Contents

Introduction .......................................................................................................... 7
Unit 1: Plan to Produce Business Process Overview ...................................... 9
Master Planning ............................................................................................ 10
Sales and Operation Planning ................................................................ 10
Demonstration: Sales and Operations Planning ..................................... 12
Demand Management ............................................................................ 22
Demonstration: Demand Management ................................................... 24
Long-term Planning ................................................................................ 28
Demonstration: Long-term Planning ....................................................... 29
Material Requirements Planning ................................................................... 36
Master Production Scheduling ................................................................ 37
MPS Planning ......................................................................................... 38
Demonstration: Master Production Planning .......................................... 39
Material Requirements Planning ................................................................... 49
Planning Execution and Procurement Proposal ..................................... 49
Planning Evaluation ................................................................................ 51
Demonstration: Material Requirements Planning ................................... 52
Capacity Planning ......................................................................................... 59
Demonstration: Capacity Planning ......................................................... 60
Discrete Manufacturing ................................................................................. 66
Demonstration: Discrete Manufacturing ................................................. 68
KANBAN ........................................................................................................ 76
Demonstration: KANBAN ........................................................................ 77
Completing the KANBAN Demand Source View ................................. 86
Engineering Change Management ............................................................... 87
Demonstration: Engineering Change Object .......................................... 89
Unit Review: Plan to Produce Business Process Overview .......................... 95
Unit 2: Production Planning Master Data ........................................................ 97
Production Planning Organizational Units ..................................................... 98
Create Company Code ........................................................................... 98
Create Plant .......................................................................................... 100
Create Storage Location ....................................................................... 101
Material Master: Production Planning Views............................................... 101
Material Master: Production Configuration .................................................. 110
Step 1: Define MRP Controller ............................................................. 110

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Klee Associates, Inc.

Step 2: Define Production Scheduler .................................................... 111

Step 3: Define Material Status .............................................................. 112
Step 4: Define MRP Area ...................................................................... 114
Exercise: Material Master Production Configuration ............................. 115
Bill of Material: Master Data ......................................................................... 117
Bill of Material Creation ......................................................................... 118
Exercise: Bill of Material ........................................................................ 125
Bill of Material Configuration ........................................................................ 127
Step 1: Define Default Values ............................................................... 127
Step 2: Define BOM Usage ................................................................... 128
Step 3: Define Default Values for Item Status ...................................... 128
Step 4: Define Copy Default for Item Status ......................................... 129
Step 5: Define BOM Status ................................................................... 129
Step 6: Define Alternative Determination for Multiple BOMs ................ 130
Work Center: Master Data ........................................................................... 130
Work Center Creation............................................................................ 131
Work Center: Configuration ......................................................................... 139
Step 1: Standard Value Key .................................................................. 140
Step 2: Standard Text Key .................................................................... 142
Step 3: Control Key ............................................................................... 142
Step 4: Default Work Center ................................................................. 143
Work Center Exercise ........................................................................... 146
Routings: Master Data ................................................................................. 147
Routing Creation ................................................................................... 148
Routings: Configuration ......................................................................... 152
Step 1: Define Profiles with Default Values .......................................... 153
Step 2: Define Material Type Assignment ............................................. 154
Routing Exercise ................................................................................... 155
Unit Review: Production Planning Master Data ........................................... 156
Unit 3: Master Planning ................................................................................... 157
Sales and Operations Planning ................................................................... 157
Standard SOP: Product Group Creation ............................................... 158
Standard SOP: Create Sales Plan ........................................................ 160
Standard SOP: Copy Version to Active Version ................................... 162
Standard SOP: Disaggregation ............................................................. 163
Standard SOP: Rough-Cut Planning Profile ......................................... 167
Standard SOP: Production Plan Change for Material Capacity Check 170

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Introduction

Transfer to Demand Management ........................................................ 171

Standard SOP Exercise ........................................................................ 174
Demonstration: Flexible Planning ............................................................... 176
Flexible Planning: Defining a Custom Info Structure ............................ 177
Flexible Planning: Planning Methods ................................................... 180
Flexible Planning: Create Planning Hierarchy ...................................... 182
Flexible Planning: Calculate Proportions .............................................. 183
Flexible Planning: Planning Types........................................................ 184
Flexible Planning: Planning Tables....................................................... 187
Flexible Planning: Transfer to Demand Management .......................... 190
Demand Management ................................................................................. 191
Demand Management: Configuration ................................................... 191
Demand Management Demonstration .................................................. 195
Demand Management Exercise ........................................................... 203
Long-term Planning ..................................................................................... 203
Long-term Planning Scenario ............................................................... 203
Long-term Planning Configuration ........................................................ 204
Long-term Planning Demonstration ...................................................... 207
Long-term Planning Exercise................................................................ 212
Unit Review: Master Planning ..................................................................... 213
Unit 4: Material Requirements Planning ........................................................ 215
Master Production Scheduling .................................................................... 217
Evaluation Profile Layout ...................................................................... 218
Exercise: MPS Evaluation .................................................................... 221
MRP Planning Process ............................................................................... 221
Master Data .......................................................................................... 222
MRP Controllers for Planning and Missing Controllers ........................ 222
MRP Types ........................................................................................... 223
MRP Areas ............................................................................................ 224
Planning Execution ...................................................................................... 225
Total Planning ....................................................................................... 226
Single-item, multi-level .......................................................................... 231
Single-item, single-level ........................................................................ 233
Procurement Proposal................................................................................. 234
Planned Orders ..................................................................................... 235
Purchase Requisitions .......................................................................... 239
Schedule lines....................................................................................... 239

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Planning Evaluation............................................................................... 239

Configuration: MRP Planning ...................................................................... 242
MRP Basic Settings............................................................................... 242
Exercise: MRP Basic Data .................................................................... 253
MRP Planning ....................................................................................... 254
Exercise: MRP Planning ....................................................................... 266
Evaluation .............................................................................................. 267
Exercise: Evaluation .............................................................................. 275
Consumption Based Planning ..................................................................... 275
Re-order Point Planning ........................................................................ 276
Exercise: Re-order Point Planning ........................................................ 277
Forecast-based planning ....................................................................... 278
Exercise: Forecast-based Planning ...................................................... 283
Time-phased planning ........................................................................... 285
Exercise: Time-phased Planning .......................................................... 286
Unit Review: Material Requirements Planning ............................................ 288
Unit 5: Capacity Planning ................................................................................ 289
Master Data ................................................................................................. 291
Work Centers ........................................................................................ 291
Exercise: Work Center .......................................................................... 301
Routing .................................................................................................. 302
Exercise: Routing .................................................................................. 306
Capacity Scheduling .................................................................................... 308
Available Capacity Check ..................................................................... 309
Scheduling ............................................................................................. 316
Dispatching ............................................................................................ 320
Exercise: Capacity Scheduling .............................................................. 328
Capacity Planning Evaluation ...................................................................... 329
Leveling and Dispatching Capacity ....................................................... 331
Leveling Mass Processing .................................................................... 337
Exercise: Capacity Leveling .................................................................. 339
Unit Review: Capacity Planning................................................................... 341
Unit 6: Production Orders ............................................................................... 343
Production Order Creation ........................................................................... 344
Planned Order Conversion .................................................................... 345
Planned Order Collective Conversion ................................................... 347
Manual Production Order Creation ....................................................... 349

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Introduction

Production Order Structure ......................................................................... 351

Production Order Header ...................................................................... 352
Master Data Selection .......................................................................... 361
Operations ............................................................................................ 363
Components.......................................................................................... 371
Demonstration: Production Order Creation ................................................. 374
Step 1: External Procurement Operation .............................................. 375
Step 2: Creation of an Alternative BOM ............................................... 378
Step 3: Creation of a Production Version ............................................. 380
Step 4: Creation of a production order ................................................. 384
Step 5: Purchase Requisition Evaluation for the External Operation ... 386
Exercise: Production Order Creation .................................................... 390
Production Order Scheduling ...................................................................... 392
Production Order Scheduling Parameters ............................................ 393
Date Scheduling ................................................................................... 395
Interoperation Times ............................................................................. 396
Splitting and Overlapping ...................................................................... 399
Reduction .............................................................................................. 401
Exercise: Location Group Creation ....................................................... 403
Production Resources and Tools ................................................................ 404
PRT Material Master View .................................................................... 405
Production Resource Tool Creation ..................................................... 407
Production Resource Tool Assignment ................................................ 411
Exercise: PRT Creation ........................................................................ 414
Unit Review: Production Order .................................................................... 415
Unit 7: Discrete Manufacturing ....................................................................... 417
Planned Order Structure ............................................................................. 419
Planned Order Structure ....................................................................... 420
Demonstration: Planned Order Availability Check................................ 423
Production Order Types .............................................................................. 428
Production Order Release .................................................................... 430
Demonstration: Production Order Type Creation ................................. 432
Exercise: Production Order Type Creation ........................................... 444
Material Staging .......................................................................................... 447
Production Confirmations ............................................................................ 457
Goods Movements ...................................................................................... 462
Goods Receipt ...................................................................................... 462

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Goods Issue .......................................................................................... 463

Goods Movement Error Processing ...................................................... 464
Exercise: Perform Confirmation and Goods Movements ...................... 465
Order Settlement ......................................................................................... 466
Make-to-Stock Settlement ..................................................................... 466
Make-to-Order Settlement ..................................................................... 467
Technical Completion ............................................................................ 468
Settlement Rule in the Production Order .............................................. 470
Unit Review: Discrete Manufacturing .......................................................... 471
Unit 8: Repetitive Manufacturing .................................................................... 473
Master Data ................................................................................................. 474
Work Center: Production Line Work Center .......................................... 474
Routing: Rate Routing ........................................................................... 476
Production Version ................................................................................ 478
Material Master: MRP 4 View ................................................................ 479
Product Cost Collector .......................................................................... 481
Planning ....................................................................................................... 483
Repetitive Manufacturing Profile .................................................................. 488
Planned Order Scheduling Parameters ................................................ 492
Planned Order Structure ....................................................................... 495
Planning Table ............................................................................................. 497
Pull List Material Staging ............................................................................. 503
Backflushing................................................................................................. 506
Unit Review: Repetitive Manufacturing ........................................................ 509
Unit 9: Reporting and Tools ............................................................................ 511
Production Planning Reporting .................................................................... 513
Master Data Reporting .......................................................................... 514
Evaluation Reporting ............................................................................. 519
Material Requirement Planning Reporting ................................................... 527
Maintaining Master Data Using Mass Maintenance .................................... 534
Mass Maintenance of Orders ................................................................ 535
Standard Master Data Mass Maintenance ............................................ 542
Review: Production Planning Course .......................................................... 549

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