SAP Production Planning

SAP MRP - Materials Requirements Planning Configuration Hints and Tips

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:29:00 +0530

The main function of SAP Material Requirements Planning is to guarantee material availability, it is used to procure or produce the requirement quantities on time both for internal purposes and for sales and distribution. This process involves the monitoring of stocks and, in particular, the automatic creation of procurement proposals for purchasing and production.

Difference between MRP type manual reorder point and automatic reorder

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:29:00 +0530

In manual reorder point, you must define the reorder point (and eventually the safety stock) according to your criteria.

For automatic, these values are estimated by SAP as a function of the forecast (coming from historical data), so the
base-quantities for the calculation of the reorder are not fixed but dynamic.

Storage Location included/excluded from MRP

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:28:00 +0530

To control whether a particular storage location will be included or excluded from the MRP run. (MD02/MD41).

To exclude it from MRP run :-

OMIR - Define storage location MRP per plant
Put the MRP ind. as. 1 - storage location stock excluded for MRP

To include it from MRP run:-

OMIR - Define storage location MRP per plant
Put the MRP ind. as. space - storage location stock also planned at plant level and save it
Next go to transaction MM01 - tick only view MRP 2
Key in Plant and Storage Location
Look at the Storage Location MRP section
change the SLoc MRP indicator to space and save it

MMD1 - Create MRP Profile - MRP profile is a useful entry aid and makes it easier to manage MRP data.
You define which fields are filled with values when MRP data is entered in the material master record, which of these values can be overwritten and which not. You use the information stored in a profile is standard information that is needed again and again in similar constellations when material master records are maintained.

Planned Independant Requirement included/excluded in MRP run

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:28:00 +0530

MD62 - Look for the indicator version

Tick to include in MRP run
Untick to exclude in MRP run

OMPG - Define consumption mode and period of adjustment.
MM02 - The field in Material Master (MRP Group) determine whether the configuration is check during MRP run.

For example, if you configure consume forward as 2 days. During MRP run, forcast (VSF) must be at least 2 days ahead of the last firm Sales Order or it would be consume into the Sales Order.

Excluding/Including Safety Stock on Stock Requirements List

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:27:00 +0530

You can do this in transaction OMIL.

In the safety stock field, you can define whether the system is to use the number of days until the warehouse stock falls below the safety stock or below the physical stock, for the days' supply or the receipt days' supply.

In the standard settings, the system uses the number of days until the warehouse stock falls below the safety stock.

If you enter indicator 1, the system uses the number of days until the stock falls below 0.

MD02 - Run MRP Single item Multi level

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:27:00 +0530

MRP reads the requirement from:

Material Master View

Purchasing
MRP 1 and 2
Work Scheduling

Sales Order
Planned Independent Requirement
BOM
Routing

Points to note:-
If you have just changed the BOM and want to have the latest update.
Execute with Planning Mode 2 - BOM is re-exploded

When you found that the MRP did not automatically Create the Purchase Requisitions for in-house production.
Execute with Planning Mode 3 - Delete planning dates.

MRP can easily re-create Purchase Requistions and Planned Orders based on the latest requirement changes. Therefore, it is allright to execute with Planning Mode 3.

BOM - Do not built a BOM with a Material Type ROH Level 1 and Level 2, as MRP will not consider the requirement for Level 2 since it is a Raw Material. (no additional process required).

Level 1 ROH

...Level 2 ROH

Batch Input for MD02

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:26:00 +0530

When you found that the MRP background run (MDBT) does not perform as expected, you can try this customized MD02.

Mass run MD02 for FERT and HALB

Shortage/Surplus of material stock level due to differences in Planned/Production Order Start and Finish date

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:26:00 +0530

Normally, the planned order determined the date from Material Master. The Planned Order created by the MRP reads the production capacity requirement from Material Master. (MM03 – Work Scheduling – Lot size dependent in-house production time). When you convert the planned order to a production order, SAP determined the date from Routing.

User Requirements:- Planned and Production Order should read the requirement from routing.

Solutions:-
Run MRP Scheduling -> 2 – Lead time scheduling and capacity planning

Transaction OPA9 (Sel. Profile - SAPA010) - Change configuration for Capacity Planning to read Production Order. Untick the Planned orders under the Order categories.

Subcontracting upgrade 3.0/3.1 to 4.x

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:26:00 +0530

Element MatSub in the MRP Requirement (MD04) is calculated wrongly. Apply note 121238. Run the OSS note program ZZSUBC40 once and the problems is solved. In the new version, stocks are tied to the Vendor.

If you want the old logic (3.0x), you can apply note 170597 and the planning will not check for Vendor.

Quota Arrangement for Multi Plant Purhasing

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:25:00 +0530

If you have more than two Plant, you can used quota arrangement to distribute the percentage of internal purchasing accordingly.

Plant A purchase from Plant B Plant C
MM02 - Procurement type F
Special procurement Blank
Quota arr.usage 3

Plant B and Plant C
MM02 - Procurement type F
Special procurement Blank
Quota arr.usage Blank

OMD9 - Maintain Special Procurement

Plnt SP Type Special Procurement type description
Plant A Plant B Procure from Plant B
Plant A Plant C Procure from Plant C

MEQ1 - Quota Arrangement for Plant A

If you press Enter, the start date comes automatically. Multiple period can be maintained.

Click Item Overview for Overview of Quota items

P S PPl. Quota
F U Plant B 30
F U Plant C 70

P - Procurement type
S - Special Procurement

MRP Planning Strategy

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:25:00 +0530

Strategy 10 - PIR Type - LSF

Net requirements planning. That is even the warehouse/storage location stock is also taken into account besides planned receipts / issues during planning for calculating the order quantity. Planned Independence Requirement quantity is reduced at the time of Goods Issue for delivery.

Strategy 11 - PIR Type - BSF

Gross requirement planning. Warehouse / storage location stock is not considered, and only planned receipts / issues are considered. Also Planned Independent Required quantity is reduced during Goods Receips for production / planned order (Repetitive). It is generally recommended for mass production industries and process oriented industries where the production has to be carried on, regardless of the stock available. The constraint in such industries is that it is not economically viable / possible to stop production.

Strategy 30 - PIR Type LSF - Production only with sales order (Demand Management entry are ignored during MRP run)

Maintain the following master data for the finished product:

Strategy group 30 on the MRP screen
Availability check field (on the MRP screen and the Sales: General/Plant screen) so that you can perform an availability check with replenishment lead times (01 in the standard system)
Item category group (for example, NORM) on the Sales Organization screen

Strategy 40 - PIR Type VSF - Make to Order Production - Production triggered by sales order. (Widely use around the world.)

Planned Independent Requirements will be reduced by sales order delivery to reflect the current stock requirement. (depending on your configuration, sales order will consume the VSF (planned independent requirement) quantity on the same date or two to three days away from it)
You can set up the consumption parameters in the material master on the MRP screen.
Check whether the fields Consumption mode, Bwd consumption, Fwd consumption contain entries. If empty, default values are taken from the MRP group parameters in Customizing. If these fields are filled in the material master, they override the MRP group parameters.
In MD04, VSF will disappear once it is consume by the sales order

4.6c

Choose Logistics -> Production -> Master Planning -> Demand Management -> Evaluations -> Display total requirements. (The Total Requirements List shows only those sales orders that have reduced the independent requirements.)

Strategy 52 - PIR Type - VSE

The lot size key EX must be set in the MRP screen because lot size optimization would be incompatible with the allocation logic, which could result in over-planning and incorrect result in the ATP check.
You also must ensure that no rounding profile or rounding values are taken into account.
Maintain consumption parameters (Consumption mode, Bwd consumption, Fwd consumption) so that the independent requirements can be found. For more information, see Consumption Strategies and Logic.
Maintain the item category group (for example, NORM) on the Sales Organization screen.
A BOM is required for the finished product. There are no major implications for the BOM components. However, it is important to note the following:
You need to set the MRP type to P* (or M*) on the MRP screen to plan the components in MRP.
You may want to consider setting the Individual/coll. Indicator to 2 on the MRP screen as a starting point for your master data setup.

Strategy 63 - PIR Type - VSEV

Set Ind./Coll. Indicator to 2 in MRP4 View for all your lower level components. It allows you to build or purchase some components only after receipt of the sales order.

Number Range by Plants during MRP Run

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:24:00 +0530

Define different sets of number range by Plants for :-

Planned Orders
Reservations
Purchase Requisitions
MRP Lists
Sim. Dependent Requirements

OMI8 - Maintain Plant Parameters

Environment -> Number Ranges

Mass change MRP indicator

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:23:00 +0530

4.6x

When you change the MRP indicator ( transaction SM30 - V_T001L_D ), SAP does not mass update all the material Sloc MRP Indicator in MRP View 4. It assume that the change are for newly created material and storage location starting from the changed date onwards.

This customized program allows you to mass changed all the storage location MRP indicator.

Connecting the planning calendar to your lot size key

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:23:00 +0530

First, you will need to set up the planning calendar.

Menu path: Production -> MRP -> Master Data -> Planning Calendar (MD25)

You will then need to use this planning calendar (the one you created) in the material master when planning your raw materials (MRP2 View in 4.6C - Field name : Planning Calendar).

1. When you maintain the planning calendar you will need to enter a valid from date and valid to date.

2. Your periods will also need to be set up and they will be weekly, for example:
From Date : 11/23/2001 To Date : 11/29/2001 (11/23 is a Friday, this is your from date).
Do this for as may weeks as you wish (say weekly for 2 years).

3. When you have set up the planning calendar, you will then need to make some changes to the weekly lot size configuration
(WB), or you may need to create a new lot size key if you do not want to change 'WB'. Essentially, you will need to use the
following in the lot size configuration (OMI4) :

No. of Periods : 1
LotSizeProced.: P
LotSize ind : K
Scheduling : 1

By using the above, you are connecting the planning calendar to your lot size key.

Question : Subject: MRP, timing of purchase requests

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:22:00 +0530

We have a problem with mrp.

I get lots of purchase requests on a daily basis & after a lot of effort, they now mostly reflect appropriate quantities of materials to buy. The problem is timing. A typical scenario is the day after I've placed an order on a vendor, there will be a request to purchase another product from the same vendor. Typically we will have sold justone more unit, bringing stock levels down to the reorder point, hence the request.

Given that usually that the additional sale was within the forecast level for the month, what do i need to do to get mrp to produce requests for all the vendors materials that will need to be ordered before the end of the month? Not only is this starting to drive me up the wall, my suppliers are starting to express frustration as well

Answer : Subject: MRP, timing of purchase requests

Hi,

I feel u can change the planning from Reorder point based to regular planning. Also, u can set up the Delivery schedules with Firming zone and TRade off zones.So, When the higher level assembly is planned based on some forecast, it will explode the BOM and dependent requirements are generated for the entire planning horizon.Based on the settings, delivery schedules within Firming period gets firmed and u can transmit it to ur Suppliers and also transmit the future/forecast schedules also for ur Vendor's knowledge and info.He will be prepared for the next set of requirements.Even if material is stock, according to forecast, some delivery schedules in TRade off zone (not firmed) will be generated and ur supplier can be prepared.
Alos, try to match the frequency of MRP run with ur requirement of passing the info. to ur suppliers.

Hope this change in the business process will help.

Answer : Subject: MRP, timing of purchase requests

I agree with mvm. If you are going to the trouble of putting together a sales forecast, why are you using reorder point planning? Let the forecast trickle down through all levels of the BOM and use it to drive procurement (either internal or external) of your lower level components. I assume that the forecast is being entered into SAP, probably in S&OP. If not, you have a bigger issue on your hands.

How System choose Production Version

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:22:00 +0530

I see that if I've different production version for a product the system chose as default (when I release a production order) always the version which has the smallest number. Is it the only way?
If not, where I can define how the system chose the default production version?

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You can change the Production Versions in MRP 4 screen in MM02. Click on the version then click details. Here you can set validity dates for the version or you can also set lot sizes. Based on the quantity of the order, a certain version will be picked. Or, the version will be picked if it falls in the date range.

The selection of Production versions can be
1) Automatic or
2) Manual

This depends on your customisations for order type.

However, the Production version number which gets selected depends on following factors:
1) Validity date of the Production version as maintained in MRP4 view Production version details (material master), and
2) Lot size maintained in MRP1 view i.e. FX (Fixed) or EX etc
3) Lot size maintained in MRP4 view Production version details(Material Master)

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Maybe you change the Production Versions in MRP 4 interface from MM02.
- Choice and Click on Prodversion.
- May be You have more than one Production version.
- Then You click detail,
- And then where are BOM do you want to choice

And the others may be you can use in MD02, If you have more than one of Production version. when did You choice? May be number one and etc

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But my problem is the follow:
I've 5 different production version all with same valitity date and all with the same lot size. The numbers of different production version are 0001, 0002, 0003, 0004, 0005. When I release the order the choice of production version is automatic and the system always choses the production version 0001.
How I can define that the sistem choses production version 0004?

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When there is five different versions available in the system, why do you want to select only version 0004. On what basis the system has to select this. If it has to select 0004 always then why do you want to keep the other versions validity. You can change the validity period of others. Otherwise you can go into Quota arrangement and give the version 0004.

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I've 5 different production version because I can realize the same product on 5 different work center (same product but different work center). But when I release the order I want the system choses automatically as default production version
0004 used for work center number 4. After, if I want, I can change production version, so I can change work center in wich realize the product. I don't know where I can define quota arrangement for production version.

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In customisation order type dependent parameters TZ OPL8, you have selection of production version. Change that to manual selection. While creating order, all versions will pop up for selection.
All the best

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As mentioned, you can control this for manual selection. Or otherwise you can do the control thru Quota arrangement settings. This you can do from MEQ1 transaction. If you set the required version for 100 percent, then automatically this version will be selected.

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Production version selection when converting planned order

I am using multiple production versions in the material master for a combination of different alternative BOMs & Routing Group counters. In the IMG (OPLD) for Order Type Dependent Parameters, the production version selection is already set to manual selection. But the production version is always defaulted as version 1 which is the first one in the material master and is not asking to select the version at the time of converting the planned order to a production order! I want to select the production version manually...any suggestions?..Any other config settings is lacking like selection priority, task list, etc? Pls advice.

Also, if it is an externally procured material, when converting the PR to PO, how can I select the version manually? Appreciate your suggestions.

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The reason sytem is not asking for a production version is very obvious as you would notice that while converting from planned order to production order (through MDO4) system already has a default production version assigned to plan order. so you need to first change production version in plan order before converting to production/ process order. System shall only ask for the selection of production version while you are creating a production order directly.

Processing Keys NETCH & NETPL in MRP

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:22:00 +0530

Can anybody explain with an example as how to use the processing keys NETCH & NETPL in MRP run. I tried, but did not find any changes between these. Or I am be wrong in using it.

There's a Planning File in SAP and in that file, materials with planning entries are listed. According to those entries MRP decides whether or not to include a material in MRP run.

For a newly created material all entries are on. And after the first MRP run, material is planned and all entries are cleared for that material. Later in time, you execute transactions, which make changes to the material that changes the material's planning status (e.g. goods receipt for the material, creating planned orders for the material, and such..).

During these transactions, Planning File entries are updated accordingly. And next time you run MRP material is included in MRP, or not included if no changes have occurred which relates to the Planning File.

Difference between NETCH and NETPL are:

NETCH is any material that has undergone some changes since last MRP run. (e.g. you have created a new planned order for the material, so al other planning data has to be replanned according to this change)

NETPL is any material that has undergone some changes since last MRP run, and those changes are in the planning horizon. (e.g. you have created a planned order which is inside the planning horizon. If your planning horizon is 3 months, and you created planned order for a date 5 months from now, that material is not included in planning with NETPL)

Individual Collective Indicator in the MRP 4 View

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:21:00 +0530

MRP 4 view in material master is for material that are listed as BOM of product or material or for material defined as dependent requirement.

Dependent requirement is affected when there are change in the Planned Independent Requirement (PIR).

When you choose 1 parameter,material requirements to buy will be generated when a customer order was entered under SD module (VA01).

On the other hand, parameter 2 like parameter 1 it is used in the BOM explosion of a product but in sales forecast basis (MD61).

To simplify, if material is unique or not common, with high value, with shelf life or short lead time, order proposals will be generated only during a customer order was received and entered in the system.

Choose parameter 1, you have better control to manage the stocks and values, parameter 2 is the reverse, when a material that is commonly used in many products that your company is producing. and when you planned product via forecast or sales plan basis then parameter 2 is your option to choose, if works when sales forecast of a product where the dependent requirement or material were being used it propose a buying proposals for the material requirement even though no receive or confirm customer order yet.

MRP Run Exception Description

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:21:00 +0530

Exception Group - Exception Description Meaning Severity

1 2 New, and opening date in the past SAP has created a new requisition and scheduled it appropriately based on the demand, however, given the lead time of the material the Purchase Order should have already been issued to the supplier. High potential that this order will need to be expedited! Critical

1 5 Opening date in the past

2 3 New, and start date in the past The order or requisition is scheduled to start in the past. High potential that this order will
need to be expedited or that the demand can not be supplied! Critical

2 6 Start date in the past

2 63 Production start before order start System configuration should not allow this situation. Review the order and ensure that the scheduled & basic dates are in line and notify the HelpDesk to report 'Inconsistent Scheduling Configuration". Critical

3 4 New, and finish date in the past The order or requisition is scheduled to finish in the past. High potential that this order will
need to be expedited or that the demand can not be supplied! Critical

3 7 Finish date in the past

3 64 Production finish after order finish System configuration should not allow this situation. Review the order and ensure that
the scheduled & basic dates are in line and notify the Helpdesk to report 'Inconsistent Scheduling Configuration". Error

4 1 Newly created order proposal New order created Informational

4 42 Order proposal has been changed Order rescheduled by SAP Informational

4 44 Order proposal re-exploded Order regenerated by SAP Informational

4 46 Order proposal has been manually changed Order rescheduled by planner Informational

4 61 scheduling: Customizing inconsistent System configuration should not allow this situation. Ensure that the order shows up
properly in CM25 and notify the Helpdesk to report 'Inconsistent Scheduling Configuration". Error

4 62 Scheduling: Master data inconsistent Check master data ! Remove "In House Processing Time" from the Material Master MRP2 view. Ensure that the Production Version & Routing are correct. Run MPS/MRP manually once corrected. Error

4 82 Item is blocked The requisition has been manually blocked and therefore cannot be converted. Remove the block from the requisition or delete the requisition and run MD02 for the material to regenerate. Critical

5 50 No BOM exists SAP was unable to find a valid Bill Of Material for the item. Check the BOM, Production Version & Selection Method. Error

5 52 No BOM selected SAP was unable to find a valid Bill Of Material for the item. Check the BOM, Production Version & Selection Method. Error

5 53 No BOM explosion due to missing config. Plant Set-Up incorrect. Contact the Helpdesk to report this error! Error

5 54 No valid run schedule header Material set for repetitive manufacturing on the Material Master MRP views. Correct Material Master or contact the Helpdesk for assistance with this error. Error

5 55 Phantom assembly not exploded SAP was unable to find a valid Bill Of Material for the phantom material. Check the BOM or contact the Helpdesk for assistance with this error. Error

5 69 Recursive BOM components possible Bill of material inaccurate (material consuming itself). Review and correct BOM and run MPS manually. Error

6 25 Excess stock Excess stock planned based on the "Range of Coverage" profile. Coverage profiles should not be in use. Remove the "Range Of Coverage Profile" from the MRP view of the Material Master and run MRP manually. Error

6 26 Shortage in individual segment There is material in the "Provided To Vendor" bucket in SAP. Remove the material using
transaction MB1B and run MRP manually. Critical

6 40 Coverage not provided by master plan Excess stock planned based on the "Range of Coverage" profile. Coverage profiles should not be in use. Remove the "Range Of Coverage Profile" from the MRP view of the Material Master and run MRP manually. Contact the HelpDesk for assistance if unable to resolve. Error

6 50 Shortage in the planning time fence SAP unable to automatically cover demand due to the time fence. Review and reschedule supply elements appropriately. Important

6 57 Disc. matl partly replaced by follow-up Order is planning to use remaining run-out material and the balance of the requirement using the replacement material. Adjust order quantities based on the run-out as appropriate. Important

6 58 Uncovered reqmt after effective-out date System unable to find replacement material. Review the run-out strategy and adjust master data appropriately. Run MRP manually once resolved. Critical

6 59 Receipt after effective-out date Receipt of discontinued material planned. Review the run-out strategy and adjust orders
appropriately. Run MRP manually once resolved. Critical

6 70 Max. release qty - quota exceeded System unable to determine source of supply. Check the effective dates of the Quota
Arrangements and adjust appropriately. If Quota Arrangements are not appropriate for the material remove the "Quota Arrangement" selection from the Material Master. Error

6 96 Stock fallen below safety stock level Supply plan insufficient to cover safety stock requirement. Review and adjust if appropriate. Important

7 10 Bring process forward Order or requisition is too late to cover requirements. Review and reschedule appropriately. Important

7 15 Postpone process Order or requisition is too early based on requirements. Review and reschedule appropriately. Important

7 20 Cancel process Supply is beyond total demand in the system. Stock Not Required! Review and re-plan appropriately. Critical

7 30 Plan process according to schedule Order or requisition early or late and within close proximity to the Time Fence, Hard Order, or Current Date. Review and reschedule appropriately. Important

8 98 Abnormal end of requirements planning System unable to process the material - Major Data or Configuration problem! Check Material Status and seek assistance if unable to resolve. Materials flagged for deletion should be set to the "DIS" MRP controller to remove them from the list. Error

Problem in the MRP Run and Frequency

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:20:00 +0530

Our central warehouse runs the MRP for the planning plant and uses special procurement key in the material master MRP2 view for the planning plant, so that the STPO are generated for different production plants. But purchase requisitions are also being generated when MRP is run at the planning plant.

Our requirement is that purchase requisitions should not be generated when the MRP is run at the planning plant. purchase requisitions should be generated when MRP is run again at the production plant. Please note that BOM are maintained in the production plant material master only.

I believe that you are maintaining PIR at planning plant where MRP is run. Please note the following basic MRP principle and logic.

1. MRP performs net requirements calculation based on forecast, available inventory and scheduled reciepts and scheduled issues out of the plant.

2. Then it applies the lot sizing procedure to calculate the order quantites and creates scheduled receipts (requisitions or planned orders) in the planning plant.

3. It creates planned orders for the lotsized quantity and determines the order dates via scheduling strategy selected during the run initiation.

4. Explodes the BOM for each planning proposal it created and repeats step 1 to 4 for each component.

Please note that the MRP logic always starts with L-L code 000 and works progressively increasing code levels.

Based on the logic explained, MRP will mandatory create planning proposals at planning plant (STTR in case of Stock Transports) in order to fulfill the step 3 and plan the production plants using logic in step 4.

The SPK will only allow you to procure from one production plant. Whereas if there are multiple production plants supplying to your planning plant, you have to consider using MEQ1 as suggested:

Try giving quota arrangement in MEQ1 , specify the spl procurment key there "p" or "u" specify qty 100% & give the production plant there. Maintain quota arrangement key 03 in mrp 2 screen.

Muthu P. Chinnadurai.

How frequently we should run MRP i.e daily weekly or fortnightly?

The frequency of MRP run depends on the business scenario. How complex the system is, how fast you would like to respond to changes. What is your planning strategy (MTO/MTS)?

In most cases, the MRP is run in background every night or can be run evevery 12 hours. It again depends on the business scenario. If it is pure MTS with very little variation...then you can run MRP twice a week. But if you are using pure MTO with lot of variation and you would like to respond immediately to client's requirement, then you will run the MRP daily or more frequently.

To answer this question, the sap consultant would have to know what planning strategy the company is using.
- How frequently does the data change?
- How huge the client data?
- How quickly the client would like to respond to you customers? etc..

SAP MRP Profile - How To Used It

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:20:00 +0530

I do know what a mrp profile is, how to create it, change it etc. but what I dont know is where and how do we use it. I have not seen any key or tab indicating mrp profile. Then what is it? What are tcodes mmd1, mmd2 all about?

MMD1 is the transaction code for creating MRP profile.

In MRP profile you can create your own record or file, when you use the transaction. Give the name and description to your own profile and you can select the fixed values and/or default values from the option given of the MRP fields. For eg. if you select or tick the check box against procurement type in the fixed values column then click on screen 1 to fix the value. You get the option of different procurement types, if you select from these option and save , your profile is created .

Now, go to material master in the MRP2 screen and go to main menu -->edit-->MRP profile. In this, you can assign your profile which has been created by you. So now you will see that the procurement type has become fixed value for your material and which cannot be changed in the material master .

You can only do the changes if you change your profile again (MMD2) or do not assign any profile. Similarly, you can store the default values if you require in MRP profile.

SAP SOP - Sales, Operation and Planning Info Structure S076

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:19:00 +0530

MC87 - Create Plan for Material (SOP is manage by version number)
MC88 - Change Plan - Click Inactive Version or hit the Enter key
MC89 - Display Plan

You should stop using MD61 and MD62 once you used SOP.

Let's Create a Plan via MC87 :-

The system will prompt you the next available version number when you create a Plan. It can be overwritten as long as there are no existing records. (Version number can be a mixture of characters and numbers)

Always have the following settings :-
Settings -> 0
Settings -> Show row totals -> Historical periods

This two settings is done to ensure that there are no plan existing in the past.

Some of options you can used :-

You can define a target stock level. Enter a quantity in the Target Stock Level, then click Edit -> Create Production Plan -> Target Stock Level

Define a target days supply by entering a quantity in the Target days supply and clicking Edit -> Create Production Plan -> Target Days Supply

If you want to plan by week click Edit -> Period Splitting -> Total -> Days or Weeks or Months

You can have some plan in weeks, some in days. Select the periods columns you want to change, then click Edit -> Period Splitting -> Selective -> Days or Weeks or Months

You can have a block range periods columns value to be increased or decreased by a certain figure or percentage. Select the period columns and click Edit -> Distribute -> Fill in the Val. field and OP

After all the data is entered, you can then transferred it to Demand Management. Click Extra -> Transfer to Demand Management.

You'll get a message "values only tranferred if saved. Saved planning values first?". Click Yes.

Be aware that if you have maintained multiple versions, you should only transfer one version to demand management as each transferred version will overwrite the requirements of the older version.

Material :
Plant :
Version :

Transfer strategy and period
X - Production plan for material or PG members

From - Put the period from date or beginning of month
To - Leave it blank or put the date up to the confirm plan you want to transfer

Invisible transfer - If tick, it will display the planned independent requirements before saving it

Requirement Type - Depend on your planning strategy

Version - "00" is requirement list

Active - Tick or your MRP will not show the PIR. Inactive means that the quantities are for information only.

To transfer, click the Transfer Now button or Edit -> Transfer Now

A warning message "Planning version to be transferred is not an active version" will be issue by the system. Just hit Enter.

The Transfer Planning Data to Demand Management screen (MD74) will be shown. Do not change anything in this screen as it will not be changed in SOP.

Save your data and you have successfully create a plan in SOP.

Some other transaction code in SOP :-

MC78 - Copying Planning Version. This is done when you want to retain the previous version.

MC80 - Delete Planning Version. Do this when you want to delete unwanted planning versions. Tick the version you want to delete and click the Delete button. An authorized user should perform this.

Please don't delete A00 which is the SAP standard active version.

FAQs on SAP PP

sirish.sites@gmail.com (Sirish WebWorld) — Wed, 7 Jan 2009 12:18:00 +0530

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
c) Base unit of measure
d) Technical data

Ans: a, b, c

7. Functions of Classification are

a) To find an appropriate object
b) To find similar objects
c) To establish that no appropriate object exists.

Ans:

8. Entering “/o” in command field

a) Ends current transaction
b) Ends the current cession
c) Opens new cession
d) Opens new transaction

Ans:

9. For creating Material Master the following Transaction Code is used :

a) md01
b) mm01
c) me01
d) mc01

Ans: b

10. The unit in which the stock keeping is done in a company is called

a) Stock unit of measure
b) Base unit of measure
c) Unit of issue
d) Purchase unit of measure

Ans: b

11. Batch is

a) Same as material code
b) Partial quantity of material managed separately from other quantity of same material in stock
c) A non reproducible homogeneous unit with unique specifications
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

Sample Questions on PP

sirish.sites@gmail.com (Sirish WebWorld) — Tue, 4 Nov 2008 13:04:00 +0530

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
c) Base unit of measure
d) Technical data

Ans: a, b, c

7. Functions of Classification are

a) To find an appropriate object
b) To find similar objects
c) To establish that no appropriate object exists.

Ans:

8. Entering “/o” in command field

a) Ends current transaction
b) Ends the current cession
c) Opens new cession
d) Opens new transaction

Ans:

9. For creating Material Master the following Transaction Code is used :

a) md01
b) mm01
c) me01
d) mc01

Ans: b

10. The unit in which the stock keeping is done in a company is called

a) Stock unit of measure
b) Base unit of measure
c) Unit of issue
d) Purchase unit of measure

Ans: b

11. Batch is

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

Routings for Configurable Materials

sirish.sites@gmail.com (Sirish WebWorld) — Tue, 4 Nov 2008 13:04:00 +0530

Use

A routing (or task list) for a configurable material contains all the operations, operation sequences, and production resources/tools (PRTs) that are required to manufacture all variants of a configurable material.

Routings (task lists) for configurable materials are known as super task lists.

When you configure the material, you assign characteristic values that are used in production to determine the operations required.

In the processing industries, master recipes are used instead of task lists. Master recipes contain all the recipe objects that are required for all product variants.

Features

To maintain task lists for configurable materials, choose Routings ® Routing ® Create. You create the routing in the same way as for other materials.

You can assign dependencies to the operations, operation sequences, and PRTs in routings for configurable materials.

You can assign dependencies to the phases, operations, BOM items, and secondary resources in master recipes.

You can assign the following dependency types:

Selection conditions

To ensure that operations, operation sequences, and PRTs are selected when they are needed in a variant, you assign selection conditions to them.

Selection conditions also ensure that the correct objects in master recipes are selected.

See Selection Conditions and

Selection Conditions for a BOM Item and Operation.

Procedures (actions)

To change fields in operations and PRTs, such as the standard values, you use procedures or actions.

In master recipes, you can change fields in operations, phases, secondary resources, and BOM components.

See Reference Characteristics in Dependencies and Master Data References in Task Lists

See also:

PP Routings

Creating a Routing

Creating Local Object Dependencies for an Operation

Creating Global Object Dependencies in an Operation

PP–PI Master Recipes

Creating Master Recipes

Editing Configurable Master Recipes

Editing Global Object Dependencies

Editing Local Object Dependencies