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Inventory Planning and Monitoring: Revised January 27, 2011
Inventory Planning and Monitoring: Revised January 27, 2011
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Overview
The Materials Management module includes two sub-modules; procurement and
inventory management.
Inventory management entails the planning and control of material stocks by
quantity and value. In AASIS, plants are either valuated plants tracking both
quantity and value or non-valuated plants which track quantity only. Most
business processes are the same for both types of plants with only minor
procedural differences. The primary difference is that goods movement for a
non-valuate plant do not create financial postings in AASIS.
It also includes the planning, data entry and documentation of all goods
movements to, from, and within the storage locations in the stock plant. Any
transaction that will cause a change of stock is entered in real time and the
resulting update of the stock takes place immediately. This provides the user
with an overview of the stock level of any material that is always current.
The objective of this document is to provide an overview of the business process
for the inventory cycle from the creation of a material master, procurement,
goods receipt, goods issue and the physical inventory process. Various reports
available to the user will also be discussed as well as the integration with other
modules throughout the inventory cycle.
Material Master
A Material Master or Material Master Record is a data record containing all the
basic information required to manage a material. The typical Material Master
record may have data that falls into three categories:
Data of a control nature. Purchasing data, MRP type data, or shelf life
data is used by the system to determine the way in which specific
processes are carried out within the system for the material. This data is
plant-specific, thus it will be maintained at the plant organizational level.
Valuation data, such as the price control and valuation price, is
maintained at plant level as well.
The material master record is divided into what are known as views. Views may
also be looked at as user departmental information. There are separate views
for areas such as purchasing, accounting, materials planning, etc. Each contains
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Basic Data 1
Purchasing
MRP1
MRP3
Accounting 1
Plant Stock
The DFA Office of State Procurement (OSP) is responsible for creating material
masters. In the normal business process, OSP receives a request to create a
new material master via the OSP web site which includes a material master
request web form for completion by the requestor. All materials are created for
the reference plant 9999 and extended to the stock plants as requested. OSP
website link is:
http://www.dfa.arkansas.gov/offices/procurement/Documents/materialMasterReq
uest.pdf
In this document, a material master previously created and extended to the plant
is displayed here.
2. <ENTER>
The Display Material (Initial Screen) screen appears. Use this screen to enter
the material number.
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3. <Material >
4. <Select viewsF5>
5. <HIGHLIGHT> Select the views to be displayed by clicking the small square
to the left of the view name. Views to highlight include: Basic Data 1,
Purchasing, Purchase Order Text, MRP1, MRP3, General Plant/Storage 1,
Accounting 1, Plant Stock.
6. <Organizational levels>
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The general data section of the basic data 1 tab provides information such as the
material description, base unit of measure and material group. The base unit of
measure is the lowest unit of measure in which the stocks are managed. The
system converts all the quantities entered in other units of measure (alternate
units of measure) to the base unit of measure.
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10. <Purchasing>
The purchasing tab provides information necessary for the procurement of the
material. Notice that some information is repeated here that appeared on the
Basic Data 1 tab such as description, base unit of measure and material group.
Order unit is an alternate unit of measure which allows the material to be
purchased in a measurement unit other than the base unit of measure. The
conversion of the order unit to the base unit of measure must be maintained in
the material master to allow the use of the order unit measure.
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Purchase order text allows for additional information or instruction concerning the
requirements for the material. This may include additional description and/or size
specification for clarification.
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The MRP 1 tab provides information necessary for the materials requirement
planning to be carried. In this example, the MRP Type is VB, Manual reorder
point planning. The lot size value is HB, Replenish to maximum stock level.
When the MRP is carried out of this material, if the material is at or below the
reorder point, the system will propose a planned order for a quantity necessary to
bring the stock level back up to the specified maximum stock level, in this case,
300. Reminder, this is in base units of measure or 300 ZR5 (ream, 500 sheets).
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MRP3 tab defines the availability check level for MRP. In this case the
availability is set at 01 for daily requirements. The Availability check specifies
whether and how the system checks availability and generates requirements for
materials planning. The value, 01, for materials planning is a default value which
defines which MRP elements (for example, purchase orders, reservations) the
system includes in the availability check.
14. <Plant data/stor.1>
Plant data/stor.1 tab provides for listing a unit of issue unit of measure if the plant
will be issuing the material in a unit other than the base unit of measure. Also,
materials that are managed by shelf life are defined here.
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The Accounting 1 tab list the valuation class to which the material is assigned.
The valuation class proposes the general ledger account to which the materials
are posted upon issue from the plant. This tab also provides the moving average
price for the material. The system calculates the moving average price
automatically by dividing the material value in the stock account by the total of all
storage location stocks in the plant concerned for the particular material. It
changes the price with each valuation-relevant movement. The valuation of
stocks at moving average price or periodic unit price means that the price of the
material is adapted to the continual fluctuations in the procurement price.
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The Plant Stock tab provides summary information concerning the on-hand
balances of the stock levels for the material. This information is also available in
various reports.
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This tab displays all the units of measure that have been defined for this material
and their conversion factors.
Purchasing Documents
The procedures for completing the purchase requisition and purchase order
transactions are discussed in the AASIS class on procurement. For this reason,
only a brief overview will be made concerning the display of these documents as
related to the plants purchasing needs.
When creating purchasing documents for a stock plant, the account assignment
category must be blank. The system is able to derive the fund, functional area,
funds center and commitment item from the plant number. When a purchase
order is created referencing a purchase requisition for the valuated plant, this
account assignment information is pulled into the purchase order. At that point
the budget commitment on the purchase requisition is relieved and placed on the
purchase order.
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2. <ENTER>
3. <Other requisitionShift+F5>
4 Purchase requisition: <10 characters>
5. <Other document>
6. Note: the account assignment category field is blank in the requisition.
7. <Status>
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The Status tab in the Item section provides the purchase order number and
indicates that a goods receipt has been completed. The user may click on the
purchase order number to drilldown and display the purchase order.
8. <Account assignment>
The fund, functional area, commitment item and fund center are derived from the
plant number.
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5. <Other document>
6. <Purchase order history>
The purchase order history tab in the Item section provides information
concerning any goods receipts and invoice receipts. In this example, a goods
receipt was entered on 09/05/2007. No invoices have been entered. The good
receipt material document number is provided in the detail section. It is possible
to drilldown to the material document for review if needed.
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7. <Account assignment>
The account assignment information from the purchase requisition is pulled into
the purchase order.
Goods Movement
Once materials have been ordered, the next step is the delivery of the ordered
materials to the plant. The goods receipt of the materials is the beginning of
goods movement cycle in the system. When a goods movement is entered, a
chain of events occurs within the system:
The stock values in the material master record are updated, as are the
stock and consumption accounts.
The goods movement is defined by the movement type. The movement type has
important control functions in Inventory Management such updating quantity
fields, updating of stock and consumption accounts, determining which fields are
displayed during entry of a document in the system.
MIGO Goods Receipt
With the MIGO transaction, the user is able to post several different goods
movements. The user may post a goods receipt, a goods reversal, or display a
material document. When the transaction is initially displayed, the last action
automatically defaults as an aid to the user in the action field.
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2. <ENTER>
3. <Goods Receipt>
Select the goods receipt option from the drop-down box. The system will
automatically display the label Purchase Order in the reference document field.
4. <Purchase order number>
5. <ENTER>
6. Place a check for the received items. If the quantity needs to be adjusted, the
correct value may be entered in the Qty in UnE field.
7. <POST>
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When all entries have been made, the document can be posted. A material
document number is assigned in the system for the goods receipt.
If the item detail section of the MIGO transaction is displayed, the OK box in the
overview section is grayed out. The OK may be selected at the bottom of the
MIGO screen.
.
3. Highlight a line by clicking on the line.
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4. <Choose>
The accounting document is displayed.
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6. <ENTER>
The Stock Overview display providing the following information:
Material (number along with description)
Material type
Unit of Measure
Base unit of measure
Company Code
Plant
Storage location
Unrestricted Use
Qual. (Quality) Inspection
Reserved
The quantity in storage location 0200 is 100 ZR5 in the unrestricted use stock.
There is no stock in either quality inspection or reserved stock.
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Description
Consumption for cost center from warehouse
Consumption for project (WBS element) from warehouse
Consumption for order (Internal Order) from warehouse
Withdrawal for scrapping
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4. Plant: <####>
5. Storage Location: <####>
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The display is returned to the initial screen and the document number just
created is displayed at the bottom of the screen.
The financial postings may be viewed by using the MIGO transaction to display
the material document just created. The accounting document is displayed here.
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Scrapping
Sometimes materials may be damaged in the storage location and cannot be
issued to users. These materials can removed from the inventory stock balances
by scrapping.
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4. Plant: <####>
5. Storage Location: <####>
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13. Reason for Mvmt (movement): <####> Use the matchcode search to display
possible entries.
12. <POST>
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Reports
In addition to the MMBE Stock Overview transaction, there are several other
transactions which can provide useful information for managing inventory stock.
MB51 Material Document List
This report creates a list of all material documents which meet specified search
criteria. Among the most common criteria are: plant, material, movement type,
and posting date. In this example the material number and plant number are the
only selection criteria entered. Hint: It is a good idea to limit searches by using
date parameters when possible.
The output shows three material documents. The middle document with
movement type 101 is the goods receipt for the purchase order. The other two
documents are goods issues from the plant. It is possible to drilldown on a
material document for further examination.
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The output provides the balance at the beginning of the selected date range, the
receipts/issues during the time frame and the ending balance. It also provides a
list of the material documents creating during the selection period.
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Storage bin has limited reporting capabilities. The field appears in the Stock Overview
transaction, MMBE, which displays materials individually. To expand the utility of this
field, a report (ZMM9 Material Stock by Storage Bin) has been developed for the plants
which includes storage bin in the output along with the current stock level.
ZMM9
Pre-requisite
The material master must be updated to include the storage bin information for the
plant/storage location.
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Transaction : ZMM9
Enter the transaction code in the command field.
Execute,
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Field
Plant
SLoc
Bin
Material
Material Description
Unrestricted
BUn
Del Flag
Description
Plant number as specified in the selection
criteria
Storage Location
Storage Bin
Material number
Long text description for the material as
given in the material master.
Unrestricted stock on hand which is
available for immediate issue.
Base unit of measure
Deletion Flag. Indicates whether a material
has been flagged for deletion.
The first three materials are assigned to Bin 1411. The remaining materials in storage
location 0100 may be updated for with a storage bin designation using transaction
MM02- Change Material Master where such an entry is applicable.
Notice that material 10000000 is flagged for deletion. The material may be flagged for
deletion at the storage location level, plant level or client level.
Selection criteria by Bin
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This search displays all plants/storage locations to which the material, 10004979, has
been extended. Note that the bin information has been updated for only two locations.
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There are two display variants created for ZMM9. The desired variant may be selected
by clicking on the small white area as shown here,
The default display lists all materials including those that have been flagged for deletion.
If a user prefers not to have these materials displayed, the user can select the standard
display.
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Selectioncriteriabyplantandstoragelocation
Plant
SLoc
Material
Material number for each material having reached the re-order point
Material
Description
Long text description for the material as given in the material master.
UoI
Unit of Issue. If the unit of issue is different from the base unit of
measure, the unit of measure for issues is specified here.
Unrestricted
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BUn
Max.Level
BUn
Reorder Point
If the stock falls below the quantity specified in the material master, the material
will be included on the material buy list.
BUn
Reorder Quantity
BUn
Del Flag
Selectioncriteriabystoragelocation
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Selectioncriteriabymaterialnumber
Two variants have been created for the Material Buy List.
The /STANDARD variant includes only those materials with a reorder quantity greater
than zero and have not been flagged for deletion. This is the default display.
The other variant includes all materials extended to the storage location regardless of
whether the material has reached the re
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The field labeled Selection Parameters allows for further refinement of the
selection process and display results.
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Using the selection parameter, WE101 Open goods receipts, created the list
above. There have been no goods receipts for this purchase order. The
selection parameters are useful tools when monitoring the status of purchase
orders.
Physical Inventory
A physical inventory count is normally done on an annual basis. In AASIS each
plant will conduct their annual inventory in June before the end of the fiscal year.
For these annual counts, the physical inventory count sheets will be generated
for the entire storage location. The count will be entered and the warehouse
manager will post the differences in the physical count, which will either increase
or decrease the inventory balances.
Sometimes it is necessary to conduct a physical inventory count for a particular
material or group of materials in addition to the normal fiscal year end count. For
these periodic counts the warehouse supervisor can generate a physical
inventory document in AASIS to begin the physical count process. The following
is intended to provide information regarding the steps involved in counting and
posting a physical inventory.
2. <ENTER>
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Enter the physical inventory selection criteria and execute the transaction.
3. Document Date: < ##/##/####> Current date defaults
4. Planned count date: <##/##/####>Current date defaults. Enter date on
which you intend to count.
5. Plant: <####>
6. Storage Location: <####>.
7. Posting Block: Click to select. By selecting Posting Block, no goods
movements involving the material listed in the physical inventory document can
be posted for the duration of a physical inventory count.
8. Batches w del Flags: <De-select>
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9. <ENTER>
The Create physical inventory document: New Items screen appears.
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icon to proceed.
The physical inventory document number appears at the bottom of the screen.
Use Mi01 when only a few items are to be counted. If all items in a storage
location are to be counted, use MI31.
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MI31 Selected Data for Phys, Inventory Documents w/o Special Stock
By using transaction code MI31, the warehouse manager may create physical
inventory count sheets for each storage location in the plant without having to
enter each material number individually.
1. Type MI31 in the Transaction command field.
2. <ENTER>
The display below shows the initial screen without selection criteria.
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Enter the selection information and execute the transaction.3. Plant number: <####>
4. Storage location<####>
5. Material Type:<####>
6. Materials marked for Deletion: <Deselect checkbox>
7. Generate Batch Input: <Accept default setting>
8. Name of Session:
(Example: 1350-0100)
9. Hold Processed session: click to select check box.
10. Issue Log: <Accept default setting>
11. Max no of Items/Doc: <15> Fifteen is the maximum number of items that
can be printed on a count sheet page. Each page will have a specific physical
count document number.
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19. <ENTER>
The following screen is presented. This screen displays a list of the items to be
included on the physical inventory count sheets. The screen also gives a total
number of items to be included on physical count sheets.
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22.<BACKGROUND>
23.<PROCESS>
The user may click the enter icon
to refresh the screen. The small clock
with the green checkmark indicates that the job is being processed.
After refreshing the screen again, the small clock is replaced by a green check
indicating that the job is complete.
If the user failed to select the Hold processed sessions check box on the initial
, the finished job will not
screen,
be listed here. However, the count sheets will have been created and a listing
can be found in transaction MI22 using the plant, storage location and planned
count date as selection criteria.
24. <LOG>
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25.<Highlight job>
26. <DISPLAY>
A listing of the physical inventory count sheet numbers just created is given.
In this session the first count sheet is number 13881, the last count sheet is
number 13923. The batch log may be printed if desired
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The printed count sheet may be used as a tool on which plant personnel can
write the counted quantities for each item. This count sheet contains the material
number, description, plant and storage location information along with a space to
write the count quantity. The sheet does not display the systems on-hand
amounts.
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Enter the
count here
Be sure to
observe the
units of
measure and
convert the
qty as
needed.
6. Quantity: <###>
7. <POST>
The message at the bottom of the screen states, Count entered for physical
inventory document XX.
MI11 Enter Recount
Sometimes it is necessary to perform a recount for a material or group of
materials after the original count has been entered
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All items are initially selected on this screen as indicated by the check mark to
the left of the item number. The user may deselect those items that do not
require a recount by clicking the selection box to the left of the material.
7. <POST>
The screen will return to the initial screen and a new physical inventory count
number will be displayed at the bottom of the screen.
The designated materials should be recounted and this value should be entered
into the system using transaction code MI04 as explained above.
MI20 List of Inventory Differences
Any differences between the entered count and the system balances must be
reconciled. These differences create financial postings which increase or
decrease the inventory stock balances.
The List of Inventory Differences provides management a means to examine
differences for a single count sheet or several count sheets at one time.
Depending upon the agencys policy and procedures, the plant management may
decide to recount some items due to wide variances while posting the differences
of other items which have only a small difference. Although material differences
may be posted from this transaction, it is recommended that differences will be
posted using transaction MI07.
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For the first material, the book quantity is 358 ZR5 vs a counted quantity of 753
ZR5 which produces a difference in amounts of $1,034.84. Differences are also
shown for the second item.
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A reason for any discrepancy must be indicated in the Reas. (Reason) field of the
MI07 transaction. The movement types associated with inventory adjustments
are 701 and 702. Movement 701 indicates an increase in the book value of the
inventory balances. Movement 702 indicates a decrease in the book value of the
inventory balances. Use the match code search box to determine the
appropriate reason
5. <SELECT Reas field Search>
The Reason for Inventory Diff. screen appears.
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The materials on the count sheet are listed on the screen as shown below.
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The count status can reflect three different possible status indicators: Blank, X,
or A. A Count status that is blank indicates that no count has been entered for
any of the materials on the count sheet. A status A means that a count has
been entered for some of the items and a status of X means that a count has
been entered for all of the materials. The example shown in the screen print has
a status of X.
The Adjustment status field indicates that differences have been posted for this
physical inventory count document. The Count status A means that inventory
differences have been posted for some of the items of the physical inventory
document. For these items, the physical inventory has been completed. Count
status X means that differences have been posted for all items of the physical
inventory document.
The Delete status is blank indicating that none of the materials have been
deleted from this document. Status A means that some of the items have been
deleted and a status of X means that all items have been deleted.
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In this example of Mi22, a list of count sheet numbers is listed for each material.
Note that on the right side of the screen, the Status doc indicates which
documents are active. In other words, a count sheet for this item has not yet
been posted. By clicking a document number twice, the document itself will be
displayed.
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Troubleshooting
MI31
Error: Accounting view is missing means that when the material was extended
to plant 1300, the accounting view was not opened (displayed).
Solution: Contact OSP. OSP will need run transaction MM01 for the material
and open the accounting view for the plant.
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Glossary
Account Assignment
Category
The account assignment category determines which account assignment data (such as
cost center, account number and so on) is necessary for the item.
Alternate Units of
Measure
Unit of measure in which quantities can be entered alternatively to the base unit of
measure/stock keeping unit. Alternate units of measure must be defined in the material
master.
Unit of measure in which stocks of the material are managed. The system
converts all the quantities you enter in other units of measure (alternative units
of measure) to the base unit of measure. The base unit of measure,
alternative units of measure, and their conversion factors are defined in the
material master record
Client
The organizational unit which groups or combines all legal, business and/or
administrative units with a common purpose. The State of Arkansas is the
only client with AASIS.
Company Code
Cost Center
Goods Issue
Goods Movement
Goods Receipt
Internal Order
Internal orders are normally used to plan, collect, and settle the costs of
internal jobs and tasks.
Material
Material Document
Material Groups
Material Master
Material Type
Materials Management
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The system calculates the moving average price automatically by dividing the material
value in the stock account by the total of all storage location stocks in the plant
concerned. It changes the price with each valuation-relevant movement. The valuation
of stocks at moving average price or periodic unit price means that the price of the
material is adapted to the continual fluctuations in the procurement price.
MRP
MRP Area
Order Unit
Planned Orders
Plant
Storage Location
Unit of Issue
Unit of measure that expresses the quantity of materials issued from the plant.
The unit of issue allows the user to record material usage or consumption,
stock transfers and physical inventories in a unit of measure other than the
stock-keeping unit. The Unit of Issue is an example of an Alternative Unit of
Measure.
Units of Measure
Unit that allows the user to determine the dimension or quantity of a material.
Valuation Area
WBS Element
The work breakdown structure (WBS) is a model of the project that organizes
project tasks into a hierarchy. It is the functional basis for further planning
steps in a project, for example, for process planning, cost planning,
scheduling, capacity planning or costing, as well as project control.
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Transaction Title
MB03
MB1A
MB1B
Enter Transfer Posting (use movement type 301 for transfers between
plants; use movement type 311 for transfers between storage locations
within the same plant)
MB51
MB52
MB5B
ME23N
ME2N
ME53N
MI01
MI04
MI07
MI11
Enter Recount
MI20
MI21
MI22
MI31
MIGO
MMBE
Stock Overview
ZMM2
ZMM9
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