MATERIAL PLANNING
Stock Final Good
3000
Plant
Activity
3000
2
Production plan (based on sales plan) can
be created several ways:
= to sales plan, target stock level, days
supply, inventory to zero, manually)
Feasibility estimates
Sales Info
Syst
SOP
Product
Group
Sales & Operation
Planning
Product
Group
Is a Product family.
It groups together
products with similar
plann. charact.
Mat.
B1
Mat.
B2
P.Groups require a
proportion factor. A higher
level is disaggregated to a
lower level
Disaggregation
Mat.
A2
Prod.
Group B
MRP TYPES (how materials should be planned)
MRP
NO PLANING
CONSUMPTION BASED:
_Based on historical rates of consumption (past cons)
_Appropriate for low value mat (b,c parts)
_No ref. to master plan (not triggered by ind. req)
_Net req. cons. is triggered when:
*stock levels fall below a reorder point (safety stock) or
*by forecast req. (from past cons. data).
_Appropriate for mat. with demand consistent
_Ind-Dep. Req and sales order don’t affect them.
MD04: Stock/Req.list: info current status of stocks
MRP list: info latest plann run
Controlling
Profitable
Analisys
Activity
Types
Multilevel Backward Scheduling
The system calculates the start dates based on
a end date.
MRP RUN
Planning run can be done in 2 levels:
1. Total planning (planning of all materials of
one or several plants.(online or in the background).
2. Single-item planning:
2.1. Multilevel. Planning of all BOM’s materials
2.2 Single-level. Planning of a specific material
2.2 Interactive. Interactive single-level planning
Disaggregation
and transfer to
Demand
Management
MPS
(Admin of Ind Req.)
MRP
Material Requirements Planning
Not normally part of MRP because MRP doesn’t consider
capacities unless scheduling parameter is set in MRP.
Who does the work?
Cost
Center
Stock + fixed receipts that exists (PR, PO,Pln.O, PrO)
VS
Safety Stock + Requirements (Pln Ind. Req, Sales O)
= quantity available for planning.
The purpose of MPS (Master Prod. Sched) and MRP (Material Req.
Planning) is to guarantee material availability on a 2 step planning process
Work
Center
Routing
Control parameters for MRP
Processing key
Create Purchase Requisit (mat. procured ext.)
Create Schedules lines (bis)
Create MRP list (always, never, only except.
Planning mode (if existing data simply be
adjusted, whether BOM and routings should be
re-exploded or whether the plann. Should be
started from the beginning again.
E
(inhouse production)
Header
+ Items
To create a Sales or Prod.
Plan at one level we must
disaggregate.
For ex. disaggregate the sales
plans of all the product groups
down to the materials, and
develop production plans at
that level.
The plan that is sent to
demand manag. is used to
manage the Ind. Req.
Sales Order
(Created in SD)
= Customer
Ind. Req.
PLANNING STRATEGY controlls the diff. mode of action of
Planned Ind. Req.
MAKE TO STOCK PROD: Plan consump. are forecast,
then procur. and prod. takes place without Sales Orders.
Requirements covered by warehouse stock (=>shorter
delivery time).
SUBASSEMBLY PLANNING: M.to.Stock Prod for
assemblies. The finished products are not produced to
stock, rather the necessary assemblies are procured.
MAKE TO ORDER PROD: products are procured and
produce once a Sales Order arrives.
STRATEGY 40 – Planning with
Final Asembly =>fast reaction to customer demand
Proc. and Prod. of all comp. and assemblies is triggered by
Plnnd. Ind. Req. in Demand Mgt before a Sales Order arrives.
Incoming Sales Orders consume these Plnnd. Ind. Req.
If Sales Ord. exceed Pl. Ind. Req, a new Plnnd Order for the
unplanned quantity is trigger for the next MRP run (thus Sales
Ord. affect requirements).
CONSUMPTION
Determines the direction on the time axis in which the arriving sales orders
are to consume the Plnnd. Ind. Req.
M1. BACKWARD CONS: the Sales Ord. consumes Pln. Ind.
Req. that lie before this sale.
M3. FORWARD CONS: the Sales Ord. consumes Pln. Ind.
Req. that lie after this sale.
M2. BACK/FORW CONS: uses both.
By default Backwards consumption. The mode and the periods
can be defined in the Material master or in each MRP group.
MRP is set of techniques that uses BOM data,
inventory data, and the MPS to calculate
requir. for materials. Time-phased MRP begins
with the items listed on the MPS and determines
1. The quantity of all components and mat.
required to fabricate those items and
2. the date that the components and material
are required.
Time-phased MRP is accomplished by
exploding the BOM, adjusting for inventory
quant, and offsetting the net requirements
(MPS) - Master production scheduling is a
form of MRP that concentrates planning on the
parts or products that have the great influence
on company profits or which dominate the entire
production process by taking critical resources.
These items are marked as ‘A’ parts (MPS
items) and are planned with extra attention.
These items are selected for a separate MPS
run that takes place before the MRP run. The
MPS run is conducted without a BOM explosion
so that the MRP controller can ensure that the
Master schedule items (MSI) are correctly
planned before the detailed MRP run takes
place.
MPS operates within only one level of the BOM,
While MRP can be utilized throughout all levels
of a material’s BOM.
(required for planning run)
1. Processing key
2. Create Purchase Req.
3. Schedule lines
4. Create MRP list
5. Planning mode
Items
Items
Costs debited
to Prod.Order
C.O.T
Items
Goods
Issue
Schedule
Lines
MM
Only in the opening period
1
OP
Planned
Orders
Purchase
Order
Goods
Receipt
Production Order
OP
FI
CO
2
Mvt 101
F
(Externally procured)
Purchase
Requisition
FI
Variances
settled
Release
Planned Orders
contain the list the sequence of steps
for producing a material:
Operations,
Operation Sequences
Usage
Time elements
Work Centers.
Component allocations
MRP Control Parameters
Scope of the Planning Run
Processing key field specify the type of planning:
NEUPL: Regenerative planning (plann of all MRP
relevant materials). (first time, errors)
NETCH: Net change for total horizon (plann all
mat. we made changes).
NETPL: Net change for planning horizon
Items
Manual Forecast
Forcasting = Warehouse Req.
= Planned Ind. Req.
Product
Group 1
Mat.
A1
CO-PA
BOM
1
SOP: planning and forecasting module with the
logistic area. It provides a method for :
Sales plan: (data from the SIS, data from
CO-PA, from past sales to forecast future
sales, from another P.group, or manually)
Material
Assembly painting
Areas of
engineering
responsibilities
Item Category:
Stock
Non Stock
Variable size
Documents Bill Of Material
Text
Class
Intra material
MRP Net Requirements calculation
Is executed in the planning run to determine if there is
a shortage for a certain material.
Stock Raw
3000
1
2
Material type:
Raw materials
Operating supplies
Semi-finished products
Finished products
controls:
Business process .
Views (Screens)
Department-specific data
Material # assignment
Procurement types
GL- general ledger accounts
Prod.
Group A
Raw
Consum
3000
Use to derive a future demand program from the demand figures in the past
CO