Professional Documents
Culture Documents
Sap Production Planning
Sap Production Planning
FI
HR
CO
QM
PP
SD PM MM PS
Procurement
Forecasting
CO/PA
Planning Process
Execution Process
REM
Mfg. Execution
Discrete
Mfg. Execution
COMPONENTS Sales Info System Information contains total sales orders already obtained, incoming sales orders, pending sales orders product wise, customer wise, region wise.
Forecasting Based on the past history of consumption, a forecast of the sales figures for a product can be made. Future projections are made using one of the Statistical forecasting methods.
CO/PA Projections will be based on the companys future projection of costing and profitability analysis. Sales & Operations Planning Higher level planning i.e.overall planning at company level Yearly/Half yearly/Quarterly Planning Demand Management Management of Requirements Requirements can be from sales forecasts, sales orders,etc.
MPS Planning of items that greatly influence the companys profits or consume critical resources/dominate production processes. After the production plan of these critical items are firmed up, the planning of other components are taken up.
MRP This is the total planning of all the components taking into consideration the existing requirements and stocks. Creation of purchase requisitions, production orders,etc. Final step in the planning process.
MANUFACTURING EXECUTION Discrete Manufacturing Production orders are released Materials are issued Completion confirmations are performed Goods are received into stock Repetitive Manufacturing Run Schedule quantities are viewed Quantities are confirmed by Backflushing Goods are received into stock
ORDER SETTLEMENT Costs accrued to an order are debited to one or several allocation receivers belonging to financial or managerial accounting.
STANDARD PRODUCTION PLANNING REPORTS Stock/Requirements List Lists the latest stock/requirement position of a material in the plant i.e. planned orders, production orders,etc. Production Plan This report lists the monthly production plans material and plant wise. Orders This report lists the orders pending/completed for a material material wise or work center wise..
Production Facilities
PP Basic Data
Production Resources/Tools
Capacities
F06010
Production Planning
Production Cost
Materials Management
Purchase Order Invoice Receipt Goods Receipt
Accounting Document
Accounts Payable
Vendor
Levels
Group Controlling areas Sales organizations Company codes Valuation areas Plants
Purchasing organizations
General Data
Data applicable throughout the client e.g. Material number Description Units of measure Weight Volume Product hierarchy
Division
Description
Service Spare Part Finished Product Semi-finished Product Trading Good Operating Supply Empty Containers Non stock Item Raw Material Packaging Competitor Product Production Resources/ Tools
Master data is a key piece of information in the system Master data can be seen from a number of views Each view can correspond to an SAP module Each view has a number of information screens Each view belongs to an org unit within the business One product may have multiple plant and sales views, one for each plant or sales area
Finance
Engineering Design
Sales
Product Data
Production Stock
Purchasing
Sales
Product Data
Production Stock
Purchasing
Bills of Material
Simple BOM Variant BOM Multiple BOM
BOM representing a material which can be made up of multiple compositions e.g. different components and quantities
BOM Structure
BOM Header
Plant Assignment Validity Period Release Indicator
Stock Items Non-stock Items Variable Size Items Document Items Text Items
BOM Group is a collective number for all BOMs in a group which allows for one
or several similar products to be described under one number. All Alternatives of a multiple Bill of Material All variants of a variant Bill of Material BOM Usage special view of the BOM which represents a specific area of the company in which the BOM is used; for example, Engineering, Production, Costing, Sales, Plant Maintenance
for the BOM,the system marks it as a Variant Bill . If there is more than one
alternative for a material, the system marks the BOM as a Multiple Bill.
BOM
Validity Bills of Material are valid over an area and effectivity period. Area of Validity -- identifies which plants the BOM has been allocated to Validity Period -- identifies the from and to effectivity dates. The default to date is 12/31/9999
Category When you enter a new Bill of Material item, an item category must be assigned. It has important control functions such as:
Screen selection Specific processing, such as material number required, negative values supported. The Item Category cannot be changed once set. It must be deleted and re-added. Sizes are maintained for variable-size items Item categories include: tock Items -- material in stock as a component S Non-stock Items -- material not stocked - with or without a material number Variable-size -- system calculates the quantity required using formulas PM Structure Item -- used with plant maintenance equipment Document Item -- used with Document BOMs
ub-Items are typically used to represent different installation points for partial S quantities of an item. In assembling resistors on a printed circuit board, the installation points are described. There is no logic related to sub-items
Work Centers
Machines
Cost Center
Assembly Line
Work Centers
People
Costing
Production Line
Work Center W1
Assembly
Work Center W1
Assembly
Operation 20
Work Center W2
Finishing
Operation 30
Work centers are allocated to different work center categories The work center category is used to control the field and screen selection for work centers during work center maintenance. Work Center Category Statistical Work center Production Work Center Screen View Basic Data Basic Data Default Values Capacity Values Scheduling Cost Center Assignment
Activity Rates
Set Up (SET) Machine (MACH) Labor (LAB)
Oper 0040
Working Hours
Operation 10
Operation 20
Operation 30
BOM Groups
Item Category
Bills of Material
Routings
Work Centers
Operation
Operation types
(Main) operation
Sub-operation HierarchyCosting Completion confirmations Scheduling always takes place on the (main) operation level
Sub-operation
The control key defines whether completion confirmations and costing are carried out on the (main) operation level, or on the sub-operation level. Indicator: group operation combined operation sub-operation level (main) operation
Operation / Sub-operation
Schedule at Operation Level
Operation 0010
Capacity Planning & Costing possible at Sub Operation Level Level Sub Operation 0010 / 10 at Work Center A1 Sub Operation 0010 / 20 at Work Center A2 Sub Operation 0010 / 30 at Work Center A3
Operation 0020
Useful when processing for operation 0010 occurs over multiple work centers
Material Allocation
Product
BOM Routing
Op. 10 Op. 30
Material-Routing Allocations
Material 1 01
Routing Group
1
1
2 2
02
01 02
1
1 2 3
2
3 1 1
A routing alterative can be allocated to several materials. A material in a plant can be allocated to several alternatives.
External Processing
Purch Reqn Purch Ord Vendor Proc Goods Rec
At goods receipt, the operation is confirmed
Routing data copied to order including quantities and dates
Operation Lead Time Queue | Setup | Process | Teardown | Wait | Move Interoperation Time Execution Time Interoperation Time
Parallel
Split
Routing includes processes which can/must be split across a number of work centers
Overlapped
Routing defines process where one operation is to overlap with the following operation
MPS
Customer Independent Requirements
MRP
Demand ie Requirements
Sales Plan
Keep Balanced
Production Plan Order Proposals Planned Orders Production Orders Purchase Requisitions
Order proposals, planned orders etc are created and adjusted by running the MRP or MPS programs.
Step 3 Disaggregation of Planning Values Determine the sales and production quantities of product group members Modify the disaggregated sales planning data and create a production plan for each member Step 4 Transfer of Planning Values to MRP Pass the planned sales and production quantities as independent requirements to demand management If product group data is transferred, the system automatically disaggregates the planning data to the finished product level
Sales and Production Planning is carried out using a Planning Table which
shows the stock level that results from the sales and operations planning for
both materials and product groups The Planning Table is divided into: Sales Quantities Production Quantities Target Days Supply and Target Stock Levels
Determine the quantities to produce to meet the sales plan Synchronize to the Sales Plan the system copies the sales quantities into the
production quantities
Zero Stock Level Use existing stock to cover sales quantities. When used up, production quantities will synchronize with the sales quantities Target Stock Level The system determines production quantities based on sales and target stock levels Target Days Supply Coverage is expressed in days
Strategy parameters are used to create the production plan from the sales plan
on to a product group member Disaggregation can be carried out for the product group or for selected members only
Transfer a single-level product group (multiple) or individual material (single) Independent Requirements Parameters Specify Requirements Type Version Number Limit scope of the time period
Master Planning
MRP/MPS
Planning
Production Push
Planned quantities that are not consumed by sales orders result in excess stock
Example is a long lead time custom product Planning Requirement Type is VSF planning with final assembly Sales Order Requirement is KSV which is sales order with consumption
Sales Order
Planning
Warehouse Stock Finished Product
Purchase
Produce
Production Push
Final assembly is initiated by the customer sales order Stop production at sub-assembly level
Purchase
Warehouse Stock Assembly 01
Produce
Warehouse Stock Assembly 02
The planning bill details, through percentages, the quantity required for common
parts Example is a bike with common sub-assemblies used in many finished items Planning Requirement Type is VSEF -- planning with planning material Sales Order Requirement is KEVV -- independent customer order with planning material
Sales Order
Planning Material
Purchase
Produce
Planned Independent Requirements Note: Percentages drive lower level demands for sub assemblies
Production Push
Sales Order
Sales orders are planned according to sales order number Produced quantities for each sales order are managed individually
MRP Features
Net requirements calculation
Lot sizing
MRP
Forecasting
MRP Overview
MRP
Purchasing
Invoice receipt
Invoice verification
Accounting
Reorder Point
Safety Stock
Time
Order Date Delivery Date
Today
Sales Orders
+
Order Proposal Shortages
Reservations
MRP Prerequisites
PLANT LEVEL MATERIAL LEVEL
Activated for MRP Valid MRP Type Valid Material Status Material MRP Views Maintained MRP Controller Planned Lead Time MRP Group Lot Size Data
Procurement Type indicates if the material is externally procured, or produced internally or both. Special Procurement identifies special planning rules which may be used for in-house production or external procurement MRP Type determines how the material is planned such as MRP, MPS, or consumption based planning Material Lead Time identifies for material planning the planned delivery days or in-house production days
Lot Size determines which lot-sizing procedure the system uses to calculate order quantities
Availability Check indicates whether the system generates individual or summarized requirements for sales orders for this material and for planning, which MRP items the system includes in the availability check.
Mat./PPC Status is used to limit the usability of materials for certain activities such as, purchasing, bills of material
MRP Indicator: determines whether or not requirements, for a specific storage location, are planned separately from the overall plan
Reorder Level: used for storage location MRP Replenishment Quantity: used for storage location MRP
MRP Types
VB Manual Reorder Point Planning: MRP produces order proposals when stock falls below a reorder point. The reorder point and safety stock levels are entered manually Automatic Reorder Point Planning: The reorder point and safety stock level are calculated based on the forecast results Forecast Planning The latest forecast is copied as requirements which are used to create order proposals Deterministic Planning MRP produces order proposal(s) to match the exact quantity of the requirements based on independent and dependent demands Master Production Scheduling Similar to PD but used for master schedule items
VM
VV PD
M0
Lot Sizing
Static
Lot for Lot Fixed Lot size Replenish up to maximum stock level
Periodic
Daily Lot size Weekly Lot size Monthly Lot size Flexible period
Optimum (Cost )
Part period balancing Least unit cost procedure Dynamic Lot size creation Groff reorder procedure
Shortage Quantity
If
Order
Order Order
Stock required to achieve maximum stock level set in the material master
All materials are reviewed by MRP regardless of activity Only the materials in a plant that have undergone a change relevant to planning since the last planning run (net change planning)
Planning Run Options for Automatic Creation of Requisitions and Delivery Schedules
MRP Control Parameter: determine whether or not MRP will automatically create requisitions or delivery schedules Options are:
Opening Period Parameter: allows the user to take advantage of MRPs automatic creation features while retaining control over the number of open purchasing documents
MRP List
Group of Materials for which controller is responsible Controllers MRP Listing
MRP Order Proposals and Planner Messages from MRP Planning run. Planner can drill down to review material movement activity
MRP Controller
Goods Issues
Goods Receipt
01/01 STOCK 01/08 ORDER Sales Order 25 01/15 PL ORD 1000 120 05 100 02/01 -----------------------------------------------------> Planning Time Fence
Stock Requirements List brings together all the supply orders, independent and dependent demands and stock balances for the material. MRP makes order proposals to balance the supply/demand position for the material
The MRP List displays the result of the last planning run The Stock Requirements List displays the most up-to-date stock and requirements situation
MRP determines the basic scheduling dates using backward scheduling If the release date lies in the past, the system automatically switches to forward scheduling
Desired Delivery Date
MRP determines the basic scheduling dates using backward scheduling If the release date lies in the past, the system automatically swithches to forward scheduling Order Release Date Order Start Date Order Finish Date
E1
Planned Orders
= Demand = Supply
Level 0
Dependent Requirements
B1
Planned Orders
Dependent Requirements
B2
Planned Orders
Dependent Requirements
Level 1
R1
Planned Orders
R2
Planned Orders
R3
Level 2
Planned Orders
Production Order
Planned Order
MRP
MRP Controller
Auto Creation
Collective Conversion into Production Order Individual Conversion into Production Order
Production Order
Select Routing
Select BOM
Print Shop Floor Papers Check Availability Actual Labor Issue Materials to Order Confirm Completion Calculate Actual Costs Receive complete goods into stock
Goods Receipt
Create Order
Production Order
Calculate Capacity
Purchase Requisitions
Goods Issue
Routing Selection
Alternate Sequence Assignments One operation is required Enter start or finish date depending on scheduling direction
300
Material 1
Unplanned Goods Issue
Production
Goods Issue
Material Document
Completion Confirmations
Production Order Operations 0010 - Assemble Board 0020 - Assemble Case 0030 - Assemble unit 0040 - Final Test C
Confirm Operation 0010 Activities
Milestone
Confirm Operation 0030 Activities
Partial or Final Confirmation Single or Collective Confirmation Milestone Confirmation Reduction of Capacity Requirements Determination of Actual Costs
Confirmation Data
Quantity
Dates
Start date Finish date Work Center Personnel Number Qualification Wage Group Wage Type
Labor