navigation profile is defined in Customizing Production → MRP → Evaluations → Define navigation profiles, and the user is assigned to a profile in the user-specific settings on the General Settings tab page.

In a navigation profile, you can determine any number of transaction calls. However, the display in the list is limited to five general transaction calls and two transaction calls per MRP element. The system always displays the first five or first two transaction calls that are relevant for the context.

For each transaction call, you can preassign three parameters for the initial screen of the transaction. You can also connect the offering of a transaction to certain parameters from the material master, such as procurement type, material type, MRP group, and MRP type.

A function similar to the navigation profiles is available with the selection of personal favorites where you can also activate up to five general transaction calls. To do this, choose Environment - Own favorites. In addition, you can activate two favorites per MRP element as transaction calls. For this, choose the * button in the details for the MRP element.

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Caution: During the user-specific maintenance of own favorites in the stock/requirements list and MRP list, users may not have the corresponding authorization. However, also users who have generally no table maintenance authorization should be able to maintain these tables in the requirements planning.

Authorization group ’MCMD’ is assigned to the affected views. This authorization group refers to authorization object ’S_TABU_DIS’ and is, in general, assigned to the tables and views of the MRP Customizing. Therefore, users who have no general authorization for the table maintenance in MRP do not have this authorization group.

If it is required that also users who are not allowed to maintain the other tables should be able to maintain entries for their own favorites, a separate authorization group should be created for this and assigned to these users. In order to create the authorization group for the affected views proceed as follows:

1. With the ABAP Dictionary (Transaction SE11), call up the table maintenance generator for views V_U444B and V_U444C (Utilities -> Table maintenance generator).

2. Here, choose ’Environment -> Authorization -> Authorization groups’. 3. Create a new authorization group for authorization object

’S_TABU_DIS’ using ’New entries’.

4. Return to the previous screen and here replace entry ’MCMD’ by your new authorization group in field ’Authorization group’.

5. Save your change.

6. Assign this authorization group to the corresponding user profiles. See note 501318 - MD04: Authorization group for maintenance of own favorites, for more information.