So
get preparation for the SAP PP job interview
1 Can we create Production order without bom and routing?
2 what is the difference between PP and PP-PI?Which one is better and how?
3 If there are some errors in goods movements, and less stock of material consumed, how
can i solve that problem in SAP?
4 If there are some errors in goods movements, and less stock of material consumed, how
can we solve that problem in SAP?
5 Explain why their is need of production version?
6 Explain what is the meaning of exploding a BOM?
7 What are all the different manufacturing scenarios in pp?
8 in sap system, how to get production order record! example: i want to know who lock
my production order!
9 What is the need of pp in sap, what is the flow diagram of sap pp
10 In which context do you use bills of material? [ ] Material Requirements Planning [ ]
Execute Production [ ] Goods Movements (to Help Data Entry) [ ] Product Costing [ ]
Development/Engineering/Design [ ] Documentation [ ] Others?
11 Do you have different BOMs for a material in different plants?
12 What structure do your BOMs have? How many levels are there?How many
components are there on each level?
13 Which BOM maintenance functions do you require (copy functions, mass changes,
and so on)?
14 Do you have products with a large number of variants? Do you need Variant
Configuration?
15 Do you have several alternative BOMs for a material, depending on the manufacturing
procedure or lot size, for example (multiple BOM)?
16 What we will do after the marking andreleasing of standard price in product costing?
17 Tell me the planning steps for 100 products?
18 What is the difference between stock transfer order and stock transport order?
19 What are the costing parameter?
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
Caution: more than one answer may be correct.
Please mark ALL correct answers.
Question:
The following control parameters can be set in a long-term planning scenario :
A
B
C
D
E
Planning period
Opening stock
Strategy group
MRP type
Version of available capacity
Question:
What is the name of the planning level for the MRP run?
A.
B.
C.
D.
SOP
MP
MRP
COPA
Question:
What are the main features of the MRP types 'PD' or 'VB'?
A.
B.
C.
D.
Question:
What is the meaning of the planning time fence?
A. It determines the planning period for the planning run
B. It determines the period in which the planned orders are to be converted into
production orders
C. It determines the period in which no automatic changes are to be made to the
production plan
Question:
In forecast-based planning, which forecast model does SAP support?
A.
B.
C.
D.
dynamic model
seasonal trend model
split trend model
Consumption model
Question:
What conditions must be fulfilled in Customizing if a production order is to be
checked for availability?
A.
B.
C.
D.
E.
Scope of check
Checking group
checking rule
Checking assignment
Inspection period
Q) Can any body explain me why work scheduling view is required for semi
finished and finished products? (Because we'll mention all details in MRP views)
A) We need to maintain working scheduling view in order to make that finished or semi
finished goods available for production as we assign production scheduler and
production scheduler profile in this view, if not maintained conversion of planned order
to production will not be possible.
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
1. Following are valid BOM categories
a) Inspection BOM
b) Material BOM
c) Equipment BOM
d) Costing BOM
Ans : b, c, d
2. Material BOM that is created without plant is called______________
a) Reference BOM
b) Master BOM
c) Group BOM
d) Master group
Ans: c
3. If a Header Material is used as a BOM item in the same BOM the BOM is referred as
___
a) Repetitive BOM
b) Alternative BOM
c) Multiple BOM
d) Flexible BOM
e) Recursive BOM
Ans:
4. Alternative BOMs are grouped under one internal number and are called__________
a) Multiple BOM
b) Variant BOM
c) Variable BOM
d) Super BOM
e) Header BOM
Ans:
5. BOM can be used for the following
a) MRP
b) Costing
c) Inspection data
d) Sales & Distribution
Ans: a, b, c, d
6. The base quantity in the BOM specifies
a) To which amount of the semi finished product the item quantities refer
b) To which amount the item quantities required for two or more finished products
c) To which amount of the finished product the item quantities refer
d) To which amount the item quantities are not calculated.
Ans: a, b, c
7. Work Center is used in
a) Routing
b) BOM
c) Material Master
d) Inspection Plans
Ans: a, d
8. Routing contains information on the following
a) Material Components
b) Operations
c) Capacity for Work Centers
d) Inspection Characteristics
Ans: a, b, c
9. Alternative sequences in routing are created with reference to
a) Parallel Sequence
b) Master Sequence
c) Standard Sequence
d) Reference Sequence
Ans:
10. Work Center requires formulas for the following
a) Move time
b) Scheduling
c) Capacity requirements
d) Cost estimate using activities
Ans:
11. Routings are identified by ____________________
a) Routing Group
b) Routing Status
c) Group Counter Values
d) Routing Group and Group Counter Values
e) Status and use
Ans:
12. You can assign work center to only one cost center in a time period.
a) True
b) False
Ans:
13. Production Planning Module is integrated with the following modules.
a) Material Management
b) Controlling
c) Quality Management
d) Sales & Distribution
Ans: a, b, c, d
14. Movement Type for Goods Receipt in to Ware House
a) 122 b) 123 c) 101 d) 102
Ans: c
15. Movement Type for Transfer Posting to storage location
When you convert Planned order to Production order. the planned order are offset by
production order. Reference of planned order can be seen in the production order.
How to attach a drawing for a material to BOM? Is it possible?
Yes, you can attach a drawing.
First create a document using Transaction Code "CV01N - Create Document".
Attach your drawing in that document.
The system will generate a document number. Assign this document in the BOM with
item category D.
Report in Long Term Planning - You use long term planning for your customers,
what they need are very simple, just to calculate future requirements for 1 or 2
years.
Are there any reports in SAP to list of material requirement from LTP?
You need a list of material requirement from long term planning result for each
item.
Use MS70 then use MCEC.
Scheduling planned order - How can you get planned orders scheduled so that you
can do capacity leveling?
MD11 and then Schedule works fine but ideally you would want the the planned
order scheduled automatically on creation? You have tried setting up an action to
schedule the orders but cannot get that to work either.
When running MRP, try selecting "2" in the scheduling box this will bring planned orders
into CM01 and CM21
Capacity planning CM01 - When you run capacity planning T-code: CM01, you
found the plan orders are not included in the pegged requirement, you checked the
profile, the check box for order and plan order are all actived.
Guess that planned orders have been created without capacity requirement indicator in
MRP ("2" - Lead Time scheduling), if this is the case, then when converted to process
orders they will have impact on the Resource. If you want to see them as planned orders,
re-run the MRP or change in every planned order, going to the Menu: Edit -->
Scheduling
Another couple of possibilities are to do with the routing/work centres used and whether
it isactually calculates consumption of capacity of the category at the work centre being
displayed in CM01 (it might consume a capacity pool or it might not consume the
category).
MPS in Backgound/Online - You want to run MPS for a plant either online or in the
background, but you do not get any results. If you run MPS for a single
material/plant, then everything is 100% OK.
You need to run a planning file and a consistency check first, transaction OMDO and
MDRE respectively you'll need to set up two jobs to do it but it is straight forward, once
you've done this set up the background job for MPS to run and do it in NEUPL first time
round and then change to NETCH after that.
What is the output of MPS run?
From MPS run you plan the materials which are of 'A' type in the abc analysis (80%
dollar value) that have to be planned before hand.
MPS is also a type of MRP only in which components just below the materials on which
MPS run is taken place, are planned.
Table for production order status - What is the table for finding status (for Ex
TECO ed prodn orders). We are not able to find from AFKO and AFRU tables the
status of production orders or at least the link tables if known can be mentionned.
You are unable to link the structure caufvd and IOHEADER WITH AFKO and
AFRU.
JEST is the table.
Data dictonary table for SOP planning data - You are using Standard SOP (Info
structure S076), in which table can you see the planning values that you maintained
in MC93 transaction?
You looked under table "S076" and did not see any values there.
Use T.Code MC95 to display your entries under the version which maintained the the
table S076.
Production order operation's component allocation - How does SAP know that an
operation has components as indicated by the component allocation indicator?
Tcode CO08.
Component allocation is done via routing maintenance or BOM maintenance for the
assembly. This is master data maintenance. As soon as a PO is created, the master data is
read into the PO.
How to delete groups of products?
How to delete a group of products that was created in screen MC84?
Delete the members in the product group and then archive the product group in
transaction SARA, object=MM_MATNR.
(The product group is created as a material master record with material type PROD and
this record is deleted in SARA.)
+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
1. Which is the highest organisational level in SAP
a) Plant b) Client c) Storage Location
Ans: b
2. For Material Master record PP Data which is the highest organisational level
a) Plant b) Client c) Storage Location
Ans: a
3. What is the difference between F1 Help & F4 Help.
a) F1 is for possible values and F4 is for application help
b) F1 is for Application Help and F4 is for Technical Help
c) F1 is for Field Help and F4 is for possible entries.
d) None of the above
Ans: c
4. Variant Configuration is typically used in
a) Make to stock Environment
b) Make to Order Environment
c) Spare parts Sale
d) Repetitive Manufacturing Environment
Ans: a
5. Configurable Material check for a material is set in _____________
a) Basic Data b) MRP View
c) Sales View d) Classification
Ans:
6. Basic Data screen contains general data such as
a) Material Number
b) Material description
d) None of above
e) All of above
Ans: b
12. A _____________________________ is a complete, formally structured list of the
components that make up a product or assembly.
Ans:
13. Component in the BOM are allocated to operation in
a) BOM
b) Material Master
c) Routing
d) Work Center
Ans: c
14. BOM contains the following
a) List of Components
b) Qty of Components
c) Operation to which components is attached.
d) Unit of Measure of components
Ans: a, b, d
15. BOMs are always created as
a) Single Level
b) Multi Level
c) Components
d) Along with routings
Ans: a
+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
1. A plant can be a physical plant or a logical section of a plant
a) Yes b) No.
Ans: a
Storage locations are areas where materials are stored within a plant
a) Yes b) No.
Ans: a
A purchasing organization can buy for a number of plants
a) Yes b) No.
Ans: a
A purchasing group is a sub-set of a purchasing organization
a) Yes b) No.
Ans: a
2. Strategy Group is relevant for Material Requirement Planning
a) True b) False
Ans: a
3. MRP can be caried out at :
a) Plant Level
b) All Routings
c) Single item single level
d) Single item multiple level
Ans: a, c, d
4. In Material Requirement Planning
a) Material availability is ensured
b) If shortage exists the corresponding elements are planned
c) Stock transfers are also possible
d) The availability of the components is ensured via dependent requirements
Ans: d
5. With Make to Stock strategy 10
a) MRP run considers only Sales Orders
b) MRP run considers only PIR
b) False
Ans: b
No ATP quantities, receipts or stocks are included
a) True
b) False
Ans: b
Determines if sufficient PIRs are planned to cover a SO
a) True
b) False
Ans: b
9. Consumption based planning is usually used for following materials
a) All A & B Class Materials
b) Materials with smooth consumption pattern.
Ans: b
10. For Planning at Phantom Assembly Level planned orders are created for
Phantom assembly
a) True
b) False
Ans: b
11. Stock Requirements List gives ___________________ situation of stock
requirement for the material
a) Static : of the last MRP Run
b) Dynamic : Existing at current situation
Ans: b
12. Is Sales order A Qty. 15 PC and Sales order B Qty. 25 PC are booked on same
date and stock is 0 PC
a) Separate Planned Order for each Sales Order shall be created if individual indicator is
set
b) Only one planned order is created if individual indicator is set
c) Separate Planned Order for each Sales Order shall be created if Collective indicator is
set
d) Only one planned order is created if Collective indicator is set
Ans: a, d
13. Planning can create the following after MRP run
a) Planned Orders
b) Production Orders
c) Purchase Orders
d) Schedule Lines
Ans: a, b
14. NETCH is
a) Used in Demand Management
b) Key to run MRP for Total horizon
c) Key to run MRP for Total Planning horizon
d) Not related to MRP
Ans: c
10) Perform Goods receipt for the prod order. It will go to Special stock i.e Sale order
Stock.
11) Perform delivery for the Sale order and PGI
12) Create Invoice
++++++++++++++++++++++++++++++++++++++++++++++++++++
4. Assigning of Cost center to work center. Assigning Activity type to work center,
Standard Cost estimate, Costing Run, Order settlement, Product costing. *-- Chandan
Majumdar
---
1. Can MRP be carried out for one particular level of a bom ( Level code : 0001/0002
etc).
Yes it can be done by running for specific materials (Single Material Single Level)
2 How Requiements( PIR,Sles Order, Customer Requirement) are reduced after
they are produced?
Reqmts are reduced automatically after Delivery is made to the Particular Order
(In case of Strategy 11, the PIRs are consumed after the GR for Production Order)
3. Can't one material be assigned to more than one operation in a routing?
One material from a BOM CANNOT be assigned to different Operations.
It can be done by defining the material for so many times as required in the BOM
4. How to insert an inspection checkpoint at the end of an operation?
If in process sample is to be defined, assign inspection type 03 in the Material Master.
Then create MICs and assign them in the Routings.
System automatically generates the Inspection Lots
5. Where we have to specify the teardown time in one operation?
Teardown time can be defined as one of the Standard Parameters...
6. How the process time is calculated in a WC when both labour, Machine categories
exist?
Scheduling is done based on the Capacity Category we define in the Workcenter
7. How to create opbject dependencies in a BOM FOR A CONFIGURABLE
MATERIAL?
Go to Extras -> Object Dependency -> Assign
For this U need to create Characteristics and Class (of Class Type 300) earlier
8. Can any body explain me why work scheduling view is required for semi finished
and finished products?
(Because we'll mention all details in MRP views)
A) We need to maintain working scheduling view in order to make that finished or semi
finished goods available for
production as we assign production scheduler and production scheduler profile in this
view, if not maintained
conversion of planned order to production will not be possible
+++++++++++++++++++++++++++++++++++++++++++++++++++++++++
1. What are Traffic Lights in MRP?
red = the stock is not available
yellow - the stock is in average level stock
any disruptions so that there is no danger that the planned finish date will be exceeded.
You plan the float after production between order finish date (planned finish date) and
scheduled end (target finish date).
Release period
The release period represents the number of workdays that are subtracted from the order
start date in order to determine the production order release. The release period is only
relevant for production order management.
7. What is opening period?
Opening period
The opening period represents the number of workdays that are subtracted from the order
start date in order to determine the order creation date. This time is used by the MRP
controller as a float for converting planned orders into purchase requisitions or into
production orders.
8. What is SLA ? Service Level Agreements
Service Level Agreements (SLA) define the attributes for service products (for example,
maintenance, Hotline) that have been agreed upon with the customer in service contracts.
The SLA confirms different parameters, such as response time, availability time and
system availability.
9. What are Basic Dates?
Earliest date for the execution of the production order. This date takes into account the
float before production.
If, on order creation, a planned order exists for the production order or process order, then
the order dates are taken from the planned order. When scheduling the production order
the system tries to adhere to the order dates (if necessary, with reduction measures).
If it is not possible to adhere to the basic dates and if the control parameter in
Customizing allows the basic dates to be adjusted, the system adjusts the basic dates of
the order during the scheduling run.
If the control parameter in Customizing does not allow the basic dates to be adjusted, the
order keeps the basic dates of the planned order.
If the production order is created manually, you must enter at least one order date
manually.
The scheduling type determines, which order dates you must enter.
10. What is planning time fence?
The planning time fence specifies a period within which no automatic changes are to be
made to the master plan.
The planning time fence is maintained in workdays.
11. What is Planning Horizon?
In this step, you define the planning horizon. This planning horizon specifies the period
for the "Net change planning in the planning horizon".
In this kind of net change planning, only those materials that have undergone a change
that is relevant to MRP within the planning horizon are included in the planning run.
Such materials receive a net change planning indicator in the planning file.
You make this specification for a plant. You can define an alternative planning horizon
for MRP groups
12. What is Group BOM?
Alphanumeric character string used to uniquely identify a BOM.
Use
If you assign a "meaningful" number to a BOM group, this gives you an additional way
of accessing the BOM.
The system stores the following under a BOM group:
all the alternatives in a multiple BOM
all the BOMs entered for a variant BOM
13. What is costing? How it is affected the PP?
Determining the material costs of a product.
When you calculate production costs using a quantity structure, the system automatically
determines the BOM and all the BOM items that are relevant to costing, in order to
calculate manufacturing costs.
14. What is Meaning of Customized Reports?
The report which is not using SAP standard reports.
15. In Project the Customization is comes under Which Phase?
Realization.
16. How you get the Ticket?
After release order,the reservation will provide the ticke to pick production material.
17. What are GAPS? Some Examples?
The GAPS are some issue in blue print that SAP cannot capture or prividing the client
bussiness process.
18. What is LSMW?
The LSM Workbench is an SAP System tool that supports you when copying data from
non-SAP.
systems.
19. After Doing Realization How we will check whether it is working or not?
Doing Final preparation to check using the test case from user.
20. What do we do in Realization Phase?
Provide ARICEF, Configuration Documents, integration test, BPP, UAT, Unit Test and
implements some SAP notes.
21. How to Move to the Realization Phase?
You must have some blueprints to go in next phase.
22. In LSMW which is most important Step?
Maintain Object Attributes
Maintain Source Structures
Maintain Source Fields
Maintain Structure Relations
Maintain Field Mapping and Conversion Rules
Maintain Fixed Values, Translations, User-Defined Routines
+++++++++++++++++++++++++++++++++++++++++++++++++++++++++
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
- Reorder planning
- Forecast based planning
- Time phased planning
Details of re-order planning
Our motive is to maintain optimum stock level of all the material included in the resource
planning. so in this user or system sets a particular quantity of stock as reorder point .
Whenever stock quantity fall below this point(reorder point) mrp comes into action and
generates procurement proposals according to the settings done in implementation guide
MRP run procedure
1. Create requirement or demand in MD61
2. MRP run by MD02 for a single material
3. See the result in stock requirement list in MD04.
MRP run we can carry out by
1. MD02 - single item multi level
2 .MD03 - single item single level
3 .MD01 - Total planning
4. MD04 Check MRP
5. MD05 MRP lists
For PP, you require following Master Data
1. Material master (MM01)
Tips: Create same Material Code in Different Company Codes
2. BOM (CS01)
3. Routing (CA01)
4. Work Center (CR01)
5. CK11N / CK40N - Cost Estimate
Production Cycle: 1. PIR (Planned Independent Reqmt. - MD61)
2. MD02 - MRP Run
3. MD04 - Stock Requirement List
Tips: MD04 - Inconsistencies after PGI - SDRQCR21
4. CO40 - Convert Planned Orders to Production Order OR CO01 - Create Production
Order
5. Here in Production Order - Schedule Order, Release order
6. MIGO / MB1A - Goods Issue against Order (Mvmt Type 261)
7. CO11N - Production Operation confirmation
Tips: Add An Entry Field In CO11n
8. MIGO / MB31 - GR against Prd order
then re-schedule the next order to the next available capacity, then the next order searches
for available capacity, and so on. This is called "Finite Scheduling". The problem with
this is the opposite of Infinite Planning, which is it doesn't take Material availablity into
consideration! The system will re-schedule a production order without thinking about
whether the materials will be available or not.
Finite Planning does Finite Sheduling at the same time. If there is no capacity available
on the desired date, the system looks for when capacity IS available. Then it stops to see
if Materials will also be available (usually based on the lead-time for those components).
If there is a material problem, then the system figures out when the materials WILL be
available, and then
checks to see if capacity is available on THAT day, and if so, it blocks off capacity, and
allocates the materials for that day
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
Assignment of the factory calendar by plant is done in transaction code 'SM30 V_T001W'.
An example of a SAP application that uses the factory calendar is the SAP MRP modules.
Assuming that you have a specified an alternate working Saturday, MRP will postponed
the planned orders to the next working day if it happened to falls on a non-working
Saturday
+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
In the case of your conflict where you produce OR source the item, then you MAY have a
problem with GR - look at both scenarios and see what your entry should be. You CAN
use the Total Replenishment Leadtime (MARC-WZEIT) field to be the TOTAL TIME
when producing the material in-house, because the external replenishment does not look
at this field. So MRP will run and depending on how you have it set, it will consider
purchasing the material, or making the material, and the fields we've mentioned will
impact the result as mentioned.
+++++++++++++++++++++++++++++++++++++++++++++++++++
1) The config in OPPQ - External procurement at plant level (or OPPR at MRP grp Scheduling/doc. type) should have the check box marked to read
SchedAgreem/Inforecord leadtime (T399D-GTERM)
2) You should have a contract/schedule agreement, or a purchase info record maintained
for that plant-material-vendor combination
3) You should maintain source list (ME01) for the contract/schedule agreement, or info
record. This changes the default behavior of MRP to use leadtime by supplier, rather than
material master leadtime. When both contract and info record exist, the contract will take
precedence.
Please watchout for the case if you're already using contracts/info records in
procurement, but not using them for planning. In this case your leadtime data in these
documents may be incorrect, or may be left blank - this will be interpreted as zero if you
make this change implementation, as mentioned in the steps above
++++++++++++++++++++++++++++++++++++++++++++++++++++++++
Safety stock:
available for planning:
Shortage quantity
Mat. 1
Mat. 2
Mat. 3
100 pc
100 pc
100 pc
0%
50%
50%
1 pc
1 pc
51 pc
0 pc
51 pc
+++++++++++++++++++++++++++++++++++++++++++++++++++++++++
If the requirement is not there, re-visit your material master and check your settings for
the MRP group.
What is the real meaning and usage of the followings configured in PP:
1. MRP Controller;
2. Schedule margin key;
3. MRP group;
4. MRP profile.
1. MRP Controller
This will help you to group the material for some controlling purpose. You can run mrp
by mrp controller.
you can do evaluation by mrp controller. This will help us if have different people in one
organisation involved in purchasing.
2. Schedule margin key
This will help you to determine the floats. In case if you have production order you can
see the impact of floats
3. MRP group
This will help you for the material to reac in tems of the settings made relavant to each
group. To know more details on the group you can chek the tcode oppr.
4. MRP profile
We can have some prefixed datas in the profile and and we can enter teh profile for diff
material so the values will copied as defaulted in the profile
+++++++++++++++++++++++++++++++++++++++++++++++++++++++++
Enter plant
Optionally, enter date/exception group/Processing indicator/material data, to
limit the number of records. Execute.
System will create a list of all materials that satisfy the previous selection.
Now, Select Find (binoculars).
If you have a large number of entries (such as 20,000) you will get a popup
asking about statistics. Say yes.
Select 'Find Exceptions' tab.
Here you will get a summary, by exception number, of each exception
contained in the previous list.
If you wish to process ONLY one or more of these exceptions, select the ones
of interest.
Now hit green check (Find exceptions).
You will be returned to the original list.
The items highlighted will be the items that have the exception(s) you selected.
Select glasses (selected mrp lists).
You will be taken to the first HIGHLIGHTED item in the list.
Perform your planning tasks.
When done, select 'next list' icon, or Ctrl-F2.
It will take you to the next HIGHLIGHTED item on the list.
Repeat.
Continue until it is time to go home.
Repeat tomorrow.
This is part of the daily job of becoming a MRP Planner.
++++++++++++++++++++++++++++++++++++++++++++++
Please explain what you understand about MRP profile, MRP group, MRP
controller and MRP type.
MRP Profile : All the MRP 1,2,3,4 views in the material master data are entered in this
profile and create MRP profile.
When you are creating Material Master in MM01 while entering the plant and storage
location enter your MRP profile so that you do not need to enter the MRP data again
MRP Group: It is a planning strategy for carrying out the MRP.
In this group there are two types from procurement side
1) MADE TO ORDER
In this once sales order is booked, MRP will run and the P.R will be converted to P.O.
2) MADE TO STOCK: Depends on the forecast model they will plan material and keep
the finished product in STOCK
You can create the MRP Group so that material can be tracked.
MRP groups are used when the plant division for planning is not enough for the division
of the different materials MRP requirements. You assign different groups according to the
requirements to run MRP (different Settings). These settings will be taken in account
when you run MRP for single item or total planning.
Setting --> SPRO --> MM --> Consumption based planning --> Define MRP group.
MRP controllers : It is like a production controller in an industry. He will plan all the
required material for the daily plan.
It will be classified according to the materials & Buyer like
Casting - one MRP controller
Forging - One MRP controller
All Bought Ourt - One MRP controller
Sheet Metal - One MRP controller
MRP controller is the person in charge of the MRP run for the materials. It is still a
further division on your MRP. This is work load related. You can have one MRP
controller for materials with different MRP groups.
Setting --> SPRO --> MM --> Consumption based planning --> Master data --> Define
MRP group.
To define the user exit key, goto SPRO -> MRP -> Planning -> 'User exit material
selection - MRP'.
Then, go to SAP enhancement (SMOD) = M61X000, and add this code :
CLEAR: NO_PLANNING, STOP_PLANNING.
CASE USER_KEY.
*----------------------------------------------------------------------*
* select materials for one MRP controller (specified in user_par)
*----------------------------------------------------------------------*
WHEN 'XXX'.
*MRP user exit key define in spro
UXPAR = USER_PAR.
CONDENSE UXPAR.
WRITE UXPAR+0(3) TO DISPO.
IF DISPO IS INITIAL.
EXIT.
ENDIF.
IF MT61D-DISPO <> DISPO.
NO_PLANNING = 'X'.
ENDIF.
ENDCASE.
Definition: MRP controller
In a manufacturing plant, a person will be identified and will be responsible for a group
of materials. Material that takes part in material requirements planning must be assigned
to an MRP controller.
MRP will guarantee material availability and once you run MRP, it will be helpful in
planning as to whether what quantity a component should be procured or what quantity
should be produced in-house. Through MRP, you can automate procurement proposals
for purchase and production.
MRP Controller is assigned in material master MRP1 view
++++++++++++++++++++++++++++++++++++++++++++++++++++++
If you set Individual indicator for both header material and dependent material, then if
sale order comes for 100 qty, then During MRP run system will create a plan order with
reference to sale order and for dependent material, system will plan dependent material as
sale order relevant. System won't consider warehouse stock for that sale order.
If you set collective indicator for dependent material system will consider warehouse
stock for dependent material.
MRP-4 as 1 : In individual planning, this indicator is used to display the dependent
requirements of a component separately.
MRP-4 as 2 : In collective requirements, this indicator is used to display the dependent
requirements of a component grouped together.
This Indicator is useful to control the planning of dependent requirements if the main
product is being planned with strategy 20 i.e.; MTO Process.
MARC-SBDKZ indicator controls whether individual or collective customer
requirements planning is allowed for dependent requirements means low level in BOM.
If you define individual requirements for explosion, dependent requirements for a
component are shown individually on the superior low-level code.
If you define collective requirements for explosion, required quantities for the material
are summarized independently of the sales order.
In the MTO scenario, if you want to check the unrestricted raw material stock when you
run the MRP for sales order. Please check by selecting individual/collective requirement
as 2.
Please note:
- If you select individual requirement then system will not consider available stock and
generate Proposals for every single requirements. Also you will find PR and Plan order
with account assignment of Sales order (in case of MD50).
- If you select collective requirement then system will not generate planning proposals
through MD50. In that case you have to go for individual MRP (MD02 / MD03 / MD41 /
MD42).
For FG stock you can assign to sales order through MB1B by 412 E movement type
++++++++++++++++++++++++++++++++++++++++++++++++++
Make-to-stock production
without replenishment lead times (in the standard system, you must enter 02 here).
In net requirements planning according to strategy 10, the order does not create a
requirement; the sales order is displayed, but does not generate planned orders.
The planned independent requirement is reduced during processing of the goods issue.
Old quantities can still be retrieved by using either
Goto -> Schedule line history in Demand Management, or by using the total requirements
list
(Evaluations -> Display total requirements from the Demand Management menu).
The quantities issued are displayed in the Withdrawal quantity field.
The system always reduces the oldest planned independent requirements unless the
consumption fields (Consumption mode, Fwd consumption per., Bwd consumption per.)
are maintained in the material master or in the MRP group.
11 BSF Gross planned independent requirements KSL Sale from stock without
independent
requirement reduction
Strategy 11 in summary :1. Sales Order creation - no impact.
2. Goods Receipt - minus the quantity for the oldest planned independent in demand
management.
For e.g. if PIR is 100 and delivery 90, PIR becomes 10 (withdrawal 90).
3. Delivery - no impact as delivery is issue from sales order.
This strategy is particularly useful if you need to produce, regardless of whether you have
stock or not. For instance, steel or cement producers might want to use this strategy
because they cannot shut down production; a blast furnace or a cement factory must
continue to produce, even if this means having to produce to stock.
You need to maintain the following master data for the finished product:
Maintain strategy group 11 on the MRP screen.
Set the Mixed MRP indicator to 2 on the MRP screen.
Maintain the item category group (for example, NORM) on the Sales Organization
screen.
Maintain the Availability check field so that you perform an availability check
without the replenishment lead time (checking group 02 in the standard system).
Strategy
10
11
Yes
No
Strategy 40 in summary :-
4. Requirements from the sales orders are passed on to production and can lead to
changes
made to procurement if the requirements from the sales orders exceed the planned
independent requirement quantities. If there is insufficient coverage of components
(the sales order quantities exceed the planned independent requirement quantities), the
sales orders cannot be confirmed. The system therefore automatically adjusts the
master
plan. Planned independent requirement quantities that are left unconsumed increase
the
warehouse stock of the finished product.
+++++++++++++++++++++++++++++++++++++++++++++++++++++++
Please Check CS15 - where used list. May be this material has been added to a BOM of a
product/Assy, which has caused an entry in planning file.
Check MD04 for the source of reqt.
Also check MD63, if a PIR exists.
If not, delete from planning file. Try report RMMDVM10 - consistency check.
======================================================
=======================================
When you go for NETPL (net change planning in planning horizon), those materials are
only planned which has undergone changes for the planning run in the specified horizon.
This is mentioned in the planning horizon
++++++++++++++++++++++++++++++++++++++++++++++++++++++++
+++++++++++++++++++++++++++++++++++++++++++++++++++++++
When MRP completion, the PR item shown 1-10-2004 290 pcs, is that any possible
to bring in material just right before dependant requirement 26-10-04 say about 24
or 25 of the month.
Because. we dont tend to keep more stocks until actual requirement.
Any comment are welcome.
In that case you might like to consider lot size key WB (weekly). It will bring in material
at the first working day of the week. In your case it is Oct 25, 2004
But in this case, I will have increase administrative cost on monitoring the material
lot weekly.
I want to have monthly lot size that group all the requirement, but bring in material
as close as possible on the first requirement.
Any comment are welcome..
How about manually change delivery date in PO item
Check your config. in OMI4 - scheduling may by ''1'" for Lot size of MB.
Change to Blank.
Friend PPS is correct, Schedule the "REQUIREMENTS DATE = DELIVERY DATE"
option in Customizing for Lot Size MB (use Blank instead of 1) & your reqt 'll be met...
We have similar problem and when I applied your solution, the proposed
requirement date is perfect.
++++++++++++++++++++++++++++++++++++++++
Reservation Not Created During MRP Run
I have created a planned order thro MRP run, but reservation for raw material is
not created, even though stock is available. After conversion to Production order
reservation is created. After confirmation and goods reciept MB31 final product is
updated in storage location, but raw material quantity is not reducing.
Can any one give solution for this.
Gururaj Hebbar
PART I
After MRP run, based on the demand Planned order will be created and for the BOM
components sytem will create dependent requirement if stock is available. If stock is not
available system creates a planned order or a purchase requistation. Once the planned
order of the Header material is converted into a production order , then system converts
the dependent requirement into reservations.
PART II
After confirmation and goods reciept if the item components are not consumed, it means
you have not defined backflush process. If you want to issue manualy to the order u can
use T-CODE MB1A, for the same.
K. Prasobh
1. Check backflush indicator either in routing /workcenter or in material master.
2. In customization production control -operations-confirmation ( general individual entry
screen ) check-- post open reservation . It will post open reservation while confirmation.
3. After doing this cross check failed goods movements
++++++++++++++++++++++++++++++++++
How to Configure Range Of Coverage Profile
I am trying to configure the range of coverage profile to provide a 6 months safety
stock, in which the 'target cov' field should be populated with 180 days, but the that
field only accepts 2 characters max. Is there another way of accomplishing this or
am I doing something wrong. Please let me know. The current setup is:
- Period Indicator = M (Month)
- Type of Period = 1 (Workdays)
- Range of coverage in the first period:
- Min = blank; Target = 90; Max = blank
In this Target value accepts only digit numbers.
Muthu Chinnadurai
Yes the system accepts only two digits. But since you want stock coverage for 180 days.
Use target as say 60 and the number of periods as 3 . Try it and keep us posted. But the
one other issue is the system calculates the dynamic safety stock.
It easy to calculate the stock for the first period but for the later periods its difficult. So if
later there is a problem with the quantity then its difficult to calculate or cross check what
system has proposed.
Raj
Using target as 60 and number of periods as 3, only results in system maintaining safety
stock for 60 days for first 3 periods. I found out that there is no way out of this. Strange
that SAP wouldn't let the companies plan for inventory coverage more than
99 days. This is a pharmaceutical client whose procurement lead times are more than 5
months for some of the materials, where they want to maintain a 6 month coverage and
SAP wouldn't allow to achieve it. Am I doing something wrong here. Is there another way
of maintaining dynamic safety stock for 180 days requirements coverage? Please share
your knowledge.
Muthu
Please let me know in details how the profile coverage works in SAP. In details means
how it is being calculated and what is being considered. As I am figuring how I could
make use of this function that my customer require us to keep 15 days inventory and
customer forecast flucuates drastically every week.
Thanking all in advance for your kind advice and help.
Alicia
In customizing in MRP calculation menu , you have Range of coverage. Define the range
of coverage you want , as you said 15 days for a period of 3 months. Then in the profile
first fill the Avg. daily req data and then the range of coverage data.
Use this profile in the material master mrp II view(I think), in range of coverage.
As far as calcualtion are concerned its very to calcualte the Qty for the first period and
then for the later periods its difficult.
May be I am wrong, just try and keep us posted
Raj
The Range of Coverage profile is define specific to a plant in IMG and then assigned to
materials in master data MRP 2 view. To define the profile, use menu path
IMG->PP->MRP->MRP Calculation->Define Range of Coverage Profile. In the
definition, there are two sections of data that you need to fill in.
1. Parameters for calculation of average daily requirements and Period indicator.
2. Minimum, Target, and Maximum stock calculation parameters.
PARAMETERS FOR AVERAGE DAILY REQUIREMENTS CALCULATION:
Choose the period indicator as Month, Period, or Week.
Specify the number of periods. This is used by system to calculate the average daily
requirements.
Select the "Type of Period Length", ie. as workdays or calendar days or standard days
(days per period). If the type of period length is selected as standard days, they you have
to specify the "days per period". Using these three parameters, the system calculates
average daily requirements using the formula:
average daily requirements = Sum of requirements in the number of periods / number of
days in the number of periods.
PARAMETERS FOR TARGET STOCK AS DAY'S OF SUPPLY
Then you have to specify how many workdays of supply you want to maintain as target
stock, in your case 15 workdays. If you wanted to maintain a constant 15 days of supply
as inventory through out the planning horizon, just specify the target stock as 15 days and
leave rest of the fields as blank, i.e min, max, and number of periods. The number of
periods in this section simply maintains the target stock for that many periods from the
date of MRP run. This way you can tell the system to maintain different target stock
levels for three different period intervals. For example, if you wanted to maintain 15 days
stock for first 3 periods, then specify the target stock as 15 days and number of periods
corresponding to it as 3. The system then will maintain 15 days supply as inventory for
first 3 periods from the date of MRP run and subsequent months zero inventory will be
maintained. This will allow you to maintain your 15 days supply constantly for 3 periods.
Muthu Chinnadurai
++++++++++++++++++++++++++++++++++++++
Lose of link between sales order and production order
Issue with production order confirmation
Due to lose of link between sales order and production order due to credit check problem
The production order for higher level component lost link and was hanging out in limbo
status.
Now the production order at lower level component also loose track and they were
already released where as production orders at higher level were not released
So now lower level production orders were tecoed with BDC program as there were 1200
production orders to be tecoed at lower level .
So once I deleted lower level, I saw that there were planned orders for same component
and same sales order and item, this was because MRP was running at same time .
So this MRP generated planned orders as the production orders at highrt level were still
hanging there and to full fill those production orders lower level component planned
orders were generated
So now cleared the production orders in top level and ran MRP in display mode and
found that there were no planned orders for lower level component.
But still there were two more planned order created at higher level has I previously
tecoed them and did zero confirmation due to some other reason, So I had to unteco them
to delete these planned orders and also cancel confirmation to get the production order
element on to MD04 screen. Once Iam done with that it show a message 26
So It should be clear that if the exception message is 20 ie cancel process then that
production order must be deleted as there is no requirement to consume this order. As all
this context was made in MTO stock product.
++++++++++++++++++++++++++++++++++++++++++++++++++++++
In this case, we define a percentage for MRP, and MRP will use that percentage for
calculation. e.g. if there's an industry standard that all vendors of that liquid produce it at
75%, or if we are always working with a vendor who produces 68%, then we can enter
this data (per material) and MRP will calculate with that percentage
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
MRP Type
The MRP type is a key that controls the MRP procedure to be used for planning a
material.
The MRP type belongs to the plant-specific data (in other words, the MRP area data of a
material).
The MRP type controls which planning parameters must or can be entered when
maintaining the material master record.
You can customize the parameters of the MRP types delivered with SAP R/3 according to
your own requirements. You can also add new MRP types.
MRP Type From SAP Help Menu
Key that determines whether and how the material is planned. You have the following
options:
- Manual reorder point planning
- Automatic reorder point planning
- Forecast-based planning
- Material requirements planning with forecasts for unplanned consumption
- Master production scheduling (MPS)
How to create storage location for MRP area?
To create storage location MRP area, do the following steps:
1. Create MRP area by SPRO -> MRP -> Master data -> MRP area -> Define MRP area.
Select MRP type 02 - storage location
2. Define scope of planning by tcode OM0E
Insert your Plant.
3. In MM02 assign MRP area in MRP1 view.
4. In SPRO -> Define parallel processing in MRP.
5. While MRP run select parallel processing in the initial screen.
After entering the reqd. routing no. and BOM alternative , carry a check.
After getting the Green signals ,Continue.
Thus you have saved the prod. version.
Mass processing TCode- C223.
Does this mean that I have to activate all the BOMs if in case I have 3 alternative
BOMs? if yes, then, will it these 3 BOMs be exploded in MRP? Im just worried
coz I might bloat our inventory if there are three active BOMs.
No.First of all need not worry about the BOM explosion.
As I told you earlier which BOM and which Routing is decided by Prod.Version.
So in MRP the active prod.version only will be considered. Thus active BOM and active
Routing will be used for MRP.
The question comes: How to deactivate the alternative BOMs and Routing?
Two Ways:
1. You lock all other non-relevant Prod.Versions in MM02 of the FG/SFG material.(Every
alternative BOM and routing forms a Prod.Version) Thus even if there are 2/3
prod.versions System will go and check for Unlocked prod. version and use it.
2. If you don't want to do this business of "Lock & Unlock" just place the required
version at the first place in list of prod.versions in MRP4 view of the material.
Once system finds the first prod.version it will not spend energy in searching other
alternatives.
Also please.don't forget to maintain the selection value of "2" in MRP 4 view for BOM
selection.
This will enable you to start the use of prod. version functionality in SAP-PP.(very good
tool for practical purposes, costing and MRP)
+++++++++++++++++++++++++++++++++++++++++++++++++
: Create Bom
cr01
ca21
The detailed sequence of T.Codes for REM including Std cost estimate.
Material master - MM01
BOM - CS01
Price Planning - KP26
Work Center - CR01
Rate Routing - CA21
Material Master Change, enter production version - MM02 (MRP 4 View)
Product Cost Collector - KKF6N
Costing - CK40N
Backflushing - MFBF
+++++++++++++++++++++++++++++++++++++++++++++++++++
planning file entries at MRP area level from this point onwards.
5. The report also converts the individual customer planning file
entries at plant level to
individual customer planning file entries at MRP area level.
Steps 2 :Activate MRP Area in SM30 - T000MD.
(Material requirements planning with MRP areas cannot be reversed once
activated).
Steps 3 :During conversion in Steps 1, SAP will automatically create a MRP area
for all your existing
Plants.
Now, you can start creating the MRP area for storage location or vendor
to be planned
separately. That's is the whole purpose for using MRP area.
Define MRP Area in SM30 - V_MDLV.
Here you define whether the MRP area type :01 - Plant
02 - Storage Location
03 - Vendor
Steps 4 :In Material Master MRP 1, the MPR area section will appear once you
successfully complete
the above Steps.
Assign MRP Areas to Materials
You assign the MRP areas to the materials by creating an MRP area
segment for each MRP area
in the material master. You can assign several MRP areas to one
material.
MRP with MRP areas for the material is not activated until an MRP area
has been assigned to
a material. If you have not assigned an MRP area to a material, that is,
you have not created
an MRP area segment in the material master, the material will continue
to be planned in the
plant MRP area only. If you have assigned an MRP area to the material,
the system can plan it
in the plant MRP area and in the assigned MRP area.
You can display an overview for all materials in an MRP area. To do
this, you go into
Customizing for MRP and choose the IMG activity Define MRP areas. Call
up an MRP area by
double-clicking and choose Material overview for MRP area.
Steps 5 :-
Material requirements planning for each MRP area allows you to have
specific control over
the staging and procurement of parts produced in-house and purchased
parts for each shop
floor and assembly area. If, for example, you define an MRP area for the
production
storage location of an assembly line, the system plans the material
requirements for the
assembly line separately from all other requirements.
Example: Subcontractor
You can also carry out planning for components to be provided in
subcontracting using an
MRP area by defining an MRP area for every subcontractor and assigning
the components to be
provided to the MRP area of the subcontractor. You therefore plan the
requirements to be
provided for these components for one subcontractor separately from all
other requirements.
Depending on the requirements situation, the system creates either stock
transfer reservations
from the plant to the stock of material provided of the subcontractor or
it creates purchase
requisitions within subcontracting/third-party order processing,
according to the special
procurement key settings.
The planning run takes into account the planning with MRP areas as
follows:
If you do not enter a separate scope of planning, the system plans the
whole plant, that is,
all MRP areas in the plant, during the total planning run. If you want
to carry out a total
planning run for a particular MRP area only, you must specify the
required MRP area in the
scope of planning.
During single-item, multi-level planning, the system plans the selected
material in the MRP
area entered. In addition, the system takes into account planning file
entries from other
MRP areas, for example, if the material is to be procured using stock
transfer.
During single-item, single-level planning, the system plans the selected
material in the
MRP area entered only.
You define the MRP areas in Customizing for MRP. You can thereby assign
the following to
an MRP area: one or more storage locations (example: you want to carry
out planning for a
particular assembly line and therefore assign a production storage
location to the MRP area)
a subcontractor.
You assign the various MRP areas to the materials in the material
master. For this, you
create an MRP area segment for a material for every MRP area, in which
it is used. In this
MRP area segment, you can define MRP parameters such as, for example,
the lot size or MRP
type. This allows you to plan the material differently in the MRP area
from how you plan it
in the plant MRP area.
MRP with MRP areas for the material is not activated until the material
has been assigned
to an MRP area. If you have not assigned a material to an MRP area, that
is, you have
not created an MRP area segment in the material master, the material
will continue to
be planned in the plant MRP area only. If you have assigned an MRP area
to it, the system
can plan it in the plant MRP area and in the assigned MRP area.
+++++++++++++++++++++++++++++++++++++++++++++++++++++