Reservations
Planned Order
Production Order
R/3s MRP is for unconstraint-based planning, APO is for the constraint-based planning Sales order / Planned Ind Requirement Planned order
Finished product
Assembly 1
Assembly 2
Raw material 1
Raw material 2
Raw material 3
BOM Explosion
Determine the valid BOM for explosion
Quota Arrangement
A lot can further be split by quota arrangements (MM will cover this)
Exception message
Tolerance
Reqmts
Tolerance
Tolerance
Lot Size
Shortage
Planned Orders Production Orders Purchase Requisitions Purchase orders Warehouse Stock Supply
SAP AG 2001, A Business View of mySAP Financials, GBU FIN - 6
MRP Procedures
controlled by MRP type in material master (MRP 1 view)
MRP Procedures
Consumptionbased
MRP
Deterministic Planning
Forecast-based planning
Time-phased planning
Master Data
Material Master (Important Ones) q MRP Group (MRP1) - Group common MRP materials together q MRP Type (MRP1) - Planning Method. q Reorder Point (MRP1) - For Reorder Point Planning Methods q Planning Time Fence (MRP1) - Restrict Planning Activities within the TimeFence q Planning Cycle (MRP1) - Only for Time Phased Planning q MRP Controller (MRP1) - Planner for the material q Lot Sizing (MRP1) - Lot Size determination q Storage Cost Indicators (MRP1) - For Optimum Lot sizing Only q Ordering Costs (MRP1)- For Optimum Lot Sizing Only q Assembly Scrap (MRP1) - For Assembly Scrap Only q Procurement Type (MRP2) - Make or Buy Indicator. q Special Procurement (MRP2) - For stock transfers, phantoms etc. q Quota Arrangement (MRP2) - Splitting of Quota for internal and/or external procurement (MM will handle this)
Reorder Point Planning (REORDER) (MRP Type VB, Reorder Level) When Available Stock falls below reorder level, planned orders are generated in the planning run to order up to reorder level. Safety Stock requirement is just for information
Safety stock Safety stock partially available Dynamic safety stock Safety time
Safety Stock
Safety stock: To be set in material master (MRP 2) or in the MRP area segment
Time
Reqmt
SAP AG 2001, A Business View of mySAP Financials, GBU FIN - 13
Receipt
Portion of safety stock available Safety Portion of safety stock not available for planning Reqmt Receipt
Time
Stock
Maximum stock Target stock
Minimum stock
Time
Days
Interval 1
Interval 2
Maximum stock
20.12.2000 10.12.2000
Maximum stock
Safety Time
Safety time: To be set in material master (MRP 2) or in the MRP area segment
28.03.
Receipts
30.03.
2 workdays
Time
Reqmts
Safety time
Time
Dep . reqmts
Receipts
Safety time
Safety time
Safety time
Time
Reqmts
2 workdays
4 workdays
2 workdays
12.12.2000
SAP AG 2001, A Business View of mySAP Financials, GBU FIN - 21
20.12.2000
Least unit cost procedure Groff reorder procedure Dynamic lot size creation
EX
FX
HB
TB MB
Period length
Period length
Period length
PC
July 2000
Mon Tue Wed Thu Fri 1 8 15 22 2 9 16 23 3 10 17 24 4 11 18 25 5 12 19 26 Sat Sun 6 13 20 27 7 14 21 28
d, e W
0 00 .2 .7 10
d, We 00 20 .7. 24
Time Period 3
Period 1
Period 2
Reqmt
Receipt
1 1
2 months ago
For 2 months, no events required a change in planning, so not planned during NETCH + NETPL! Problem
2 2
Today
Additional Restrictions
You can use these additional restrictions to further define lot sizes :
q
Short Term and Long Term Lot Size (SHORTLONGTERMLOT) (Lot Size Key LL) Minimum Lot Size Maximum Lot Size Rounding Value Rounding Profile
q q q q
Overview: Scheduling
Procurement Types
Procurement Types
In-house production
Stock transfer
External procurement
Subcontracting
Vendor
Components Components
Scheduling
The following times are taken into account : q processing time required by purchasing department (workdays) q planned delivery time of the material (calendar days) q goods receipt processing time (workdays) These times will be used to determine the release date of the planned order or purchase requisition.
Planned order
Opening period In-house production time Goods receipt processing time
MRP 2
Lot-size dependent: MRP 2 Scheduling margin Lot-size independent: work scheduling key (MRP 2)
Time
Opening date
Availability date
Time
Availability date
...
...
Time Delivery date
Release date
SAP AG 2001, A Business View of mySAP Financials, GBU FIN - 36
Basic Scheduling
Separate scheduling for planned orders Exact to the day Basic dates calculated Order finish date
Periods
Order start date Opening date Basis for in-house production or replenishment lead time Improved performance No calculation of capacity requirements
Order header
Arbeitsvorgnge
Materialkomponenten
manual Target dates calculated (scheduled dates) Target start date Target finish date Basis for in-house production or operations Capacity requirements calculated Exact to the second
Fertigungshilfsmittel
Kosten
100 20 50
Product
OD OS OF
Assembly
OS OD OF
Available
Raw material
OD
OS OF
Available Available
Opening period Goods receipt processing time Time
OF
OD
Opening date
1 1
OS
Float before production
Scheduling margin key
Planned order
OF
Operations Operations (from routing) (from routing) Float after production
Scheduling margin key
2 2
OS
Order start date Production Production start date start date
10
20
30
OF
Production Production finish date finish date Order finish date
10
20
30
40
50
Calculation of order dates In-house prod. time greater than scheduling in routing In-house production time shorter
Backward scheduling
OD OS PS PF OF
Product
10
20
Assembly 1
10
20
30
Assembly 2
10
20
30 Time
OS OF
OD PS PF
Finished product
Planned order
Determining components
Component 1
Dependent reqmts w/o lead time/lead-time offset
Component 2
Dep ..reqmts Dep reqmts Lead time Lead time
Lead time
+
Lead-time offset BOM maintenance
Time
Note: the lead time and lead-time offset are not taken into account in the lead time scheduling!
SAP AG 2001, A Business View of mySAP Financials, GBU FIN - 42
BOM Explosion
SAP AG 2001, A Business View of mySAP Financials, GBU FIN - 43
BOM Explosion
Target
Usage quantity/dates
Dependent reqmts quantities and dates Component selection Change status of alternative BOM Selection of Alternative BOM Selection of BOM usage
Explosion date
BOM Selection ID
Planned order
Priority 1 2 Usage Production Engineering Used if no valid production BOM exists
Production BOM
Engineering BOM
Costing BOM
for multipleBOMs
1 2, 3
Multiple BOM
Alternative 1
Planned order
Alternative 2
Large lot
>1 0p iec
es
Customizing
Planned order
BOM explosion using
Order start
Order 2
Alternative BOM 1
Alternative BOM 2
Alternative BOM 3
Time Valid from (relevant to planning from) Valid from (relevant to planning from) Valid from (relevant to planning from)
Order 1
Order 2
Alternative BOM 1
Alternative BOM 2
Alternative BOM 3
Time Valid from (relevant to planning from) Valid from (relevant to planning from) Valid from (relevant to planning from)
1.2.2000
BOM explosion no. xxx Order for assembly 1 BOM explosion no. xxx Order for assembly 2
BOM
Time
Explosion date
Change status 2
Explosion date
Change status 2
Change status 3
Technical change
1.2.2000
BOM explosion no. xxx Order for assembly 1 BOM explosion no. xxx Order for assembly 2
Gross date
SAP AG 2001, A Business View of mySAP Financials, GBU FIN - 56
Planning Time Fence Discontinued Parts Alternative Parts Single and Multi Level Pegging Multi-Plant Planning Storage Location/MRP Area Blocked Storage Location Other Special Procurement
Orders Moving Into Firming Types TimeFence Type 1 Firmed Type 2 Firmed Type 3 Not Firmed Type 4 Not Firmed
New Order Proposals Creation Outside Time Fence No Orders Created Outside Time Fence No Orders Created
Regenerative (NEUPL) Net Change Planning (NETCH) Net Change Planning in planning horizon (NETPL)
Important Configurations
Most Important : :Production-->MRP-->Planning File Entries Most Important Production-->MRP-->Planning File Entries -->Activate MRP and set up planning file -->Activate MRP and set up planning file
This Configuration should be done before materials are mass This Configuration should be done before materials are mass created in aanew plant created in new plant
Plant Parameters MRP Groups MRP Types Special Procurement Types Stock Availability Lot Size Calculation Define Floats Define External Procurement BOM Explosion / Determine Routing Define Storage Location/MRP area per Plant Procurement Proposals
Implementation Decisions
Group materials with common planning profile together. Decide an MRP Type for each group of materials. Decide what the lot sizing should be for each material/group of materials. Decide for each material, whether you require safety stock and if safety stock is required, what method of planning the safety stock ? Which material require quota arrangements ? What are the materials that have to be procured from another plant ? Are there any storage locations to be blocked from planning ? Are there storage locations/MRP area needed to be planned separately ?