SAP MM/WM Configuration Configuration Pack MRP Published by Team of SAP Consultants at SAPTOPJOBS SAPTOPJOBS Visit us at www.sap-topjobs.com
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INDEX 1.
INTRODUCTION:-
4
2.
MRP RELATED CONFIGURATION SETTINGS
5
2.1 2.1
................................ ...................... ...................... ...................... ............... .... 5 Defi Define ne Numbe umberr Ran Range ges s for for Plan Planni ning ng run run.....................
2. 2
Plant parameters ............................................................................................................... 12
2. 3
MRP Pl Plant Pa Parameter Number Number Ranges ................................................................... 15
2. 4
MRP Plant Parameters Backorder Backorder processing checking rule.......................... 18
2. 5
MRP Pl Plant Pa Parameter MRP MRP Controller.................................................................... 20
2. 6
MRP Pl Plant Pa Parameter Special Special Procurement Key ................................................ 25
2. 7
MRP Pl Plant Pa Parameter Float Float (Schedule Margin Key)........................................... 30
2. 8
MRP Pl Plant Pa Parameter Conversion Conversion ............................................................................ 33
2. 9
MRP Pl Plant Pa Parameter Dependant Dependant Availability check rule ............................... 36
2.10 2.10
MRPMRP-Pl Plan antt par param amet eter er BOM/routing BOM/routing selection ..................................................... 38
2. 11
MRP Plant Plant Parameter detailed detailed scheduling......................................................... 40
2.12 2.12
MRP MRP Pla Plant nt Para Parame mete terr Rescheduling Rescheduling........................................................................ 48
2.13 2.13
MRP MRP Pla Plant nt Para Parame mete terr Planning Planning horizon................................................................. 52
2.14 2.14
MRP MRP Pla Plant nt para parame mete terr Available Available stock .................................................................... 54
2.15 2.15
Define Define Numb Number er Ranges Ranges for for Manua Manuall Proce Processi ssing ng ....................................................... 56
3.
MRP GROUP
3. 1
Maintain MRP Group scheduling scheduling /doc.type ......................................................... 72
4.
MRP TYPE
75
5.
DEFINING PLANNING STRATEGY
80
5. 1
Requirement Class (PP) ................................................................................................... 84
5. 2
Requirement Type (PP).................................................................................................... 88
5.3 5.3
Requi Require reme ment nt Clas Class s (Sa (Sale les s and and Dist Distri ribu buti tion on)) ............................................................ 92
64
5. 4
Define St Strategy Gr Group..................................................................................................... 97
6.
DEFINING SCOPE OF PLANNING
100
7.
LOT LOT SIZI SIZING NG PROC PROCED EDUR URE E AND AND ROUN ROUNDI DING NG OFF OFF PROF PROFIL ILE E
104 104
8.
ACTIVATING MRP AND PLANNING FILE ENTRIES
110
9.
SU SUMMARY: -
113
1. Introduction:In this document we will learn more about Production Planning and MRP. So stay tuned. 1. Planning Related configuration The following three are the important planning methods in SAP: MRP Consumption based planning SOP & Flexible planning
Let us now try to understand MRP and Consumption Based Planning thoroughly. In this step of MRP & Consumption Based Planning we will have to configure the following related steps: ü Configuration of Plant parameter ü Configuration of MRP type ü Configuration of Planning Strategy ü Configuration of Requirement type ü Configuration of Requirement Class ü Configuration of Lot size procedure
2. MRP Related configuration settings 2.1 Define Number Ranges for Planning run
BACKGROUND This configuration setting enables to define the number Range interval for planned order, purchase requisition. Number range interval has to be defined for both planning run and for Manual process. MRP run will consider the number range interval for planning run and in turn it is assigned in the plant parameter. Manual number range interval will be used when creating the planned order or purchase requisition manually. This will help to assign the different number range series for different document type.
SCENARIO Define the number range interval. INSTRUCTION Follow the Menu Path: IMGà Productionà Material Requirement Planning à Number Ranges à Define Number Ranges for Planning run
Click
Click
in the Planned Orders row
Click
to add new number range interval
Note: this is to display the interval this is to change the current number status
Click
To add the new number range.
Leave the check box Ext in the right side blank to indicate this as internal number range. Then this can be referred in the MRP plant parameter to define this number range interval. Click
Click Click Click two times to reach the number range interval maintenance screen
Click
in the purch. requisitions row.
Repeat the above steps to create new number range interval.
Impact of this configuration in Master Data / Transaction Number range defined for planning process will appear to select in the MRP Plant parameter maintenance screen as shown below.
While creating the Planned through MRP run, the appropriate number will be assigned to the planned order.
2.2 Plant parameters BACKGROUND This configuration setting enables to configure the plant parameter for Materials Requirement Planning (MRP). MRP will ensure •
Availability of right material at right time.
•
Calculate the capacity requirements.
Following MRP related parameters must be configured to perform MRP. •
Frequency of planning,
•
How to explode the BOM,
•
Order type to be used when converting planned order
•
Planning horizon
•
Scheduling
Apart from above there are more parameters to be configured, which we shall discuss. When creating plant by copying from one plant, many plant parameters are copied, however it is required to maintain plant specific parameters. SCENARIO
Maintain MRP plant parameter for the plant IND6. INSTRUCTIONS Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parametersà carryout over all maintenance of plant parameters Click
Click Enter Plant IND6 Click
By default while copying from one plant, many values are copied. Status maintained indicates that the values are maintained and the status Initial denotes that no value is maintained. Let’s discuss the important tab screens one by one.
2.3 MRP Plant Parameter Number Ranges BACKGROUND This configuration enables to maintain number ranges for MRP related documents. MRP related document subject to number range are ü Planned order generated through MRP run ü Dependent Requirements ü Purchase Requisitions ü Simulated Requirements
SCENARIO Define number range for plant IND6 INSTRUCTIONS Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parametersà carryout over all maintenance of plant parameters Click Click Enter Plant IND6 Click
Click
Click to maintain number range for planned order created by MRP run.
Select the appropriate number range for planned order. Click two times to reach maintenance screen.
Over
all Plant parameter
Impact of this configuration in Master Data / Transaction
MRP generated planned orders will have numbers from number range 01.
2.4 MRP Plant Parameters Backorder processing checking rule BACKGROUND This configuration setting enables to define the checking rule for back order processing. Backorder processing is the process of allocating and deallocating the product from one customer to another and changing the delivery dates according to the availability. SCENARIO Define checking rule for backorder processing for plant IND6 INSTRUCTION Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parametersà carryout over all maintenance of plant parameters Click Click Enter Plant IND6 Click Click
Checking rule maintained for Back Order processing. No need to change. Click screen.
to reach Over all Plant parameter maintenance
Impact of this configuration in Master Data / Transaction While performing the backorder processing, checking rule BO will be used.
2.5 MRP Plant Parameter MRP Controller BACKGROUND This configuration setting enables to configure MRP controller specific to a plant. MRP controller will •
Material availability for production.
•
Confirm the purchase request generated by MRP run.
•
Schedule the production.
•
Initiate action for shortage items and avoid shortages.
SCENARIO Maintain MRP controller for the plant IND6. INSTRUCTIONS Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parameters à carryout over all maintenance of plant parameters Click Click Enter Plant IND6
Click Click
Click
To create the new MRP controller, Click
Update the Following fields Field Plant MRP controller MRP controller Name
Click Save
.
Description Enter the plant number. E.g. IND6 Enter the MRP controller. E.g. RMP Name of the MRP controller. E.g. Raw Mat. planner
Click three times to reach Over all Plant parameter maintenance screen.
Impact of this configuration in Master Data / Transaction MRP controller has to be maintained in the material master MRP1 view.
2.6 MRP Plant Parameter Special Procurement Key BACKGROUND This configuration setting enables to define the special procurement key. Special procurement key used to •
•
•
•
•
Transfer requirements from one plant to another plant. Make material issue from another plant Create the direct process order in another plant or in own plant Define the phantom item. I.e. item not exist physically but planning will be done. To calculate standard cost estimate in one plant referring the BOM and Task list data from another plant.
SCENARIO Define the special procurement key for plant IND6 INSTRUCTIONS Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parameters à carryout over all maintenance of plant parameters
Click Click Enter Plant IND6 Click Click
Click
To crate new entries follow the below steps. Click Update the Following fields Field Plant Special procurement type
Description Procurement Type
Special procurement
Description Enter the plant number. E.g. IND6 Enter the special 2 digit procurement type key, alpha numeric field. E.g. 40 Description of this key. E.g. procure from Plant 1100. Indicating what type of procurement, whether internal or external. Enter F to denote external procurement. Indicating what type of
Plant
Phantom item Direct production
Direct procurement
With drawn plant
Issuing Plant
Click Save
from
procurement it is. Whether produced in other plant, procured outside, stock transfer, sub-contracting. Enter value U for stock transfer Enter the plant from which the material is going to be stock transferred. E.g.1100 To indicate this is a phantom item. If the item is directly produced for superior item as a collective order. The item is not put into stock, directly consumed by higher level material. Indicates that the items is directly procured and consumed. Item will not be stocked, directly consumed to the order. alternate Controls whether the material can be procured as a component using withdrawal from an alternative plant. This means, the reservation occurs at an alternative plant if dependent requirements exist. If the check box of with drawn from alternate plant is selected, it is mandatory to mention issuing plant.
.
Click two times to reach the over all plant parameter maintenance screen.
Impact of this configuration in Master Data / Transaction When the material is to be stock transferred from another plant, maintain the special procurement key in MRP2 view of the material master. In this configuration example, if the special procurement key 40 is maintained, stock transfer PR will be generated indicating the supplying plant as 1100.
2.7 MRP Plant Parameter Float (Schedule Margin Key) BACKGROUND This configuration setting enables to define the float for production. It is used to schedule the production or process order. Float is the cushioning durations in days before and after the actual production date. It is also called as schedule margin key. Cushioning period covers the days •
Before production
•
After production
In order to take care of any unforeseen situation during manufacturing and to make the committed date of production safer, the extra days are defined here. These extra days defined here will be added in the start date of production and in the end date of production. SCENARIO Create schedule margin key for plant IND6 INSTRUCTIONS Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parameters à carryout over all maintenance of plant parameters
Click Click Enter Plant IND6 Click Click
Click
Update the Following fields Field Plant
Description Enter the plant number. E.g. IND6
SMK – Schedule Margin Key Opening Period
Float Before production
Float after production
Key identify the float periods. E.g. 555 Number of working days subtracted from the order start date to find the creation date. This is an extra time to MRP controller. It is used in backward scheduling only. Number of working days between the order start date and the scheduled start date; used as a float in production Scheduling. Number of working days used as a float for scheduling between the order due date and the scheduled finish date. The safety margin after production is used for compensating malfunctions within the order production.
Click Save
.
Click two times to reach the over all plant parameter maintenance screen.
Impact of this configuration in Master Data / Transaction Schedule Margin Key has to be maintained in the material master MRP1 view.
2.8 MRP Plant Parameter Conversion BACKGROUND This configuration setting enables to define the order types while converting the planned order in to process order or production order. Order type is a mandatory entry while creating the process order or production order. Order type controls the creation of order and responsible for entire production or process order processing. MRP run will create the planned order for the net required quantity after considering the stocks and receipts. Planned order will be converted to process order if it is produced inhouse or into the purchase request if it is procured from outside. SCENARIO Maintain the conversion parameter to convert planned order into the production order or into the process order. INSTRUCTIONS Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parameters à carryout over all maintenance of plant parameters Click Click
Enter Plant IND6 Click Click
Click
By default SAP standard production order type PP01 and process order type PI01 will appear. It can be changed to the required order types. - Maintain the production order type to convert planned order into production order
- Maintain process order type to convert planned order into process order. Click Save
.
Click till the over all plant parameter maintenance screen is reached.
Impact of this configuration in Master Data / Transaction When converting the planned order into production order or process order, order will be determined automatically by the system.
2.9 MRP Plant Parameter Dependant Availability check rule BACKGROUND This configuration setting enables to define the availability checking rule for dependant in MRP run. Combination of Availability check rule and availability check maintained in the material master, decides the type of stock availability checking to be performed for each item. SCENARIO Define checking rule for plant IND6 plant parameter. INSTRUCTION Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parameters à carryout over all maintenance of plant parameters Click Click Enter Plant IND6 Click Click
Maintain Checking Rule PP.
Impact of this configuration in Master Data / Transaction While performing the availability check in MRP for dependant requirements, system will take the checking rule PP.
2.10 MRP-Plant parameter BOM/routing selection BACKGROUND This configuration setting enables to define the BOM and Routing selection for MRP run. There may be more than one BOM and Routing. Selection right BOM and Routing can be defined in this configuration setting. It will be selected automatically during MRP run based on the selection id defined here. SCENARIO Define BOM and Routing selection for plant IND6 for MRP run. INSTRUCTION Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parameters à carryout over all maintenance of plant parameters Click Click Enter Plant IND6 Click Click
Selection id for BOM and Routing maintained. If required change it. Note:- Selection id for routing can be maintained in scheduling parameter also.
Impact of this configuration in Master Data / Transaction BOM and Routing with selection id 01 will be traced during the MRP run in the plan IND6.
2.11 MRP Plant Parameter detailed scheduling BACKGROUND This configuration setting enables to define the scheduling to be done during MRP run. Scheduling determines the production order or process order start date and end date, operation start date and end date. Routing / master recipe is the basis for scheduling. SCENARIO Define scheduling parameter for plant IND6 for MRP run. INSTRUCTION Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parameters à carryout over all maintenance of plant parameters Click Click Enter Plant IND6 Click Click
Standard entry maintained may be sufficient. Important parameter in this setting is discussed below. Select the first line by clicking the grey box in the left Click
Field Plant Order type
Description Enter the plant number. E.g. IND6 Production order type to hich this setting need to be
applicable. Enter * to make it applicable to all order type in IND6 plant. Production Scheduler Production scheduler to which this settings is applicable. Enter * to make it applicable to all production scheduler in IND6 plant. Scheduling Horizon The scheduling horizon is a time period that is in working days. If a planned order basic start date falls in this date, then lead time scheduling is carried out. Selection ID Selection criteria to select the routing. Enter selection id E.g. 01. Scheduling Ensure this tick mark as it will schedule the operation start and end date in planned order Generate Capacity Ensure this tick mark as it Requirements will calculate the capacity requirement using the routing. Type of scheduling. scheduling. Select Detailed scheduling. This is for
This is for
**
Determines how the basic dates / Dependent requirement dates are adjusted during the lead time scheduling and after the scheduling. In backward scheduling system adjust the basic start date.
This is for
Scheduling type
***
In forward scheduling system adjust the basic finish date. ..more explanation given below (**) You use this indicator to define how dependent requirements dates are to be readjusted when the basic dates in the planned order are adjusted. This is then used for dispatching the planned orders in the graphic planning table. ..more explanation given below (***) Type of scheduling. Whether Backward, forward or only capacity requirements. Select backward to automatically determine the start date. Leave the entries as it is.
** Adjust Dates:In backward scheduling the system adjusts the basic start date if necessary, in the case of forward scheduling the basic finish date. The basic finish date is not adjusted in planned orders. There are the following possibilities:
•
•
•
•
The basic dates are adjusted and the dependent requirements are scheduled for the start dates of the relevant operations. The basic dates are not adjusted and the dependent requirements are scheduled for the start dates of the relevant operations. The basic dates are adjusted and the dependent requirements are scheduled for the order basic start date. The basic dates are not adjusted and the dependent requirements are scheduled for the order basic start date.
How the system adjusts the basic start date in backward scheduling is described below. During scheduling, it starts at the basic finish date and redetermines the production dates and the basic start date. If the new basic start date differs from the old date in the order, the system copies the new basic start date to the order. If the new production start date is before the old basic start date in the order, the system reduces the lead time - if you have set reduction up- before it adjusts the basic start date. It tries to reduce the lead time sufficiently so that the production dates are within the old order basic dates. In the case of forward planning, the system correspondingly - apart from planned orders. *** Capacity Scheduling
procees
•
•
•
•
The basic dates are always adjusted and the dependent requirements dates of the components are always set to the start dates of the operations. The basic dates are always adjusted and the dependent requirements dates of the components are set to the order start date of the planned order. The basic dates are only adjusted if a delay occurs (for example, if the dates gave to be postponed meaning that the delivery date be adhered to), and the dependent requirements dates of the components are set to the start dates of the operations. The basic dates are only adjusted if a delay occurs and the dependent requirements dates of the components are set to the order start dates of the planned order.
When dispatching the planned order in the planning table, the order finish date is also adjusted. Click Save
.
Double click Maintain the similar settings to Long Term Planning for Plant, production scheduler and Scenario combination.
Note:- Please create your own planning scenario in LTP process and maintain that scenario here. Generic entry * may not be accepted in Scenario. Click Save
.
Click till the over all MRP plant parameter maintenance screen is reached.
Impact of this configuration in Master Data / Transaction Scheduling of planned order will be done according to the scheduling parameter defined here. Reading of master data routing and scheduling of operations will be done.
2.12 MRP Plant Parameter Rescheduling BACKGROUND This configuration setting enables to define the rescheduling. Rescheduling will be performed to the already scheduled orders during the subsequent MRP run Rescheduling is essential to adjust the production dates already determined according to the demand situation at the time of MRP run. SCENARIO Define Rescheduling parameter for Plant IND6 for MRP run. INSTRUCTION Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parameters à carryout over all maintenance of plant parameters Click Click Enter Plant IND6 Click Click
Update the Following fields Field Rescheduling Horizon
Description It is the total number of working days during which the procurement proposals are rescheduled. Starting from the end of the replenishment lead time (the system calculates the end of the replenishment lead time by the planning date + number of days for the replenishment lead time), in which the system checks in the net requirements calculation whether firmed or fixed receipt elements (purchase orders, production orders, firmed planned orders, and so on) should be rescheduled in. The rescheduling horizon is calculated in workdays. ..more explanation given
Tolerance value forward
Tolerance value backward
below The system compares this value with the number of days which results from calculating the difference between the requirements date and the delivery/order finish date. If the difference is greater than the comparison value, the system provides the receipt elements in question with an exception message and a rescheduling proposal that is based on the requirements date. The system compares this value with the number of days which results from calculating the difference between the delivery/order finish date and the requirements date. If the difference is greater than the comparison value, the system provides the receipt elements in question with an exception message and a rescheduling proposal that is based on the requirements date.
Use of rescheduling Horizon:-
In this period, rescheduling proposals are created by the system for firmed or fixed receipt elements if this receipt element can cover the requirement and if the tolerance values for rescheduling in have been exceeded. In this case, no new order proposal is created - instead the system includes this fixed receipt in the net requirements calculation with the rescheduled date. Firmed elements
List of elements can be considered for rescheduling. If it is to be considered tick the check box.
Impact of this configuration in Master Data / Transaction Rescheduling of order will be performed during MRP run according to the configuration settings maintained here.
2.13 MRP Plant Parameter Planning horizon BACKGROUND This configuration setting enables to define number of days to which the planning is to be performed, is called planning horizon. In other words, planning horizon is the duration in days to which the MRP run to consider the requirements. This will be calculated based on the maximum lead time required to procure components. SCENARIO Define the planning horizon to the plant IND6 for MRP run. INSTRUCTION Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parameters à carryout over all maintenance of plant parameters Click Click Enter Plant IND6 Click Click
Maintain the number of days in planning horizon column. Planning horizon is the number of working days to which planning is done. It can be equal to the longest lead time of any component or assembly required to make the final product.
Impact of this configuration in Master Data / Transaction During MRP run, planning will be done to the next 100 days requirements.
2.14 MRP Plant parameter Available stock BACKGROUND This configuration setting enables to define the available stocks to be considered during the MRP run. MRP run will consider the free stock and expected receipts by default. In addition, following stocks can be considered during MRP run. Stock in transfer Restricted stock Blocked stock SCENARIO Define the available stock for Plant IND6 for MRP run. INSTRUCTION Follow the Menu Path: IMGà Productionà Material Requirement Planning à Plant parameters à carryout over all maintenance of plant parameters Click Click Enter Plant IND6 Click
Click
Stock in transfer – tick the check box if that stock is to be considered during MRP Blocked stock – tick the check box if that stock is to be considered during MRP Restricted-use stock – tick the check box if that stock is to be considered during MRP Click Click
till the main IMG screen is reached.
Impact of this configuration in Master Data / Transaction During MRP run stock in transfer and restricted use stock will be considered in plant IND6.
2.15 Define Number Ranges for Manual Processing
BACKGROUND This configuration setting enables to define the number Range interval for planned order, purchase requisition. Number range interval has to be defined for both planning run and for Manual process. Manual number range interval will be used when creating the planned order or purchase requisition manually. This will help to assign the different number range series for different document type.
SCENARIO Define the number range interval for manual processing. INSTRUCTION Follow the Menu Path: IMGà Productionà Material Requirement Planning à Number Ranges à Define Number Ranges for Manual processing Click
Click intervals.
Click
in the Pld orders row to create new
to add new number range interval
Note: This is to display the interval This is to change the current number status
Click
To add the new number range.
Tick the check box Ext in the right side to indicate this as External number range. Then this can be referred in the Manual processing to define this number range interval. Click
Click Click Click two times to reach the number range interval maintenance screen
Click
in the Pld orders
Maintain the entry as explained below. Field name Object
Field description and value Object name to indicate whether planned order or purchase requisition. E.g. Enter 1 to indicate as Planned order. Order type Indicating the order type to which the planned order is to be referred. E.g. VP to indicate the planned orders of Planned Independent Requirements Internal number Range Number range to be referred when creating the planned order by automatic process. E.g. MRP run process. External Number range Number range to be referred when creating the planned order manually. Number range for reservation Maintain the number range
and dependent requirement
for reservations and the dependent requirements against this planned order type.
Click Click Click
two times in the purch. requisitions
Repeat the above steps to create new number range interval. Click
in the purch. Requisitions
Repeat the above steps to create new number range interval. Click
Impact of this configuration in Master Data / Transaction Number range defined for manual pocess will be selected automatically while manually creating the planned order or purchase requisitions.
3. MRP Group BACKGROUND This configuration setting enables to define the MRP group. MRP group contains essential master date related data and configuration related data mainly related to MRP run. Important data a MRP group contains are MRP Strategy Consumption mode Planning horizon Planning time intervals Conversion to order type MRP group will be assigned to a material master and the material master will perform as per the controls in the MRP group. SCENARIO Create MRP group and Maintain parameters for plant IND6. INSTRUCTIONS Follow the Menu Path: IMGà Productionà Material Requirement Planning à MRP Groupà carryout over all maintenance of MRP group
Click
Enter Plant E.g IND6 Click
Enter MRP group E.g.RMG1 Enter Description E.g. Raw material MRP group Click
Click Click
Click
Status indicates no detail inside the MRP group is maintained. Most of the details which are required to be maintained here are already discussed in previous MRP plant parameter maintenance topic.
Here the maintenance of value is only discussed. To maintain the value click the respective tab screen and enter the value as per the guide line given below in the table. Note: - maintenance of value screen will be similar to that of MRP plant parameter, hence not repeated here. Field Click (Master Data information)
Description Strategy in the material master will decide the type of planning to be performed to a material. Example: Strategy - 10 to plan without considering the Sales requirements. Strategy - 40 to plan with considering the sales requirements. Strategy - 11 to plan without considering the sales requirements and also without considering the existing stock. MRP Strategy value applicable to this MRP group. E.g. 40
Click and click is reached. Click
till MRP group maintenance main screen Planned Independent Requirement consumption mode. Whether backward or forward or combination of both. E.g. Enter 2 – Backward and
forward. Enter the number of days in backward and forward consumption period to consume from PIR. E.g. enter 31 days in backward and forward consumption period. Click and click is reached. Click (IMG related)
till MRP group maintenance main screen
Click and click is reached.
till MRP group maintenance main screen
Click (IMG information)
Discussed above in MRP plant parameter
Click and click is reached. Click (IMG information)
till MRP group maintenance main screen
Click and click is reached. Click (IMG information)
till MRP group maintenance main screen
Refer below * in the topic 3.1.
Discussed above in MRP plant parameter
Discussed above in MRP plant parameter
Click and click till MRP group maintenance main screen is reached. Max MRP interval (IMG Irrespective of MRP type information) master data and changes made to the system, MRP can be run for an item by this setting. E.g. Enter 90. So that once in 90 days MRP run will happen to this material irrespective of any other settings. Click and click is reached.
till MRP group maintenance main screen
MRP group once maintained will look like as shown below.
Impact of this configuration in Master Data / Transaction
MRP group RMG1 has to be maintained in material master of material type Raw Material to have the effect of this MRP group configuration setting.
3.1 Maintain MRP Group scheduling /doc.type
* Scheduling / Document type External procurement (IMG information) Background This configuration setting enables to define the document type for purchase requisition. Every purchase requisition will have a document type in SAP. Purchase requisition will requirements of materials.
be
generated
for
the
net
Standard SAP configuration refers the Purchase Requisition document type NB. It might be required to identify the different document type for different material. I.e. Document type ZNB for standard Raw material procurement and document type SCNB for subcontract material and TRNB for stock transfer material. This can be mapped through MRP group. SCENARIO It is required to have different PR document type for Regular material and stock transfer material. INSTRUCTIONS Follow the Menu Path: IMGà Productionà Material Requirement Planningà MRP Groupà carryout over all maintenance of MRP group Click
Enter Plant – E.g IND6 Click Enter MRP group E.g. RMG1 Click Click Update the Following fields Field Scheduling info record/agreement (Check box) (IMG related setting)
Description Determines whether the planned delivery time specified in the purchasing Info record is used for scheduling in the planning run. NOT TO TICK Standard purchase order Identifier allowing a distinction to be made between various kinds of purchase requisitions in the SAP system. E.g. Enter NB Document type for PR document type for SC PR. Subcontract E.g. Enter NB Document type for stock PR document type for Stock transfer transfer PR. E.g. Enter NB Note: - If it is required to create different document type of Purchase Requisition to the different processes, the respective document has to be mentioned here. In this example, only one document NB for all three processes is indicated.
Impact of this configuration in Master Data / Transaction When maintaining the MRP group RMG1 to the material, Purchase Request of appropriate type will be generated.
4. MRP type BACKGROUND This configuration setting enables to define the MRP type. MRP type determines the type of planning to be employed to a material. Important types of Planning are Material Requirement Planning (MRP) Consumption Based Planning Forecast based planning Parameter which are defined in the MRP types are • • • • • •
MRP procedure or MPS procedure Basis for planning Reorder point and consumption method Lot size procedure Forecast Not to plan the material at all
Above types of planning are governed through the MRP type. SCENARIO Create a MRP type ZD with forecast and to plan regularly. INSTRUCTIONS
Follow the Menu Path: IMGà Productionà Material Requirement Planningà Master dataà check MRP type Click
Click
Update the Following fields Field MRP Type
MRP Procedure
Description Key defining the MRP type. E.g. Enter ZD and maintain description as MRP +forecast & Regular plan SAP internally identified key to do the planning according
to the internal control. E.g. Enter D for MRP Firming type Confirming the order proposal. Leave it blank here. Roll forward To delete or not the old planned orders. Leave it blank Plan Regularly (Check box) Planning takes place only if any change happened to the material, other wise it is not planned, if this check box is ticked, material will be planned in every MRP irrespective of any changes happening to it. E.g. Tick this check box Forecast Indicator To consider the forecast requirement. E.g. Enter * to make it as optional forecast. Forecast requirement consideration become optional. Consumption Indicator Defines, which consumption forecast are relevant for forecast. E.g. Enter G to indicate Total consumption MRP indicator forecast To define whether the forecast requirements are to be considered in MRP. E.g. Enter G to consider total requirement in MRP run. Reduce forecast Indicates how the forecast requirements are to be reduced. E.g. Leave blank to reduce forecast value by consumption Safety stock (Check box) To calculate safety stock automatically, tick this check box. E.g. Leave it blank Reorder Point To calculate Reorder point
automatically, tick this check box. E.g. Leave it blank Click Save
.
Impact of this configuration in Master Data / Transaction Assign this MRP type ZD to the material master MRP1 view. This material will be planned regularly irrespective any changes happening to this material. If is required Forecast can be run and those forecast requirements will be considered in MRP.
5. Defining Planning Strategy BACKGROUND This configuration setting enables to define the planning strategy. Planning strategy decides how the planning is to be carried out. Whether to plan as ü Make to stock ü Make to Order ü Combination of above both ü Planning only the components of final products
Planning strategy also governs the consumption of ware house stock and independent requirements. It is the combination of Customer Independent requirement and Production Independent requirement. Planning strategy establishes relation between PP module and SD module to transfer the requirements. SCENARIO Most of the cases, it is sufficient to use the SAP standard Planning strategy. Detailed settings about planning strategy are discussed. INSTRUCTIONS
Follow the Menu Path: IMGà Productionà Production Planningà Demand managementà Planned Independent Requirements à Planning strategy à Define strategy Click
Click
(only to create new entries)
Let’s discuss the strategy number 40 Select the line 40 by clicking the grey box in the left Click
Update the Following fields Field Strategy Description Requirement type Independent requirement
Description Key identifying the Strategy. E.g. Enter 40 Description of Strategy. E.g planning with final assembly for It is the key referring to Requirement class. Certain
controls related to PP module are built with requirement class. E.g. VSF contains the Production requirement class 101. Requirement type of customer It is key referring to requirement requirement class. Certain control related to PP/SD module integration is built with this requirement class. E.g. KSV contains the customer requirement class 050. Click Click Save
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Impact of this configuration in Master Data / Transaction Planning strategy is assigned to the strategy group. Strategy group is maintained in the material master. Material will be planned according to the planning strategy. I.e. planning as per ü Make To Stock ü Make To Order ü Combination of Both above ü Planning only the components
5.1 Requirement Class (PP) BACKGROUND This configuration setting enables to define the requirement class. Requirement class defines •
Planning mode
•
Consumption of Planning
•
Requirements to be considered
There are two requirement classes defined. •
One for Independent Requirement class (PP Module)
•
Another for Customer Requirement class (SD Module)
Requirement class will be assigned to requirement type.
SCENARIO Most of the cases, it is sufficient to use the SAP standard Requirement class. A detailed setting about standard requirement class is discussed. INSTRUCTIONS Follow the Menu Path: IMGà Productionà Production Planningà Demand managementà Planned Independent
Requirementà Requirement Maintain Requirement classes
type/Requirement
classà
Click Click
(to create new entries)
Update the Following fields Field Requirement class Description
Planning Indicator PI
Consumption Indicator
Description Key identifying the requirement class. E.g. 101 Description of Requirement class. E.g. planning with final assembly Mode of planning for Independent requirement. To plan considering the stock (Net requirement) or to plan without considering the stock (Gross requirement) or Planning only components (Individual planning) E.g. 1 – Net requirement planning Indicates how the customer
requirement consumes the Planned Independent requirement. E.g. 1. Consume planning with final assembly. Planned Independent requirements are reduced along with the customer requirement. Configuration allowed Leave it blank Consumption of configuration Leave it blank Requirement reduction Leave it blank indicator Requirement Category To specify whether it is planned Independent requirement or customer independent requirement. E.g. 1. Planned Independent requirement Click Save
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Impact of this configuration in Master Data / Transaction This Independent requirement class (from PP module) has to be attached with Requirement type. Requirement type will be assigned with planning strategy. (Recollect the planning strategy configuration setting to have better understanding.) Below screen shot shows the planning strategy screen shot for your ready reference.
Requirement class 101 attached to the requirement type VSF. We have discussed the configuration of requirement class 101.
5.2 Requirement Type (PP) BACKGROUND This configuration setting enables to define the requirement type. Requirement type is the simple text entry configuration to map with the requirement class. Requirement type will be assigned to the planning strategy. SCENARIO Most of the cases, it is sufficient to use the SAP standard Requirement type. A detailed setting about standard requirement class is discussed. INSTRUCTIONS Follow the Menu Path: IMGà Productionà Production Planningà Demand managementà Planned Independent Requirementà Requirement type/Requirement classà Define requirement type and allocate requirement class. Click
Click
(only to create new entries)
Enter requirement type. Key to identify the requirement type. E.g. ZSF Description of requirement type Enter the Requirement class. E.g. enter the requirement class created already. 902
Note: - Above entry is shown for example. You have to assign your own requirement type with requirement class. Click Save
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Impact of this configuration in Master Data / Transaction This requirement will be mentioned in the planning strategy. Planning strategy screen shot is given below for your ready reference.
Requirement class VSF contains the Requirement type 101.
We have discussed the mapping of requirement type with requirement class in this configuration setting.
5.3 Requirement Class (Sales and Distribution) BACKGROUND This configuration setting enables to define the requirement class from Sales and Distribution (SD) module point of view. There are two requirement class defined. •
One for Independent Requirement class (PP Module)
•
Another for Customer Requirement class (SD Module)
This requirement class (from SD) defines •
•
Availability check Transfer requirement to production
•
MRP related
•
Configuration related to variant configuration
•
Costing related controls like costing method, costing variant etc
SCENARIO Most of the cases, it is sufficient to use the SAP standard Requirement class. A detailed setting about standard requirement class is discussed. INSTRUCTIONS
Follow the Menu Path: IMGà Sales and Distribution à Basic functionà Availability check and Transfer of requirementsà Transfer of requirementsà Define Requirement classes Click
Click
(only to create new entries)
Availability Check box confirms the Availability check Req.Transfer check box confirms that the requirements are transferred to PP module.
Allocation Indicator , specifies how the Planned Independent requirements are consumed. Similar to the production consumption indicator, maintain 1 consume with final assembly. No MRP selection box, leave it blank, then the requirements will be planned. Other option in this box is
Above explained settings are very important from PP and SD point of view for strategy 40. I.e. make to stock with final assembly.
Impact of this configuration in Master Data / Transaction This requirement class is linked with the Customer requirement type. Steps to create the link between this requirement class and Customer requirement type is same as explained. The combination of this requirement type and requirement class may have to be assigned to the planning strategy. Please refer “Define planning strategy screenshot” shown below for your ready reference.
We have discussed the important configuration settings related to requirement class 050 which will be assigned to the requirement type KSV.
5.4 Define Strategy Group BACKGROUND This configuration configuration setting enables to define define the strategy strategy group. Strategy group controls the type of planning to be performed to the material. Available type of planning are ü Make to stock ü Make to Order ü Combination of above both ü Planning only the components of final products
Planning strategy group will be assigned to the material master MRP3 view. SCENARIO Most of the cases, it is sufficient to use the SAP standard Planning strategy group. A detailed setting about planning strategy group is discussed. INSTRUCTIONS Follow the Menu Path: IMGà Production à Production Planningà Demand managementà Planned Independent Requirements à Planning strategy à Define strategy group. Click
Click
(only to create new entries)
Update the Following fields Field Strategy Group Description
Main Planning strategy
Description Key id identifying the strategy group class. E.g. 40 Description of strategy group. E.g. planning with final assembly Planning strategy key created. E.g. 40
Impact of this configuration in Master Data / Transaction Strategy group created (E.g. 40) has to be assigned in the material master. Planning will be performed considering both sales order and Independent requirement to that material.
6. Defining scope of planning BACKGROUND This configuration setting enables to define the scope of planning to a particular plant. Planning scope is used to run Material Requirement Planning in the background. Scope of planning defines the plant sequence at which MRP run is to be carried in each plant. This is more suitable when MRP run is to be scheduled covering more than one plant. SCENARIO Define scope of planning to run MRP in background covering plants IND6 and 9100. INSTRUCTIONS Follow the Menu Path: IMGà Productionà Material Requirement Planningà Planningà Define scope of Planning for Total Planning. Click
Click Update the Following fields Field Planning Scope Description
Description Key identifying the planning scope. E.g. IND Description of Planning scope
E.g MRP IND6 & 1100 Click
Select line INDA Double click
Click
Update the Following fields Field Cntr (counter number)
Description Serial Number. E.g. Enter 1
Plant
Plant number to which MRP has to run first. E.g. INDA
Repeat the above till all required plant entries are made according to the sequence.
Impact of this configuration in Master Data / Transaction While scheduling a background job or Running total MRP using transaction code MD01, scope of planning has to be mentioned. Press F4 in Scope of planning field to select the available entry.
MRP run will be carried out first in IND6 plant and then in 1100 plant.
7. Lot sizing procedure and rounding off profile BACKGROUND This configuration setting enables to define the lot sizing procedure. Lot sizing procedure helps to derive the requirement period and to cumulate the requirements. Material Requirement Planning calculates the requirement of right material at right time. It is required to cumulate the requirement together on weekly, monthly or biweekly etc. Lot sizing procedure helps to derive the requirement at the •
Beginning of the period
•
End of the period
•
Exact date on which it is required
•
Cumulate the requirements
•
Not to cumulate the requirements
SCENARIO Define the lot size procedure to cumulate the requirement monthly and to get the requirement date as beginning of the month. 25 days should be treated as one month.
INSTRUCTIONS Follow the Menu Path: IMGà Productionà Material Requirement Planningà Planningà Lot size calculation à Check lot sizing procedure Click
Click
Click Update the Following fields Field Lot size Description
Lot size procedure
Number of Period
Description Key identifying the Lot size. E.g. ZB Description of Lot size E.g. 25 Days Lot size Del.date = Req date Defining the lot sizing procedure as periodic lot size. E.g. Enter P The requirements from this number of periods are grouped together into
Lot size Indicator
Scheduling
one lot size. E.g. Enter 25 to indicate to group the requirement of 25 days. Determines how the lot size is calculated for a certain lotsizing procedure during material requirements planning. E.g. Enter M to indicate Monthly. Specifying the delivery date with respect to requirement date. E.g. Leave blank to mention the delivery date to be calculated as the date on which it is required. If you enter 1 – the delivery date will be mentioned as the beginning of the period always irrespective of the requirement day.
Note: - Lot size for the long time period is to be used for period after the short term period. E.g. In this case, after 25 days it is treated as long term period. If it is required to cumulate the requirements differently after 25 days, maintain the settings in long term period area.
Click Save
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Impact of this configuration in Master Data / Transaction Lot sizing procedure has to be maintained in the material master MRP1 view.
Requirement date and the grouping of requirements will be performed according to the configuration setting maintained here.
8. Activating MRP and Planning file entries BACKGROUND This configuration setting enables to activate or deactivate the MRP single item multilevel. MRP single item multi level is used to run MRP for a specific material at any given point of time. Single item multi level MRP run can be done to check the planning result of a specific material after changing the plan. Planning file is the internal file in SAP. Items which undergo any change will be maintained in the planning file internally by the system automatically. Items maintained in the planning file will be considered in the next net change MRP run. SCENARIO Activate MRP in the Plant IND6. INSTRUCTIONS Follow the Menu Path: IMGà Productionà Material Requirement Planningà Planning file entriesà Activate MRP and setup planning file entries Click
Click Update the Following fields Field Plant
Description Select the Plant from the display. E.g. IND6 Requirement Check box to be ticked to activate single item multilevel MRP run. E.g. Ensure the check box is ticked.
Activate Planning
Click Save
.
Impact of this configuration in Master Data / Transaction Transaction codes MD01 and MD02 can be performed only with this configuration setting.
Error message will be generated if this is not configured.
