Sap Pp-erp Great.docx

What is SAP Production Planning SAP PP is mainly divided into planning and execution. Planning contains materials planning and capacity planning. Materials planning can be done for different lengths : long term planning, material requirements planning etc. Execution contains creation of production order, scheduling, work flow (such as release printing), confirmations, goods movements, technical completion. Most of the above mentioned sub processes need master data to be maintained. And when you carry out, they generate transactional data like planned orders, production orders, accounting documents etc. Also, there are sub modules for different types of industries like discrete production, process production (like chemicals), repetitive production, kanban, all these normally follow the above mentioned sub processes. Now we will go thru the nuts and bolts of Production Execution. There are three types of production process in SAP. 1. Discrete Manufacturing 2. Repetitive Manufacturing 3. Production – Process Industries. First let us understand what is happening in the system prior to the production execution process. a. Planning quantities are derived and maintained in the system. b. Material Requirement Planning run will generate the planned order for the net required quantity with the start date of the production process. c. Master data (BOM and Routing details) will be copied in to the planned order automatically during MRP run. Ok, I believe you got an idea about the steps involved prior to the production execution process. Next, let’s discuss about the production execution process now. Production Execution process contains five important steps. They are : 1. Converting planned order to production order 2. Releasing the production order 3. Goods Issue for production order 4. Confirmation of production order 5. Goods Receipt against production order 1. Converting Planned Order to Production Order:Planned order has to be converted to production order to account the entire production. Production order or process order type has to be mentioned when converting the planned order. Entire master data will be copied to the respective order when converting the planned order. Order type is the most important configuration setting for production execution.

2. Releasing the production order:Release of production order is an important step in production order. Releasing of production order indicates the commencement of production. Unless the order is released, further processing of order is not possible. While releasing the production order system can perform : a. Material availability b. Capacity availability c. Creation of Batch d. Reservation creation 3. Goods Issue for production order:Goods issue covers issuing required components to make the finished product to a production order. While making the goods issue, the document number can be updated in the production order. Goods issue can be made in parallel during confirmation of operation. 4. Confirmation of production order:Reporting of usage of components and activities are termed as confirmation. Confirmation to the each operation will be executed according to the control key attached with each operation. 5. Goods Receipt against production order:Once the production is completed, finished products will be received from the production order into the respective storage area. This can be achieved through two ways : 1. Through confirmation 2. Through separate transaction. Document number will be generated for each goods receipt. This document number can be updated in the production or process order. Now you will easily understand what is backflushing? It is the process of issuing components automatically while confirming the production or process order. Hope the above notes has given you enough idea about the SAP production execution process. SAP PP Questions and Answers What are the cutover activities followed for PP module? I am listing some cut over activities to be followed (for PP - Discrete Manufacturing). Production Planning / Master data: For Production planning, only master data shall be migrated to SAP. In the 1st Stage, there is no master data. Following is the master data elements relevant for PP: - Bill of materials - Routing. - Work Centres. Transaction data: As of the cut off date, ideally there should not be any work in process. All the open production orders should be

closed and semi finished goods should be dismantled and should be added to Raw materials. This strategy should be followed for all production orders where lead time to complete the production order is not large. Since, the production orders are for longer duration and it is not possible to dismantle the product and add it to inventory, following can be the strategy for migrating the data to SAP: - Create a material master for the work in process and set the standard price as the cost incurred for that product (ie. Work in process) - Create a bill of material (which will be used only for this production order) including this material and other materials still to be consumed. - Create Routing for rest of the production process. - Bring the work in process material into inventory as of the cut off date. - Create the production orders in SAP for the Work in process and issue materials to production order. Complete the production process after the cut off date of the project. Tips by: K.S.Kulkarni What happens to planned after it has been converted into production order? When you convert Planned order to Production order. the planned order are offset by production order. Reference of planned order can be seen in the production order. How to attach a drawing for a material to BOM? Is it possible? Yes, you can attach a drawing. First create a document using Transaction Code "CV01N - Create Document". Attach your drawing in that document. The system will generate a document number. Assign this document in the BOM with item category D. Report in Long Term Planning - You use long term planning for your customers, what they need are very simple, just to calculate future requirements for 1 or 2 years. Are there any reports in SAP to list of material requirement from LTP? You need a list of material requirement from long term planning result for each item. Use MS70 then use MCEC. Scheduling planned order - How can you get planned orders scheduled so that you can do capacity leveling? MD11 and then Schedule works fine but ideally you would want the the planned order scheduled automatically on creation? You have tried setting up an action to schedule the orders but cannot get that to work either. When running MRP, try selecting "2" in the scheduling box this will bring planned orders into CM01 and CM21 Capacity planning CM01 - When you run capacity planning T-code: CM01, you found the plan orders are not included in the pegged requirement, you checked the profile, the check box for order and plan order are all actived. Guess that planned orders have been created without capacity requirement indicator in MRP ("2" - Lead Time scheduling), if this is the case, then when converted to process orders they will have impact on the Resource. If you want to see them as planned orders, re-run the MRP or change in every planned order, going to the Menu: Edit --> Scheduling Another couple of possibilities are to do with the routing/work centres used and whether it is actually calculates consumption of capacity of the category at the work centre being displayed in CM01 (it might consume a capacity pool or it might not consume the category). MPS in Background/Online - You want to run MPS for a plant either online or in the background, but you do not get any results. If you run MPS for a single material/plant, then everything is 100% OK.

You need to run a planning file and a consistency check first, transaction OMDO and MDRE respectively you'll need to set up two jobs to do it but it is straight forward, once you've done this set up the background job for MPS to run and do it in NEUPL first time round and then change to NETCH after that. What is the output of MPS run? From MPS run you plan the materials which are of 'A' type in the abc analysis (80% dollar value) that have to be planned beforehand. MPS is also a type of MRP only in which components just below the materials on which MPS run is taken place, are planned. Table for production order status - What is the table for finding status (for Ex TECO ed prodn orders). We are not able to find from AFKO and AFRU tables the status of production orders or at least the link tables if known can be mentionned. You are unable to link the structure caufvd and IOHEADER WITH AFKO and AFRU. JEST is the table. Data dictonary table for SOP planning data - You are using Standard SOP (Info structure S076), in which table can you see the planning values that you maintained in MC93 transaction? You looked under table "S076" and did not see any values there. Use T.Code MC95 to display your entries under the version which maintained the the table S076. Production order operation's component allocation - How does SAP know that an operation has components as indicated by the component allocation indicator? Tcode CO08. Component allocation is done via routing maintenance or BOM maintenance for the assembly. This is master data maintenance. As soon as a PO is created, the master data is read into the PO. How to delete groups of products? How to delete a group of products that was created in screen MC84? Delete the members in the product group and then archive the product group in transaction SARA, object=MM_MATNR. (The product group is created as a material master record with material type PROD and this record is deleted in SARA.) 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 SAP PP Test Questions (MCQ) 1. A plant can be a physical plant or a logical section of a plant a) Yes b) No. Ans: a Storage locations are areas where materials are stored within a plant a) Yes b) No. Ans: a A purchasing organization can buy for a number of plants a) Yes b) No. Ans: a A purchasing group is a sub-set of a purchasing organization a) Yes b) No. Ans: a

2. Strategy Group is relevant for Material Requirement Planning a) True b) False Ans: a 3. MRP can be caried out at : a) Plant Level b) All Routings c) Single item – single level d) Single item – multiple level Ans: a, c, d 4. In Material Requirement Planning a) Material availability is ensured b) If shortage exists the corresponding elements are planned c) Stock transfers are also possible d) The availability of the components is ensured via dependent requirements Ans: d 5. With Make – to Stock strategy 10 a) MRP run considers only Sales Orders b) MRP run considers only PIR c) MRP run considers both Sales Order & PIR d) Sales Order can consume PIR Ans: b 6. The Individual / Collective indicator in the material Master determines a) Whether a component is procured for a special customer requirement in the individual segment b) Requirement quantities of dependent materials are grouped together during MRP run c) The Material Requirement Planning d) The Special Procurement. Ans: c 7. ATP – Available to Promise (Availability check) a) System checks if all issues are covered by existing receipts b) Checks if receipts’ quantity still available to cover newly received issues Ans: a 8. Availability Check PIRs System does not check against PIRs a) True

b) False

Ans: b No ATP quantities, receipts or stocks are included a) True Ans: b

b) False

Determines if sufficient PIRs are planned to cover a SO a) True

b) False

Ans: b 9. Consumption based planning is usually used for following materials a) All A & B Class Materials b) Materials with smooth consumption pattern. Ans: b 10. For Planning at Phantom Assembly Level planned orders are created for Phantom assembly a) True

b) False

Ans: b 11. Stock Requirements List gives ___________________ situation of stock requirement for the material a) Static : of the last MRP Run b) Dynamic : Existing at current situation Ans: b 12. Is Sales order A Qty. 15 PC and Sales order B Qty. 25 PC are booked on same date and stock is 0 PC a) Separate Planned Order for each Sales Order shall be created if individual indicator is set b) Only one planned order is created if individual indicator is set c) Separate Planned Order for each Sales Order shall be created if Collective indicator is set d) Only one planned order is created if Collective indicator is set Ans: a, d 13. Planning can create the following after MRP run a) Planned Orders b) Production Orders c) Purchase Orders d) Schedule Lines Ans: a, b 14. NETCH is a) Used in Demand Management b) Key to run MRP for Total horizon c) Key to run MRP for Total Planning horizon d) Not related to MRP Ans: c 15. Regenerative Planning a) Plans all material for a specified plant b) Plans all material for a specified plant for total planning horizon c) Stands practical for the first time planning run Ans: Steps of a Typical Production Process

What are the steps of a typical production process? You can see the steps of a production process scenario as: Your Client being the Sub-contract vendor for the customers. A typical process will be as below : 1) Create materials masters for the Raw material and FERT materials in your system in tcode : MM01. 2) Create BOM in Tcode : CS01 for the FERT material using the Raw material created as BOM item. 3) Create Routing in Tcode : CA01 for the FERT material with the various operation ./ activities you perform on the raw material to convert it into FERT material. 4) Create Pricing for the FERT material in TCode : VK11 (provide only the Job work price) 5) Create a Sale order for the FERT Material in Tcode : VA01 6) Inward the raw material in Tcode : MB1C with movement type 501 E or 521 E (special Movement Type) 7) Create the Production Order right to Sale order in Tcode : CO08 8) Perform Goods Issue against the production order with the same spl movement 261 E. 9) Carry out the confirmation for the order. 10) Perform Goods receipt for the prodion order. It will go to Special stock i.e. Sale order Stock. 11) Perform delivery for the Sale order and PGI 12) Create Invoice SAP Production Execution Process This document material is basically an overview of the SAP Production Execution Process. -- By Victor There are in fact three types of production process that can be executed in SAP. They are : 1. Discrete Manufacturing 2. Repetitive Manufacturing 3. Production – Process Industries. The configuration settings related to Discrete Manufacturing and essential Repetitive manufacturing is discussed in detail here. First, it is good to understand what is happening in the system prior to the production execution process. a. Planning quantities are derived and maintained in the system. b. Material Requirement Planning run will generate the planned order for the net required quantity with the start date of the production process. c. Master data (BOM and Routing details) will be copied in to the planned order automatically during MRP run.

Here, I believe you have got an idea about the steps involved prior to the production execution process. Next, let’s discuss about the production execution process now. The SAP Production Execution process contains five important steps. They are : 1. Converting planned order to production order 2. Releasing the production order 3. Goods Issue for production order 4. Confirmation of production order 5. Goods Receipt against production order 1. Converting planned order to production order :Planned order has to be converted to production order to account the entire production. Production order or process order type has to be mentioned when converting the planned order. Entire master data will be copied to the respective order when converting the planned order. Order type is the most important configuration setting for production execution. 2. Releasing the production order :Release of production order is an important step in production order. Releasing of production order indicates the commencement of production. Unless the order is released, further processing of order is not possible. While releasing the production order system can perform : a) Material availability b) Capacity availability c) Creation of Batch d) Reservation creation Configuration settings related to the above functions are covered in Availability check, order type parameters. 3. Goods Issue for production order:Goods issue covers issuing required components to make the finished product to a production order. While making the goods issue, the document number can be updated in the production order. Configuration setting related to this is discussed in order type parameter. Goods issue can be made in parallel during confirmation of operation. Relevant configuration settings related to goods issue during confirmation are discussed in confirmation parameter. 4. Confirmation of production order :Reporting of usage of components and activities are termed as confirmation. Confirmation to the each operation will be executed according to the control key attached with each operation. - Confirmation configuration setting controls - Adhering to the sequence of operation - Under delivery / over delivery tolerance - Back-flush components

- Proposal and calculation of activity standard value Above configuration settings are in the confirmation parameter. 5. Goods Receipt against production order:Once the production is completed, finished products will be received from the production order into the respective storage area. This can be achieved through two ways a) Through confirmation. b) Through separate transaction. Document number will be generated for each goods receipt. This document number can be updated in the production or process order. Configuration settings related to these are in the Production scheduling profile and order type parameter. Now, you will easily understand What is Backflushing? It is the process of issuing components automatically while confirming the production or process order. Production Resources Tools Self Review Questions and Answers Select the correct answers to these SAP PP relevant questions on Production Resources Tools. 1) The R/3 System differentiates between the following types of production resources/tools, according to their properties and business function: A. Materials that are accounted for in materials management, for instance in inventory management, requirements planning and procurement. B. Equipment, for instance measuring instruments or valuable tool, which are serviced C. Documents, for instance drawings or programs, which use the document management system. D. Miscellaneous production resources/tools (with a PRT master record), that require less maintenance in the system.

2) For information about how to classify the other PRT categories, as follow: A. for materials - LO - Managing material Master Data B. for equipment - PM - Structuring Technical Systems C. for documents - CA - Document Management Guide

3) You use production resources/tools (PRT) that have an equipment master record you can, A. plan and monitor the wear of the PRT B. create a maintenance plan that accounts for the PRT

4) You create the following information for the maintenance planning of PRTs: A. a PRT wear counter that gives information about the level of wear for a PRT. B. the wear to be expected for each operation C. an activity related maintenance plan

5) You can only delete a production resource/tool (PRT) A. if it is no longer assigned to an operation B. if it is no longer linked with a document C. None of above

6) For information about how to set deletion flags for the other PRT categories, as follow: A. for materials - LO - Managing Material Master Data B. for equipment - PM - Structuring Technical Systems C. for documents - CA - Document Management

7) The PRTs must have a master record in the system. According to the PRT category the following conditions have to be met additionally: A. Materials, equipment and documents must be released, using their status, as production resources/tools. B. Production resources/tools with a PRT master record must be released in their status for use in resource planning. C. PRTs with material masters, PRT masters or equipment masters must be intended for use in routing in their task list usage.

8) The R/3 System distinguishes between the following types of production resource/tool on the basis of their attributes and business function: A. Materials considered in materials management, for as follow: in inventory management, material requirements planning, and procurement. B. Equipment such as measuring devices or high-quality tools requiring preventive maintenance. C. Documents such as drawings or programs for which document management functions are used. D. Other PRTs (with a PRT master record) requiring less maintenance.

9) In the following objects, you can assign PRTs to operations and phases: A. Task lists (including standard networks and recipes) B. Production orders and maintenance orders C. Networks --Correct Answers 1) A, B, C, D 2) A, B, C 3) A, B

4) A, B, C 5) A, B 6) A, B, C 7) A, B, C 8) A, B, C, D 9) A, B, C Interview Questions and Anwsers on SAP PP 1. If you have released Prdn order today and it had gone to shop floor. Next day it was found that there is shortage of material. What will you? 2. How you define Standard Cost and Variable cost in PP? 3. Where can you find Read PP Master in SAP(PP)? 4. What are all the settings done for configuring integration of PP with FICO? 1. Do availability check. You will get missing parts list. Procure those missing parts. Then confirm the production order. One more thing you can do, change customize setting so that user cannot release if parts are missing during order release. 2. Standard cost is the cost which is fixed for a period, variable cost is varying with period. As for example cost of semi finished, finished materials are fixed & cost of raw materials are varied. 3. You will find in master data tab page of production header data overview, CO02 - Read PP Master Data. Also from Functions menu you will get Read PP Master Data. This means that you want the system to re-update the production order with the latest BOM structure.

4. Assigning of Cost center to work center. Assigning Activity type to work center, Standard Cost estimate, Costing Run, Order settlement, Product costing. *-- Chandan Majumdar --1. Can MRP be carried out for one particular level of a bom ( Level code : 0001/0002 etc). Yes it can be done by running for specific materials (Single Material Single Level) 2 How Requiements( PIR,Sles Order, Customer Requirement) are reduced after they are produced? Reqmts are reduced automatically after Delivery is made to the Particular Order (In case of Strategy 11, the PIRs are consumed after the GR for Production Order) 3. Can't one material be assigned to more than one operation in a routing? One material from a BOM CANNOT be assigned to different Operations. It can be done by defining the material for so many times as required in the BOM

4. How to insert an inspection checkpoint at the end of an operation? If in process sample is to be defined, assign inspection type 03 in the Material Master. Then create MICs and assign them in the Routings. System automatically generates the Inspection Lots 5. Where we have to sw2pecify the teardown time in one operation? Teardown time can be defined as one of the Standard Parameters... 6. How the process time is calculated in a WC when both labour, Machine categories exist? Scheduling is done based on the Capacity Category we define in the Workcenter 7. How to create opbject dependencies in a BOM FOR A CONFIGURABLE MATERIAL? Go to Extras -> Object Dependency -> Assign For this U need to create Characteristics and Class (of Class Type 300) earlier 8. Can any body explain me why work scheduling view is required for semi finished and finished products? (Because we'll mention all details in MRP views) A) We need to maintain working scheduling view in order to make that finished or semi finished goods available for production as we assign production scheduler and production scheduler profile in this view, if not maintained conversion of planned order to production will not be possible. SAP PP Interview Questions 1. What are Traffic Lights in MRP? red = the stock is not available yellow - the stock is in average level stock green = the stock is available 2. What is MRP List and what is the use of it? Definition of the MRP List The system creates MRP lists during the planning run according to how you set the creation indicator. These lists contain the planning result for the material. The MRP list always displays the stock/requirements situation at the time of the last planning run and it also provides a work basis for the MRP controller. Changes that are made after the planning date are not taken into consideration, so the list is static. MRP lists are stored in the system until they are either deleted manually or replaced by new lists from a subsequent planning run. 3. What is the use of Stock Requirement List? In the stock/requirements list, the most up-to-date stock and requirements situation is displayed. The main difference between the MRP list and the stock/requirements list is that each time the stock/requirements list is called up, the system selects the various MRP elements and displays the most up-todate situation. You thus always see the current availability situation of the material in the stock/requirements list. Changes that are made after the planning date are displayed directly, so the list is therefore dynamic. Stock/requirements lists are not saved in a fixed state in the system, but are subject to change and only exist in the working memory. Comparison The screen layout of both lists is basically the same. The system automatically runs the rescheduling check directly when both lists are created and puts forward rescheduling proposals. The number of exception messages displayed in each list is roughly the same. The only difference lies in the fact that, due to the nature of the list, no exception messages can occur for newly planned MRP elements in the

stock/requirements list. Directly after the planning run, both lists contain the same information. As soon as a change relevant to MRP is made, the system updates the information in the stock/requirements list. As stock/requirements lists are subject to change, they cannot be set with a processing indicator. 4. What is MRP controller Means? The MRP controller is a person or a group of persons responsible for monitoring material availability. You can use the number entered here, for example, to select the planning results per MRP conroller. Every material that is relevant to the planning run must be assigned an MRP controller number in the material master record. You can also determine a special person for backorder processing who receives a mail if a goods receipt was posted for a missing part. You must enter the mail name of this person in the field entitled, recipient name. In addition, you can define a person or a group of persons, who are to informed if you send a mail from the MRP list or stock/requirements list to the MRP controller for the material displayed. Actions 5. What is MRP group and what is the use of it? MRP Groups In this step, you can carry out the total maintenance of the MRP groups and you can allocate a material type to an MRP group. The MRP group is an organizational object that can be used to allocate special control parameters for planning to a group of materials. You can maintain MRP groups if planning control per plant is not precise enough for your requirements and you want to allocate certain material groups different control parameters from the plant parameters. For this purpose, MRP groups are defined with these specific control parameters and are assigned to the material in the material master record (MRP 1 screen). For example, the following control parameters can be set for the total planning run: the creation indicator for the plarequisitions, MRP lists, and so on) the planning horizon the consumption mode The following is valid for total planning and single-item planning: for all materials without an MRP group, the system uses the plant parameters, or the entries in the initial screen of the planning run for all materials with an MRP group, the system uses the parameters recorded in the MRP groupnning run (creation of purchase 6. What is Purpose of Schedule Margin Key? In this step, you specify the floats for determining the basic dates of the planned orders. The floats are allocated to the material via the release period key in the material master record. Opening period The opening period represents the number of workdays that are subtracted from the order start date in order to determine the order creation date. This time is used by the MRP controller as a float for converting planned orders into purchase requisitions or into production orders. Float before production The float before production represents the number of workdays that are planned as a float between the order start date (planned start date) and the production start date (target start date). On the one hand, this float is intended to guarantee that delays in staging a material do not delay the production start. On the other hand, the production dates can be brought forward by means of the float to cope with capacity bottlenecks. Float after production The float after production should provide a float for the production process to cope with any disruptions so that there is no danger that the planned finish date will be exceeded. You plan the float after production between

order finish date (planned finish date) and scheduled end (target finish date). Release period The release period represents the number of workdays that are subtracted from the order start date in order to determine the production order release. The release period is only relevant for production order management. 7. What is opening period? Opening period The opening period represents the number of workdays that are subtracted from the order start date in order to determine the order creation date. This time is used by the MRP controller as a float for converting planned orders into purchase requisitions or into production orders. 8. What is SLA ? Service Level Agreements Service Level Agreements (SLA) define the attributes for service products (for example, maintenance, Hotline) that have been agreed upon with the customer in service contracts. The SLA confirms different parameters, such as response time, availability time and system availability. 9. What are Basic Dates? Earliest date for the execution of the production order. This date takes into account the float before production. If, on order creation, a planned order exists for the production order or process order, then the order dates are taken from the planned order. When scheduling the production order the system tries to adhere to the order dates (if necessary, with reduction measures). If it is not possible to adhere to the basic dates and if the control parameter in Customizing allows the basic dates to be adjusted, the system adjusts the basic dates of the order during the scheduling run. If the control parameter in Customizing does not allow the basic dates to be adjusted, the order keeps the basic dates of the planned order. If the production order is created manually, you must enter at least one order date manually. The scheduling type determines, which order dates you must enter. 10. What is planning time fence? The planning time fence specifies a period within which no automatic changes are to be made to the master plan. The planning time fence is maintained in workdays. 11. What is Planning Horizon? In this step, you define the planning horizon. This planning horizon specifies the period for the "Net change planning in the planning horizon". In this kind of net change planning, only those materials that have undergone a change that is relevant to MRP within the planning horizon are included in the planning run. Such materials receive a net change planning indicator in the planning file. You make this specification for a plant. You can define an alternative planning horizon for MRP groups 12. What is Group BOM? Alphanumeric character string used to uniquely identify a BOM. Use If you assign a "meaningful" number to a BOM group, this gives you an additional way of accessing the BOM. The system stores the following under a BOM group: all the alternatives in a multiple BOM all the BOMs entered for a variant BOM 13. What is costing? How it is affected the PP?

Determining the material costs of a product. When you calculate production costs using a quantity structure, the system automatically determines the BOM and all the BOM items that are relevant to costing, in order to calculate manufacturing costs. 14. What is Meaning of Customized Reports? The report which is not using SAP standard reports. 15. In Project the Customization is comes under Which Phase? Realization. 16. How you get the Ticket? After release order, the reservation will provide the ticket to pick production material. 17. What are GAPS? Some Examples? The GAPS are some issue in blue print that SAP cannot capture or providing the client business process. 18. What is LSMW? The LSM Workbench is an SAP System tool that supports you when copying data from non-SAP. systems. 19. After Doing Realization How we will check whether it is working or not? Doing Final preparation to check using the test case from user. 20. What do we do in Realization Phase? Provide ARICEF, Configuration Documents, integration test, BPP, UAT, Unit Test and implements some SAP notes. 21. How to Move to the Realization Phase? You must have some blueprints to go in next phase. 22. In LSMW which is most important Step? Maintain Object Attributes Maintain Source Structures Maintain Source Fields Maintain Structure Relations Maintain Field Mapping and Conversion Rules Maintain Fixed Values, Translations, User-Defined Routines.

Transaction Code To View All SAP Tables What is the transaction code to view all SAP (PP) table,or there is some other way to view? By: Riki Paramita To browse tables which specified for PP module only, you can use SE16 with a specified application component & sub-component. First, go to SE16, browse the application component (ex : PP), then select the sub-component (ex : PP-SFC, for Production Orders related tables); and all tables within the specified area will be displayed. In tcode SE16, click the Down Arrow next to the Table Name field: Then it will pop-up a screen, look at the bottom of the screen:

Then select components by clicking the + sign to open up the sub-component you want. For e.g.:

Some important tables within the PP area : MAST - Material BOM STKO - BOM Header STPO - BOM Positions (detail) MAPL - Assignment for Task Lists to Materials PLKO - Routing Group Header PLSO - Routing Group Sequence PLPO - Routing Group Operations AFKO - Production Order Header AFPO -Production Order Position (details) Related tables in MM area : MAKT - Material Descriptions MARA - General Material Data MARC - Plant Data for Material MARD - Storage Location Data for Material MAST - Material to BOM Link

Commonly Used Tcodes in PP Module Part 1 MATERIAL CREATE-GENERAL CHANGE FLAG FOR DELETION DISPLAY DISPLAY CHANGES

MM01 MM11 MM02 MM12 MM13 MM06 MM16 MM03 MM19 MM04 MM14

IMMEDIETELY SCHEDULE IMMEDIETELY SCHEDULE ACTIVATE IMMEDIETELY SCHEDULE DISPLAY CURRENT DISPLAY AT KEY DATE ACTIVE CHANGES SCHEDULE CHANGES

OTHER

MM17 MMAM MMBE MMPV MMRV

MASS MAINTENANCE CHANGE MATERIAL TYPE STOCK OVERVIEW CLOSE PERIOD ALLOW POSTING TO PREVIOUS PERIOD INSTANT MATERIAL VIEW ENTER STORAGE LOCATIONS MATERIAL LIST ARCHIVE/DELETE DISPLAY ARCHIVE

MM50 MMSC MM60 ARCHIVING(MATERIAL) MM71 MM72 BILL OF MATERIAL (MATERIAL BOM) CS01 CREATE CS02 CHANGE CS03 DISPLAY EXTRAS CS28 ARCHIVING CS20 MASS CHANGES EVALUATION/BOM CS11 BOM MULTILEVEL EXPLOSION/MATERIAL CS12 STRUCTURE MULTILEVEL BOM CS13 SUMMURISED BOM WORK CENTRES CR01 CREATE CR02 CHANGE CR03 DISPLAY CA85 REPLACE CAPACITY CR11 CREATE CR12 CHANGE CR13 DISPLAY HIERARCHY CR21 CREATE CR22 CHANGE CR23 DISPLAY LINE HIERARCHY LDB1 CREATE LDB2 CHANGE LDB3 DISPLAY REPORTING CR60 W/C INFORMATION SYSTEM CR05 W/C LIST CR06 COST CENTRE ASSIGNMENT CR07 W/C CAPACITIES CR08 W/C HIERARCHY WHERE USED CA80 WORK CENTRE CR15 CAPACITY CR10 CHANGE DOCUMENTS EXTRAS CR09 STD. TEXTS TASK LIST CR41 ARCHIVING ROUTING STAD. ROUTING CA01 CREATE CA02 CHANGE CA03 DISPLAY REF. OPERATION SETS CA11 CREATE CA12 CHANGE CA13 DISPLAY RATE ROUTING CA21 CREATE CA22 CHANGE CA23 DISPLAY REF. RATE ROUTING CA31 CREATE CA32 CHANGE CA33 DISPLAY EXTRAS CA85 REPLACE W/C MASS CHANGES CA95 REPLACE REF. OP. SET CA75 REPLACE PRT DELETE TASK LIST CA99 WITH ARCHIVING CA98 W/O ARCHIVING REPORTING CA80 WORK CENTRE WHERE USED LIST CA90 REF. OP. SETS CA70 PRODUCTION RESORCE TOOLS COST CENTRE OKKP MAINTAIN CONTROLLING AREA

KS01 KZS2 KA01 KA06 KL01 KP26

CREATE COST CENTRE CREATE COSTING SHEET CREATE PRI. COST ELEMENT CREATE SEC. COST ELEMENT CREATE ACTIVITY TYPE ACTIVITY TYPE/PRICE PLANNING

What is the T-Code for trigger point? CO30 CO31 CO32 CO33

MENUCO30 SAPMCNSM SAPMCNSM SAPMCNSM

Standard trigger points Create standard trigger point Change standard trigger point Display standard trigger point

What the tcodes to archieve/delete a material BOM? - by Jia Look at this option to delete a material BOM There are two ways of deleting BOMs: - Using the Delete function. - Using the Deletion indicator. If you select the deletion indicator, the BOM is archived in the next reorganization run, and can be deleted if required. In the BOM header, you set the indicator that controls physical deletion after the archiving run. You can still process the BOM within its validity period.This also applies if the deletion indicator is entered with reference to a change number with a valid-from date that is after the date of the next reorganization run You can use the below mentioned tcodes: CS25/CS28 Archiving for BOMs CS26 BOM deletion CS27 Retrieval of BOMs

Commonly Used Tcodes in PP Module Part 2 SALES AND OPERATIONS PLANNING PRODUCT GROUP MC84 MC86 MC85 GRAPHIC MC91 MC92 PLANNING MC81 FOR PRODUCT GROUP MC82 MC83 MC75 FOR MATERIAL MC87 MC88 MC89 MC74 MC9K VERSION MANAGEMENT MC78 MC80 FLEXIBLE PLANNING MC93 PLANNING MC94 MC95 MC9K TOOLS/PLANNING TYPE MC8A MACRO MC8B MC8C EVENT MC64

CREATE CHANGE DISPLAY PRODUCT GROUP OVERVIEW CREATE CHANGE DISPLAY TRANSFER PG TO PLANNING CREATE CHANGE DISPLAY TRANSFER MATERIALS TO DM MATERIAL AVAILABILITY COPY DELETE CREATE CHANGE DISPLAY MATERIAL AVAILABILITY CREATE CHANGE DISPLAY CREATE

ROUGH CUT PLANNING PROFILE ENVIRONMENT ACTIVITY REQT.

SETTINGS DISSAGGRIGATION

FORECASTING INDIVIDUAL FORECAST TOTAL FORECAST

DEMAND MANAGEMENT PIR

MC65 MC66 MC35 MC36 MC37 MC90 KSPP KSBL KSOP CPBL MC9C MC96 MC76 MC77 MC75 MC74

CHANGE DISPLAY CREATE CHANGE DISPLAY TRANSFER MATERIALS TO DM TRANSFER TO COST CENTRE COST CENTRE OLANNING REPORT TRANSFER TO ACTIVITY BASED COSTING PLANNING REPORT PROCESSES REPORTING FORECAST PROFILE BREAKDOWN PG PLAN DISPLAY PG PLAN TRANSFER PG TO PLANNING TRANSFER MATERIALS TO DM

MP30 MP31 MP32 MP38 MP33 MP39 MPBT MPDR

EXECUTE CHANGE DISPLAY EXECUTE REPROCESS PRINT EXECUTE BACKGROUND PRINT BACKGROUND

MD61 MD62 MD63 MD65 MD66 MD70 EVALUATION MD73 MD79 MD4C MD72 CUSTOMER REQT. MD81 MD82 MD83 REPETITIVE MANUFACTURING MASTER DATA C223 PRODUCT COST PLANNING COSTING RUN CKMATSEL SELECTION LIST CKMATCON CK40N

CREATE CHANGE DISPLAY REQTS. FOR SCINARIO COPY SIMULATED DEPENDENT REQT. COPY TOTAL FORE CAST DISPLAY TOTAL REQT. EXCELL INTERFACE ORDER REPORT CHARECTERISTICS PLANNING CREATE CHANGE DISPLAY PRODUCTION VERTION CREATE Edit EDIT COSTING RUN

Commonly Used Tcodes in PP Module Part 3 Material Requirement Planning Menu Nodes TransactionActivity Master Data MD25 Create planning calendar MD26 Change planning calendar MD27 Display planning calendar MDSA Display BOM explosion number MDSP Edit BOM explosion number MEQ1 Maintain quota file OPPP Explode BOM by date MDUS Display project assignment MDUP Process project assignment MDL1 Create production lot MDL2 Change production lot MDL3 Display production lot Planning MD20 Create planning file entry MD21 Display planning file entry MDAB Set up planning file entry in background MDRE Check planning file entry MD01 Total planning online

Evaluations

Planned Order

LONG TERM PLANNING PALNNING SCENARIO

MDBT MD03 MD02 MD43 MD50 MD51 MF52 MF50 MF57 MF51 MD04 MD07 MD05 MD06 MDLD MD45 MD46 MD44 MD47 MD48 MD4C MD09 CO46 MD11 MD12 MD13 MD16 MD14 MD15 MDUM CO40 CO41 CO48 COR7 COR7_PC COR8 MDVP MDAC

Total planning in background Single-item, single-level planning Single-item, multi-level planning Interactive single-item planning Multi-level, make-to-order planning Multi-level project planning Display planning table Change planning table Planning table by MRP lists Planning table by production list Stock/requirements list Collective access of stock/requirements lis MRP list Collective access of MRP lists Print MRP list Planning result Collective access of planning result Planning situation for a material Planning situation for a product group Cross-plant planning situation Order report Pegged requirements Order progress Create planned order Change planned order Individual access of planned order Collective access of planned orders Individual conversion of planned order into Collective conversion of planned orders int Convert planned order into purchase requisi Convert individual planned order into produ Collective conversion of planned orders int Partial conversion of planned order into pr Individual conversion of planned order into Collective conversion of planned orders int Partial conversion of planned order into pr Collective availability check Execute action for planned order

MS31 CREATE MS32 CHANGE MS33 DISPLAY PLANNING RUN MS01 ON LINE MSBT SA BACKGROUND JOB MS02 SINGLE ITEM - MULTI LEVEL MS03 SINGLE ITEM - SINGLE LEVEL MS50 SINGLE ITEM - SALES ORDER MS51 SINGLE ITEM PLANNING, PROJECT MFSO PLANNING TABLE EVALUTIONS MS05 MRP LIST MATERIAL MS06 MRP LIST COLLECTIVE DISPLAY MSLD PRINT MRP LIST MS04 STOCK/REQUIREMENTS LIST MS07 STOCK/REQUIREMENT LIST COLLECTIVE DISPLAY MS44 PLANNING SITUATION MATERIAL MS47 SITUATION PRODUCT GROUP MPS-MASTER SCHEDULE ITEMS TOTAL PLANNING MD40 ON LINE MDBS SA BACKGROUND JOB MD41 SINGLE ITEM - MULTI LEVEL MD42 SINGLE ITEM - SINGLE LEVEL MD43 SINGLE ITEM - INTERACTIVE MD50 SINGLE ITEM - SALES ORDER MD51 SINGLE ITEM PLANNING, PROJECT *** EVALUTION IS SIMILAR TO MRP PRODUCTION CONTROL ORDER - CREATE CO01 WITH MATERIAL

CONTROL

GOODS MOVEMENT MATERIAL STAGING

CONFIRMATION FOR OPERATION

TOOLS-ARCHIVING CAPACITY PLANNING EVALUTION

CO07 CO40 CO41 CO08 CO10 CO02 CO03 MD04 COHV COMAC CO05N CO04N CO09 MF65 MF68 MB1A MB31 COWBPACK CO1V CO14 CO13 CO1L CO1P CO78 KOAA

WITHOUT MATERIAL FROM PLANNED ORDER COLLECTIVE CONVERTION OF PLANNED ORDER FOR SALES ORDER FOR PROJECT CHANGE DISPLAY STOCK/REQUIREMENTS LIST MASS PROCESSING COLLECTIVE AVAILABILITY CHECK COLLECTIVE RELEASE PRINT AVAILABILITY OVER VIEW STOCK TRANSFER FOR RESERVATION LOG GOODS ISSUE GOODS RECEIPT PACK MATERIAL TIME TICKET DISPLAY CANCEL REQUESTED CONFIRMATIONS PREDEFINED PROCESSES ORDER SETTELMENT DOCUMENTS

CM01

LOAD

WORK CENTER VIEW

CM02 CM03 CM04 CM05 CM07 EXTENDED EVALUTION CM50 CM51 CM52 LEVELLING CM21 WORK CENTER VIEW CM22 INDIVIDUAL CAPACITY VCM27 CM28 ORDER VIEW CM31 CM32 AVAILABLE CAPACITY CR12 CAPACITY CR13 OP4A OP43

ORDERS POOL BACKLOG OVERLOAD VARIABLE WORK CENTER VIEW INDIVIDUAL CAPACITY VIEW ORDER VIEW PLANNING TABLE (GRAPHICAL) PLANNING TABLE (TABULAR) PLANNING TABLE (GRAPHICAL) PLANNING TABLE (TABULAR) PLANNING TABLE (GRAPHICAL) PLANNING TABLE (TABULAR) CHANGE DISPLAY SHIFT SEQUENCE FACTORY CALENDER

Where shall we maintain number range for planned orders? To maintain number range for planned order. Go to: MM-->CBP-->NUMBER RANGE-->DEFINE NUMBER RANGE FOR PLANNING RUN. Don't allow External Number Assignment. What is t.code for planning calendar and factory calendar? Planning Calendar--MD25 Factory Calender--SCAL Menu Path SPRO-->Materials Management-->Master Data-->Maintain Planning SPRO-->Calendar--md25 SPRO-->General Settings-->Currencies-->Expiring Currencies-->Maintain SPRO-->Calendar-->SCAL

SAP ECM Transaction Codes and What is Engineering Change Management What is engineering change management? The Engineering Change Management (ECM) is used to track and control all the changes with reference to Material master, BOM, Work Center & Routing. The first step you need to do is to create a Change master thru CC01 T-code. The system will give you one change number. Using this number you can change all the masters record. By default, you need to activate the change number, thru ABAP program, you need to activate this field as a mandatory. Through authorisation we can control the access. The following are SAP ECM transaction code activities in Engineering Change Management. Change number CC01 - Create change number CC02 - Change change number CC03 - Display change number Object management record CC22 - Change object management record CC23 - Display object management record Engineering Change Management for production orders COCM - Change order process u2013 source item Revision level CC11 - Create revision level for material CC12 - Change revision level for material CC13 - Display revision level for material CC15 - Change revision level for document CC16 - Display revision level for document Reporting CS80 - Material BOM change document CV80 - Document BOM change document CS82 - Order BOM change document CC05 - Change overview CC60 - Change hierarchy CJ00 - Find digital signatures Configuration Management CMWO - Configuration Management workbench Undo Changes CCUNDO - Undo changes with Engineering Change Management (Available from SAP ECC 6.0)

Tcodes of Common SAP PP Process Step 1: Material Master Logistics > Production > Master Data > Material Master > Material > Create General > Immediately MM01 Step 2: BOM creation Logistics > Production > Master Data > Bills of Material > Bills of Material > Material BOM > Create CS01 Step 3: Work Center creation Logistics > Production > Master Data > Work Center > ( New Screen ) Work Center > Create CR01 Step 4: Route creation Logistics > Production > Master Data > Routings > Routings > Routing > Create CA01 Step 5: PIR Generation Logistics> Production>production planning>demand management>PIR>Create MD61 Step 6: MRP Run Logistics>Materials Management>Material planning>MRP>MRP>Total Planning>Online MD01 or Logistics > Production > MRP > MRP > Sng-Item, Multi-Level MD02 Step 7: Evaluation through MRP list and Stock requirement list Logistics>Materials Management>Materials Planning>MRP>Evaluations>MRP List>Individual Display MD05 Logistics>Materials Management>Materials Planning>MRP>Evaluations>Stock Requirements List MD04 Step 8: Conversion of Planned order to Production order Logistics > Production > Production control > Order > Create > With a planned order CO40 or Logistics >Production > Production control >Order > Create >With material CO01(For creating production order Without planned order) Step 9: Order management Logistics >Production > Production control >Order > Change >With material CO02 Step10: Confirmations Logistics >Production >Production control >Confirmation >Enter >For order CO15 or Logistics >Production >Production control >Confirmation >Enter >For Operation >For time ticket CO11N Step11: Goods issue 1. Logistics >Production >Production Control >Environment >Goods Movement >Goods Issue 2. Logistics >Materials Management >Inventory Management >Goods Movement >Goods Issue MB1A-261Movement type Step12: Goods receipt

Logistics > Production > Production Order > Environment > Material Movement > Post Mat to Stock or Logistics > Materials Management > Inventory Management > Goods Movement > Good Receipt > For Order MB31 Step13: Techo Or Close Order. This can be done from Prd. Order Header menu. SAP PP Customizing Transaction Codes Tcode Name OLPF Customizing Production Order OPJ0 Maintain User OPJ1 Maintain User Profiles OPJ2 Production order stock determination OPJ3 Maintain Authorizations OPJ4 Schedule batch function request OPJ6 Maintain Status Profiles OPJ7 Maintain Routing Usage OPJ8 Maintain Operation Control Key OPJ9 Maintain prod. scheduler group OPJA Maintain setup group/group category OPJB Specify system messages OPJC Maintain Wage Groups OPJD Item Categories OPJE User Selection OPJF Automatic Selection OPJG Maintain Default Values OPJH Order types production order OPJI BOM Usage Priorities OPJJ Maintain Scope of Check OPJK Maintain Control OPJL Maintain Checking Rule OPJM Application-Specific Criteria OPJN Maintain Scheduling Type OPJO C MM-BD units of measurement

OPJP Maint. acct.assgnm.types for orders OPJQ Standard Value Key OPJR Maintain move time matrix OPJT Maintain Strategy Levels OPJU Production order control parameters OPJV Maintain Capacity Category OPJW Maintain Capa.Planr.Grp for WrkCentr OPJX Factory Calendar C OPJY Maintain perf. efficiency rate key OPJZ Maintain Release Periods OPK0 Confirmation Parameters OPK2 Formula Parameters OPK3 Define Formula OPK4 Confirmation Parameters OPK5 Maintain variances OPK6 List Layout OPK7 Accessing Customizing PDC transfer OPK8 Maintain print control prod. orders OPK9 Maintain Goods Receipt Valuation OPKA Maintain Movement Types OPKB Control parallel confirmation OPKC Control confirmation process chain OPKD Control confirmation process chain OPKE Screen Sequence for Components OPKF Control parallel confirmation OPKG Maintain Messages OPKH Maintain Breakpoints OPKI Maintain Collective Confirmation OPKJ Maintain PRT Control Key OPKK Standard Text OPKL Formula Parameters OPKM Define Formula OPKN Overview variant production control

OPKO Command File for Production Orders OPKP Shop floor control profile OPKS Maintain Origins for CO Object OPKT Initial Screen: Settlement Structure OPKV Print Flag OPKW Print shop papers OPKX Deletion Flag/Indicator OPKY Archiving OPKZ Customizing Matchcode for ProdOrder OPL2 Maintain trigger point group OPL3 Trigger point usage OPL4 Profile for missing parts list OPL5 Order type LIS parameters OPL6 Profile for documented goods mvmts OPL7 Order change management profile OPL8 Order type parameters: Overview OPL9 Parameters for order change mgmt OPLA Conditions: V_T682F for H CO OPLB "CondTab: Create (batch, prod.)" OPLC "CondTab: Change (batchs, prod.)" OPLD "CondTab: Display (batches, prod.)" OPLE Strategy types: Batch determ. (prod) OPLF Access: Maintain batch determ.(prod) OPLG Batch determ.: Procedure for prod. OPLH Overview variant - production orders OPLI Background job for goods movements OPLJ "Job ""Fast entry confirmation""" OPLK Overall profile for order prog. rep. OPLL Order progress: Displayed fields OPLM Order progress: Displayed fields OPLP "Job ""Convert planned order""" OPM0 Maintain profile - field selection OPM2 Maintain Detail Screen Control Oper.

OPM3 Maintain Detail Scrn Control Header OS11 Spare Part Indicators OS12 Material Provision Indicators OS13 Item Categories OS14 Material Types Allowed in BOM Item OS15 Variable-Size Item Formulas OS16 BOM Item Object Type OS17 Explosion Types OS18 Relevancy to costing OS20 BOM Usage OS21 BOM Usage Default Values OS22 Copying Defaults for Item Statuses OS23 BOM Statuses OS24 Material Types Allowed in BOMs OS25 BOMs with History Requirement OS26 Laboratory/Office OS27 Modification Parameters for BOMs OS28 Defaults for BOMs OS29 User-Specific Settings for BOMs OS30 Application OS31 BOM Usage Priorities OS32 Alternative BOM Determination OS33 Alt. Determination in Inventory Mgmt OS34 Alt. Determination in Costing OS35 Alt. Determination in Production OS36 Alt. Determination in SD OS37 Alt. Determination in PM OS38 Alt. Determination in MRP OS40 Generate BOM Transfer File OS41 Transfer BOM without Long Text OS47 Field Groups: Assigned Fields OS48 Field Groups: Definition and Descs OS70 User-Specific List Profiles

OPJS - Defining Reduction Strategy Give a business scenario where reduction strategy can be used? Reduction Strategy can be used in the following area: 1. Lead Time in any operation under work center. This basically the percentage of reduction in various operation timing like Move Time, Queue Time, Inter-operation Time to optimize the Scheduling. This reduction can be by Overlapping and Splitting based on the setting in OPJS. 2. You can specify maximum 6 reduction level. 3. Reduction Strategy can be used in Network in Project System, Quality Planning, Scheduling. 4. In OPU3 - Define Production Scheduling Profile - you include this reduction type in All Operation, Max reduction level, % in reduction in Float. Why do we need to maintain Reduction strategy? When the lead time of the operation exceeds the basic dates, system try to reduce the lead time of operation time by using reduction strategy. This strategy reduce the lead time by following ways, 1. Reducing move time 2. Queue time 3. Overlapping (reduction in opn time) 4. Splitting (reduction in opn time) In OPU5 and OPU3, reduction strategy is assigned. In this you can limit the system to use strategy up to six levels. Ex: In production order Basic start date is 20.10.2099 & finish date 25.10.2099. But scheduled date 18.10.2099 and 25.10.2099 So, system will try to reduce the lead time to match to basic dated by using reduction strategy. Configuration These steps are done for defining the reduction strategy. Procedure 1. Access the activity choosing one of the following navigation options: IMG Menu Production -> Basic Data -> Routing -> Operation Data -> Define reduction strategy Transaction Code : OPJS 2. On the Change View “Reduction strategy”: Overview screen, choose New entries. 3. On the New Entries: Details of Added Entries screen enter BP01 in the Plant field and Standard reduction strategy in the Reduction strategy field. 4. Select the entry and choose Reduction levels from the Dialog Structure to get to Change View “Reduction levels”: Overview screen.

5. On the Change View “Reduction levels”: Overview screen, you can make the following entries: R 1 2 3 4

Red. queue Transport 50 100 Indicator set 100 Indicator set 100 Indicator set

Overlap

Indicator set Indicator set

Split

Indicator set

6. Save your entries. 7. Your reduction strategy is defined.

SAP Production Planning Table Demand Management PBED Independent Requirements Data PBIM Independent Requirements by Material Repetitive Manufacturing SAFK RS Header Master Data S025 LIS -- Run Schedule Quantities S026 LIS -- Material Usage S028 LIS -- Reporting Point Statistics CEZP Reporting Point Document Logs CPZP Reporting Points - Periodic Totals MRP Records MDKP MRP Document Header Data MDTB MRP Table Structure (no data) PLSC Planning Scenario (Long-term Planning) MDFD MRP Firming Dates MDVM Planning File Entries S094 LIS -- Stock/Requirements Analysis Reservations RESB Reservations/Dependent Requirements Planned Orders PLAF Planned Orders

Discrete Production AFKO Order Header AFPO Order Item Detail AFVC Order Operations Detail AFFL Order Sequence Details AFFH Order PRT Assignment AFBP Order Batch Print Requests AFRU Order Completion Confirmations AFFW Confirmations -- Goods Movements with Errors AFRC Confirmations -- Incorrect Cost Calculations AFRD Confirmations -- Defaults for Collective Confirmation AFRH Confirmations -- Header Info for Confirmation Pool AFRV Confirmation Pool AFWI Confirmations -- Subsequently Posted Goods Movements Classification KLAH Class Detail CABN Characteristic Detail AUSP Characteristic Values CAWN Characteristic Values CAWNT Characteristic Value Texts KSML Characteristic Allocation to Class KSSK Material Allocation to Class

SAP PP Master Data Tables MASTER DATA Engineering Change Management AENR Customer and priority AEOI Revision Numbers Work Center CRHD Workcenter Header Data CRCA Workcenter Capacity Allocation CRCO Workcenter Cost Center Assignment CRHH Hierarchy Header CRHS Hierarchy Structure CRTX Workcenter Text KAKO Capacity Header KAZY Intervals of Capacity Routing PLPO PLKO MAPL PLAB PLAS PLMZ PLPH PLFH PLWP PLMK

Routing Operation Details Routing Header Details Routing Link to Material Relationships - Standard Network Task List - Selection of Operations Component Allocation CAPP Sub-operations PRT Allocation Maintenance Package Allocation Inspection Characteristics

Bill of Material STPO BOM Item Details

STPU STKO MAST STZU STAS STPF

BOM Sub Items (designators) BOM Header Details BOM Group to Material BOM History Records BOM Item Selection BOM Explosion Structure

Line Design LDLH Line Hierarchy Header LDLP Line Hierarchy Items LDLT Line Hierarchy Takt Times LDLBC Takts/No. Individual Capacities per Line LDLBH Line Balance Header LDLBP Line Balance Items LDLBT Line Hierarchy Entry and Exit Takts PRT's CRFH CRVD_A CRVD_B CRVE_A CRVE_B CRVM_A CRVM_B CRVS_A CRVS_B

PRT Master Data Link of PRT to Document Link of Document to PRT Assignment of PRT data to Equipment Assignment of equipment to PRT data Link of PRT data to Material Link of Material to PRT data Link of PRT Internal number to PRT External number Link of PRT External number to PRT Internal number

How to create a query that is very similar to CA03? What tables contain those information and what are the relationships? See below routing table relationships: Table MAPL, pass input material number, plant, routing group counter. Table PLKO, field PLNNR, PLNAL eq mapl-plnnr, mapl-plnal Table PLAS, field PLNNR, PLNAL eq mapl-plnnr, mapl-plnal and LOEKZ ne ' ', take field PLNKN Table PLPO, field PLNNR, PLNKN eq plas-plnnr, plas-plnkn You will get correct result same as CA03 list.

Table of the Order Production Operation Which is the table of the order production operation details? I need to get the activities for production order : Setup, Labor, Machine, Confirmed and to confirm. I can see look at this in CO02 / Operation Overview (f5) / Operation Detalis / Qty-Activities That is probably the hardest information to piece together, I used 5 tables with multiple joins to get User Fields for operations in a production order. Maybe you can use something simular. AFKO - this is for your basic production header info - order number, basic finish date etc

S022 - this is for your operation header details - operation number, Work centre etc if you are only after the header details such as setup time and execution time, you can probably stop here without going to AFVC or AUFV (you definitely need AUFK if you want order status) AUFK - this is for your order master data - Order released flag, order complete flag, technically complete date, you'll need this to filter out closed orders AFVC - this is to link to the detail table - however I used the control key field in it so I would know whether it was a MILE stone or GPP1 for confirmation's sake AUFV - this is the user field table - you may want to replace this with whatever detail you are after Delete all the automatic joins: AFKO -> AUFK on: AUFNR -> AUFNR AFKO -> S022 on: AUFNR -> AUFNR PLNBEZ -> MATNR AFKO -> AFVC on: AUFPL -> AUFPL S022 -> AFVC on: WERKS -> WERKS PLNFL -> PLNFL VORNR -> VORNR The join below is for user fields in operation detail, you will have to find your own relevant table, but I assume the two key fields will be the same? AFVC -> AFVU on: AUFPL -> AUFPL - Routing number of operations in the order APLZL -> APLZL - General Counter for order

Cost Analysis Table In Production Order How to find the cost breakup table in SAP? The cost breakup analysis that is shown in the production orders? Try program RKACSHOW, see note 28145. RKACSHOW shows all the tables that are updated on an order. I managed to find the cost analysis details table for the CO Production Order: COVP - CO Object: Line Items (by Period and Document Header) Use tcode SA38 or SE38 to run the report RKACSHOW (5 star for this report) Order............... 509060343 Ledger.............. 0 Object Number OR000509060343 File

No.of Rec. Name

JSTO JCDO JEST JCDS COBRA COBRB AUAK COKA COKP COSPA COSPRA COSPD COKS COSSA COSSD COVP COEPD COEPBR COVJA COOI V_COFP COKR COSRA COVPR COVJRA COKL COSLA COVPL COVJLA COSLD COSTA COVPT COVJTA COSBA COSBD COVPB COANZ FMSU V_COFP RPSCO RPSQT

- Status object information - Change Documents for Status Object (Table JSTO) - Individual Object Status - Change Documents for System/User Statuses (Table JEST) - Settlement Rule for Order Settlement - Distribution Rules Settlement Rule Order Settlement 2 Document Header for Settlement 3 CO Object: Control Data for Cost Elements CO Object: Control Data for Primary Planning 4 CO Object: Cost Totals for External Postings (All Periods) CO Object: Enhancement to COSPA for Recipe Planning 2 CO Object: Settled Primary Cost Totals CO Object: Control Data for Secondary Planning 1 CO Object: Cost Totals for Internal Postings (All Periods) 1 CO Object: Settled Secondary Cost Totals - CO Object: Line Items (by Period and Document Header) - CO Object: Line Item Settlement, Not Valuated, With Status - CO Object: Valuated Line Item Settlement - CO Object: Line Items by Year + Doc. Header for All Periods - Commitments Management: Line Items - Document Lines (Flow of Funds) and Document Header CO Object: Control Data for Statistical Key Figures CO Object: Statistical Key Fig. Totals (All Periods) - CO Object: LIs for Stat. Key Figs (by Period and Doc. Hdr) - CO Object: LIs for Stat. Key Figs (by FYear; All Periods) CO Object: Control Data for Activity Types 1 CO Object: Activity Type Totals (All Periods) - CO Object: LIs for Acty Types (by Period and Doc. Header) - CO Object: LIs for Acty Types (by Year, Doc. Hdr; All Prds) CO Object: Activity Type Totals - of Which Settled CO Object: Price Totals (All Periods) - CO Object: LIs for Prices (by Period and Document Header) - CO Object: LIs for Prices (by FYear, Doc Hdr; All Periods) CO Object: Total Variances/Results Analyses - All Periods CO Object: Total of variances/accruals, of which settled - CO Object: Variance/Res.Analysis and Doc. Header Line Items Index of Objects With Down Payments/Requests FI-FM Totals Records - Document Lines (Flow of Funds) and Document Header Project info database: Costs, revenues, finances Project info database: quantities

SAP MRP Area Forecast Table Receive a ticket from user that their customized MRP report was wrong. The MRP Area forecast data was not shown correctly. It was showing the Plant Forecast data instead of the MRP Area forecast data.

I was able to dig out the MRP forecast table which was as follows. MRP Forecast Relevant Table MAPR - Material Index for Forecast DBPR - Material Index MRP Area for Forecast PROP - Forecast parameters PROW - Forecast Values S031 - Statistics: Movements for current stocks S033 - Statistics: Movements for Current Stock (Individual Records) With the MRP table, I found the forecast data were stored in table PROP

MRP Forecast Data Link

Key Field: PROP-PNUM1 - Pointer: forecast parameters

Material Index for Forecast MAPR-PNUM1 - PROP-PNUM1

Material Index MRP Area for Forecast DBPR-PNUM1 - PROP-PNUM1 With the information of table MAPR and DBPR the abap programmer was able to do the necessary changes to the MRP customized report.

MRP Report In SAP What are the standard MRP reports available in SAP? The following are the standard MRP programs that is available in SAP: RHLOG24D - Program for Object Type T024D: MRP Controller RM61SR00 - Background Program: Creating MRP Record for Changing BOM Explosion No. RMCB0400 - MRP Controller Analysis RMCB0405 - MRP Controller Analysis: Data Selection Report RMDLDR00 - Print MRP List RMDLDR01 - Print MRP List: Long-Term Planning RMDMAIL4 - Send e-mail to MRP controller RMDMAIL5 - Workflow: mail to MRP Controller RMMDAS10 - Exception statistics for MRP RMMDBTCH - MRP RMMDDIBE - Mass processing of MRP areas (create/change/delete) RMMDKP01 - Delete MRP Lists RMMDKP02 - Delete MRP Lists (long-term planning) RMMDKPIN - Include: Form Routines for Reorganization of MRP Lists RMMDMDMA - Material overview for MRP Area RMMMDP01 - Display MRP profile Usage RMMMDD00 - Delete All MRP Profiles in Current Client (W/O Material Master Recs.) RMRPAEVAL - Reorganization of Storage Location MRP Areas

ROOLMD01 - MRP Text ROOLMD02 - MRP Text RM61SR00 - Background Program: Creating MRP Record for Changing BOM Explosion No. RMCB0400 - MRP Controller Analysis RMCB0405 - MRP Controller Analysis: Data Selection Report RMMD07DB - MD07/MS07 - Example of User-Specific Entry RMMD07EX - MD07/MS07 - Example of User-Specific Entry RMMDABLP - Average Stocks for Long-Term Planning RMMDEKS1 - Set Up Purchasing Info Data from Long-Term Planning RMMDMONI - Technical Statistics of the Planning Run RMMDPERF - Technical statistics for the planning run - material hit list RMMDVL00 - Long-Term Planning: Set up Planning File Entries for a Scenario RMMDVL10 - Long-Term Planning: Delete Planning File Entries for a Scenario RMMDVL20 - Long-term planning: Create planning file entries for Scenario The Concept Of MRP In ERP ERP SAP Modules ==> PP In SAP The Concept Of MRP in SAP MRP in brief : MRP is the planning tool in SAP which will look at all aspects of a material and is highly based upon the master data of the material. MRP looks at current inventory, current requirements, open purchase req/orders and so on. So if a material is required to satisfy a sales order and there is no inventory, MRP will create a planned order if the item is to be produced in house. This planned order can then be converted to a production order by the master scheduler. If the item is to be procured, then MRP will create a purchase req which the Buyer will convert to a purchase order. This is just one scenario, the system is highly configurable and will do pretty much whatever you tell based on config and master data. Consumption based planning - Reorder planning - Forecast based planning - Time phased planning Details of re-order planning Our motive is to maintain optimum stock level of all the material included in the resource planning. so in this user or system sets a particular quantity of stock as reorder point . Whenever stock quantity fall below this point(reorder point) mrp comes into action and generates procurement proposals according to the settings done in implementation guide MRP run procedure 1. Create requirement or demand in MD61 2. MRP run by MD02 for a single material 3. See the result in stock requirement list in MD04. MRP run we can carry out by

1. MD02 - single item multi level 2 .MD03 - single item single level 3 .MD01 - Total planning 4. MD04 Check MRP 5. MD05 MRP lists For PP, you require following Master Data 1. Material master (MM01) Tips: Create same Material Code in Different Company Codes 2. BOM (CS01) 3. Routing (CA01) 4. Work Center (CR01) 5. CK11N / CK40N - Cost Estimate Production Cycle: 1. PIR (Planned Independent Reqmt. - MD61) 2. MD02 - MRP Run 3. MD04 - Stock Requirement List Tips: MD04 - Inconsistencies after PGI - SDRQCR21 4. CO40 - Convert Planned Orders to Production Order OR CO01 - Create Production Order 5. Here in Production Order - Schedule Order, Release order 6. MIGO / MB1A - Goods Issue against Order (Mvmt Type 261) 7. CO11N - Production Operation confirmation Tips: Add An Entry Field In CO11n 8. MIGO / MB31 - GR against Prd order 9. CO02 - Technical completion of order 10. KO88 - Order Settlement Why used Planning tools like APO or I2? APO and I2 are Finite PLANNING tools. When MRP runs with APO or I2 (or Red Pepper or Manugistics), it takes Capacity issues into consideration. MRP in SAP R/3 Core does not, it assumes infinite capacity available. (MRP only looks at material availablity.) However, SAP R/3 DOES do finite SCHEDULING, which is where the system 'dispatches" operations on a production order until it fills up the capacity available, then moves to the next time period and dispatches until that period is filled up. In SAP speak, that is called capacity leveling. I believe APO should only be used in very large companies (billions) because of the amount of master data that must be maintained, and that data better be ACURATE, or you've wasted a heck of a lot of time. By the way, APO stands for Advanced Planner and Optimizer tool, obviously a German sort of name! Differences between planning and scheduling, finite and infinite R/3 does planning without consideration for capacity situations. So if MRP says you need 500 parts on 3/1/04, it schedules them all to be built at the same time, even though you can only do 100 at a time. Assume you have a fixed lot size of 100, you'll get 5 planned orders for 100 to start on the same day. This is "Infinite Planning". APO would recognize that constraint, and instead schedule out the 5 orders over time. The important part of that is that it also will schedule out the deliveries of the components for 5 different days. This is "Finite Planning". Now, assume old fashion MRP. It schedules all 5 orders for the same day, and the buyers go out an get all of the components for the same day. Then the planner realizes he can't do all 5, and manually changes the schedule, and manually spreads out the 5 orders. The buyers will recieve rescheduling notifications, but not until the scheduler does the manual rescheduling. You could call this "Infinite Scheduling", but that only means the same thing as Infinite Planning.

But, SAP has "Capacity Leveling". What that means is you run another program after MRP (CM27 and CM28), which can be run in batch mode overnight. (There is a ton of configuration and thinking that will be required to do this!). The capacity leveling program will recognize the constrant at the work center level, and fill up the first day, then reschedule the next order to the next available capacity, then the next order searches for available capacity, and so on. This is called "Finite Scheduling". The problem with this is the opposite of Infinite Planning, which is it doesn't take Material availablity into consideration! The system will re-schedule a production order without thinking about whether the materials will be available or not. Finite Planning does Finite Sheduling at the same time. If there is no capacity available on the desired date, the system looks for when capacity IS available. Then it stops to see if Materials will also be available (usually based on the lead-time for those components). If there is a material problem, then the system figures out when the materials WILL be available, and then checks to see if capacity is available on THAT day, and if so, it blocks off capacity, and allocates the materials for that day. Difference between MRP vs MPS Explain the difference between MRP & MPS. Though both components gives you the requirement list, what we gain out of MPS run rather than running MRP. What is the main idea behind this? The following might help in explaining the difference between MPS and its counter part MRP. Master Production Schedule (MPS) : MPS operates within only one level of the BOM, While MRP can be utilized throughout all levels of a material’s BOM. If a MPS is run on a material, the necessary orders are planned at that level. Dependent requirements (if any) are placed on the next BOM level down, and then the process stops. Main Idea : Master production scheduling (MPS) is a form of MRP that concentrates planning on the parts or products that have the great influence on company profits or which dominate the entire production process by taking critical resources. These items are marked as ‘A’ parts (MPS items) and are planned with extra attention. These items are selected for a separate MPS run that takes place before the MRP run. The MPS run is conducted without a BOM explosion so that the MRP controller can ensure that the Master schedule items (MSI) are correctly planned before the detailed MRP run takes place. The master production schedule is a line on the master schedule grid that reflects the anticipated build schedule for those items assigned to the master scheduler. The master scheduler maintains this schedule, and in turn, it becomes a set of planning numbers that drives material requirements planning. It represents what the company plans to produce expressed in specific configurations, quantities, and dates. The master production schedule is not a sales item forecast that represents a statement of demand. The master production schedule must take into account the forecast, the production plan, and other important considerations such as backlog, availability of material, availability of capacity, and management policies and goals. Syn: master schedule. Material Requirements Planning (MRP) : A set of techniques that uses bill of material data, inventory data, and the master production schedule to calculate requirements for materials. It makes recommendations to release replenishment orders for material. Further, because it is time-phased, it makes recommendations to reschedule open orders when due dates and need dates are not in phase. Time-phased MRP begins with the items listed on the MPS and determines (1) the quantity of all components and materials required to fabricate those items and (2) the date that the components and material are required. Time-phased MRP is accomplished by exploding the bill of material, adjusting for inventory quantities on hand or on order, and offsetting the net requirements by the appropriate lead times. MRP Interview Questions: What is the need of mrp list if stock requirement list is already there?

The MRP list displays the result of the last planning run. Changes that have occurred between planning runs are ignored in the MRP list. In contrast to this, the system displays all changes in stock, receipts and issues, which have currently occurred, in the stock/requirements list. Which tcode are used to run MRP? - MD01 is generally used to run the MRP for all the materials in a plant normally just before go-live. - MD02 is used to run MRP for materials which have a BOM i.e multi-level. - MD03 is used to run MRP for materials which do not have a BOM i.e single level. SAP Factory Calendar Factory calendar contain company specific dates such as alternate working Saturdays, Plant shutdown etc. You can create your company factory calendar via transaction code 'SCAL'. Assignment of the factory calendar by plant is done in transaction code 'SM30 - V_T001W'. An example of a SAP application that uses the factory calendar is the SAP MRP modules. Assuming that you have a specified an alternate working Saturday, MRP will postponed the planned orders to the next working day if it happened to falls on a non-working Saturday. GR processing time in PP and MM I have one material number that is procured externally but also produced inhouse. Now I have one problem with the GR processing time. As far as I can see the parameter on the material master on MRP2 view and Purchasing view is the same (MARC-WEBAZ). But in my case the GR processing time should be only used for goods receipts in MM (from purchase oders). This GR processing time must not be added to my lead time scheduled in production (when producing the material). How to solve this conflict? We have a make to order enviroment, that means our production orders are created (and scheduled) directly from the sales order. The sales gets back a confirmed date and quantity from production order scheduling - and here this GR processing time is also added. Absolutely useless in this scenario, but MM needs this GR processing time for the external procurement of the material. I'm hearing at least two problems here. Let me lumber through them as I see them. #1 - We have a make to order enviroment, that means our production orders are created (and scheduled) directly from the sales order. The sales gets back a confirmed date and quantity from production order scheduling - and here this GR processing time is also added. Absolutely useless in this scenario, but MM needs this GR processing time for the external procurement of the material. The GR processing time is quite legitimate, and needful. It represents the time it takes once a material is 'delivered', before it is usable. If that is instantaneous for you, then this field is blank. In fact if it is less than one day, the field should be blank. (MARC-WEBAZ) If you DO have to do testing or documentation or even just 'checking' to be sure the proper certificates have arrived with this material, then it's nice to have a day here for this. --- I may have overlooked one thing, if you are ONLY thinking of the FERT that your customer ordered, then maybe this field seems trivial. However, if your process requires that the FERT be purchased from some other company (or even supplied from within YOUR company), then there IS a receiving process that has to happen . . . it does take time to back a truck up, get a fork truck to unload it, the identification process, and then relocating the item to where it can be shipped to your customer. Also, if you produce this item, then there are 'other' items that need to be 'built' into this item . . . THEY need the GR field, even if you produce the saleable item, it has to be 'received' from production into inventory for you to ship it out.

There is another field that should be considered. This is the procurement lead time. The time it takes for purchasing to "react" to the requirement. When the sales order is placed, the signal will come for 'purchasing' to occur (via MRP perhaps). Purchasing MAY take as long as a day to get that order to a vendor where the vendor can now react. This time is generally a 'standard' time for any given plant/purchasing org and is included using OMDT. Thirdly, the vendor lead time has to be considered. This is what the field "Planned delivery time" (MARC-PLIFZ) is about. The vendor's turn around time - from the time they are notified of your intention (via a PO perhaps), until they can put it on your dock . . . that is what this field is about. And MRP knows the difference between this field and the others. Between the three fields mentioned, the 'purchased' item is properly planned for . . . except for the exceptions and the fact that this is all based on "norms" and averages which never seem to be exactly what is needed, but that's another discussion . Next we think of the situation where the item requested is produced by us. In this case (as mentioned before), the GR is STILL legitimate - perhaps not needed if it takes less than a day for your company to receive material from production, inspect it, certify it, and load it up. However, a "0" is a legitimate entry to this field. What is also needed is a place to locate the time for "producing" this item. That is where there are options. One option in MRP 2 is the field "in-house production" (MARC-DZEIT). This is sometimes useful, but dangerous. It assumes that no matter how large an order is or how much of a material is needed, it can always be produced in the same period (in 'days', of course). The number of days fits in this field. If that doesn't 'do it' for you, you can go to the "Work Scheduling" view of the Material Master and include the details for the fields under the "in house production time in days" grouping (Setup time; Interoperation; Processing time; and base quantity). At LEAST this gives the system a 'shot' at planning longer times for greater quantities. If you fill both data points in (in house production time and " in days, the 'in days' will supersede the other). Now you've put in all the data that you HAVE to input to have the system plan the length of time needed for telling your customer when you will have their product ready for them. In the case of your conflict where you produce OR source the item, then you MAY have a problem with GR - look at both scenarios and see what your entry should be. You CAN use the Total Replenishment Lead-time (MARC-WZEIT) field to be the TOTAL TIME when producing the material in-house, because the external replenishment does not look at this field. So MRP will run and depending on how you have it set, it will consider purchasing the material, or making the material, and the fields we've mentioned will impact the result as mentioned. Calculation to determine the delivery date and release date There have been three parameters that SAP will take it into calculation to determine the delivery date and release date during material requirement planning. They are 1) Planned Delivery Time which is the vendor-dependent lead time being measured from the time PO is outputted (for sending to the vendor) till the time the shipment is delivered at the warehouse. 2) GR processing time represents the necessary period of time being required for receipting the shipment into the warehouse. This period is, usually, for quality and quantity inspection. 3) Purchasing Processing Time. This is the internal required time for processing the purchasing document (Purchase Requisition) till Purchase Order. You can set it up plant-wise via Transaction OMI8. With these three parameters, it is possible that you can set it up correctly in your system to enable the appropriate planning of your material requirement. Purchasing processing Time - OPPQ Please refer above subject and would like to do following. External Processing Time I have set in using OPPQ. My client want this time set differently for different Vendor. Is there any userexit or customization settings? For MRP to take lead time by supplier, you need to have 3 settings:

1) The config in OPPQ - External procurement at plant level (or OPPR at MRP grp - Scheduling/doc. type) should have the check box marked to read SchedAgreem/Inforecord leadtime (T399D-GTERM) 2) You should have a contract/schedule agreement, or a purchase info record maintained for that plant-materialvendor combination 3) You should maintain source list (ME01) for the contract/schedule agreement, or info record. This changes the default behavior of MRP to use leadtime by supplier, rather than material master leadtime. When both contract and info record exist, the contract will take precedence. Please watchout for the case if you're already using contracts/info records in procurement, but not using them for planning. In this case your leadtime data in these documents may be incorrect, or may be left blank - this will be interpreted as zero if you make this change implementation, as mentioned in the steps above. Define Safety Stock Availability The IMG can be set in SM30 - V_438M_S You define per plant and per MRP group the percentage of the safety stock that is to be available for planning. This helps to avoid a situation where order proposals are created unnecessarily by the system to cover small shortage quantities. For example: Mat. 1 Safety stock:

Mat. 2

Mat. 3

100 pc

100 pc

100 pc

0%

50%

50%

1 pc

1 pc

51 pc

Order proposal quantity for lot-for-lot order qty 1 pc

0 pc

51 pc

available for planning: Shortage quantity

Defining MRP Groups What is MRP group? The MRP group is known as an organizational object that can be used to allocate special control parameters for planning to a group of materials. You can maintain MRP groups if planning control per plant is not precise enough for your requirements and you want to allocate certain material groups different control parameters from the plant parameters. Objective To define MRP Groups for the assignment of materials. Where to used MRP groups are defined with these specific control parameters and are assigned to the material in the material master record (MRP 1 screen). Example The following control parameters can be set for the total planning run: 

the creation indicator for the planning run (creation of purchase requisitions, MRP lists, and so on)



the planning horizon



the consumption mode

The following is valid for total planning and single-item planning: 

for all materials without an MRP group, the system uses the plant parameters, or the entries in the initial screen of the planning run



for all materials with an MRP group, the system uses the parameters recorded in the MRP group

Configuration Setup Steps: 1. Access the activity choosing one of the following navigation options: IMG Menu: Production -> Materials Requirements Planning -> MRP Groups -> Carry Out Overall Maintenance of MRP Groups (Transaction Code: OPPRC) 2. On the MRP Group screen enter the Plant field and choose Overview. 3. On the Change View “MRP Control Parameters – Material Level”: Overview screen choose New entries. 4. On the New Entries: Details of Added Entries screen, make the required entries: Field name 

Plant



MRP Group



Create purchase requisition



Scheduling agreements



Create MRP list



Avail. safety stock



Direct procurement/production



Ord.type - proc.ord



Rescheduling period



Tolerance value forward



Tolerance value displace



Planning horizon



Consumption mode



Bwd consumption per.



Fwd consumption per.



Planning strategy group



Checking rules

5. Choose Back and enter following descriptions for the MRP groups. 6. Save your entries. Result Your company MRP groups are defined.

Questions on MRP Group and MRP Controller MRP groups are used when the plant division for planning is not enough for the division of the different materials MRP requirements. You assign different groups according to the requirements to run MRP (different Settings). These settings will be taken in account when you run MRP for single item or total planning. MRP controller is the person in charge of the MRP run for the materials. It is still a further division on your MRP. This is work load related. You can have one MRP controller for materials with different MRP groups. On your MRP group, you will define the parameters for the MRP run. These parameters are calculated in accordance with the settings on your material master MRP views. Available stock = Plant stock - safety stock + receipts of (purchasing orders + purchasing agreements + production orders) - required quantity. This means that all the requirements are calculated in the bases of your material master settings and your MRP group settings. What if nothing happens when you run MRP? The reasons could be :- You have purchase requisitions that are delayed but the delivery time has not been updated on the system. - The settings on your material MRP screens are not correct, i.e. your material have not yet entered the re-order point level. - Your requirements have not been taken in account when running MRP. Assuming that everything is well and the requirement has been calculated, go to transaction code MD04 and verify that the different requirements are reflected in the MRP list and also if there is any purchase requisition scheduled by the system. Verify also if there is any other delivery schedule that will exceed the actual requirements. If the purchasing requisition is there, the only thing that you have to troubleshoot is the message to tell you that the purchasing requirement was calculated. If the requirement is not there, re-visit your material master and check your settings for the MRP group. What is the real meaning and usage of the followings configured in PP: 1. MRP Controller; 2. Schedule margin key; 3. MRP group; 4. MRP profile. 1. MRP Controller This will help you to group the material for some controlling purpose. You can run mrp by mrp controller. you can do evaluation by mrp controller. This will help us if have different people in one organisation involved in purchasing. 2. Schedule margin key This will help you to determine the floats. In case if you have production order you can see the impact of floats 3. MRP group This will help you for the material to reac in tems of the settings made relavant to each group. To know more details on the group you can chek the tcode oppr.

4. MRP profile We can have some prefixed datas in the profile and and we can enter teh profile for diff material so the values will copied as defaulted in the profile. Daily Task Of MRP Planner Using MD06 This is to give you an idea of the daily task of a Planner using tcode MD06 Tcode MD06 - MRP List: Initial

Enter plant Optionally, enter date/exception group/Processing indicator/material data, to limit the number of records. Execute. System will create a list of all materials that satisfy the previous selection. Now, Select Find (binoculars).

If you have a large number of entries (such as 20,000) you will get a popup asking about statistics. Say yes. Select 'Find Exceptions' tab. Here you will get a summary, by exception number, of each exception contained in the previous list. If you wish to process ONLY one or more of these exceptions, select the ones of interest. Now hit green check (Find exceptions). You will be returned to the original list. The items highlighted will be the items that have the exception(s) you selected. Select glasses (selected mrp lists). You will be taken to the first HIGHLIGHTED item in the list. Perform your planning tasks. When done, select 'next list' icon, or Ctrl-F2. It will take you to the next HIGHLIGHTED item on the list. Repeat. Continue until it is time to go home. Repeat tomorrow. Explain MRP profile, MRP group, MRP controller, MRP type SAP ERP Modules ==> PP In SAP Please explain what you understand about MRP profile, MRP group, MRP controller and MRP type. MRP Profile : All the MRP 1,2,3,4 views in the material master data are entered in this profile and create MRP profile. When you are creating Material Master in MM01 while entering the plant and storage location enter your MRP profile so that you do not need to enter the MRP data again MRP Group: It is a planning strategy for carrying out the MRP. In this group there are two types from procurement side 1) MADE TO ORDER In this once sales order is booked, MRP will run and the P.R will be converted to P.O. 2) MADE TO STOCK: Depends on the forecast model they will plan material and keep the finished product in STOCK You can create the MRP Group so that material can be tracked. MRP groups are used when the plant division for planning is not enough for the division of the different materials MRP requirements. You assign different groups according to the requirements to run MRP(different Settings). These settings will be taken in account when you run MRP for single item or total planning. Setting --> SPRO --> MM --> Consumption based planning --> Define MRP group. MRP controllers : It is like a production controller in an industry. He will plan all the required material for the daily plan. It will be classified according to the materials & Buyer like Casting - one MRP controller

Forging - One MRP controller All Bought Ourt - One MRP controller Sheet Metal - One MRP controller MRP controller is the person in charge of the MRP run for the materials. It is still a further division on your MRP. This is work load related. You can have one MRP controller for materials with different MRP groups. Setting --> SPRO --> Material Management --> Consumption based planning --> Master data --> Define MRP group. MRP types : In the MRP types different categories are there 1) Produce to Demand 2) Consumption based planning 3) Forecast based planning It is procedure that you set in the system on how the Material is planned - Reorder Point - Seasonal requirement - Replenishment - Vendor Managed - Forecast Based - Master production Scheduling Setting --> SPRO --> MM --> Consumption based planning --> Master data --> Define MRP types How to Take The MRP Run for Individual MRP Controller When you want to run MRP, entry user exit key and put your MRP controller as user exit parameter

To define the user exit key, goto SPRO -> MRP -> Planning -> 'User exit material selection - MRP'. Then, go to SAP enhancement (SMOD) = M61X000, and add this code : CLEAR: NO_PLANNING, STOP_PLANNING. CASE USER_KEY. *----------------------------------------------------------------------* * select materials for one MRP controller (specified in user_par) *----------------------------------------------------------------------* WHEN 'XXX'. *MRP user exit key define in spro UXPAR = USER_PAR. CONDENSE UXPAR. WRITE UXPAR+0(3) TO DISPO. IF DISPO IS INITIAL. EXIT. ENDIF.

IF MT61D-DISPO <> DISPO. NO_PLANNING = 'X'. ENDIF. ENDCASE. Definition: MRP controller In a manufacturing plant, a person will be identified and will be responsible for a group of materials. Material that takes part in material requirements planning must be assigned to an MRP controller. MRP will guarantee material availability and once you run MRP, it will be helpful in planning as to whether what quantity a component should be procured or what quantity should be produced in-house. Through MRP, you can automate procurement proposals for purchase and production. MRP Controller is assigned in material master MRP1 view. Individual Collective Requirement Indicator What is the relevance of individual/Collective Requirement indicator from MRP4 view of material for Finished product as well as its sub assemblies in case of make to Stock planning strategies. Answer: Individual & collective indicator plays a major role in MRP. If you set Individual indicator for both header material and dependent material, then if sale order comes for 100 qty, then During MRP run system will create a plan order with reference to sale order and for dependent material, system will plan dependent material as sale order relevant. System won't consider warehouse stock for that sale order. If you set collective indicator for dependent material system will consider warehouse stock for dependent material. MRP-4 as 1 : In individual planning, this indicator is used to display the dependent requirements of a component separately. MRP-4 as 2 : In collective requirements, this indicator is used to display the dependent requirements of a component grouped together. This Indicator is useful to control the planning of dependent requirements if the main product is being planned with strategy 20 i.e.; MTO Process.

MARC-SBDKZ indicator controls whether individual or collective customer requirements planning is allowed for dependent requirements means low level in BOM. If you define individual requirements for explosion, dependent requirements for a component are shown individually on the superior low-level code. If you define collective requirements for explosion, required quantities for the material are summarized independently of the sales order. In the MTO scenario, if you want to check the unrestricted raw material stock when you run the MRP for sales

order. Please check by selecting individual/collective requirement as 2. Please note: - If you select individual requirement then system will not consider available stock and generate Proposals for every single requirements. Also you will find PR and Plan order with account assignment of Sales order (in case of MD50). - If you select collective requirement then system will not generate planning proposals through MD50. In that case you have to go for individual MRP (MD02 / MD03 / MD41 / MD42). For FG stock you can assign to sales order through MB1B by 412 E movement type. PP - The Common Planning Strategy used The planning strategies are maintained in Customizing for Demand Management in SM30 - V_T461S. Define the Planned Requirement Type and assign the requirement class in OMP1. Define the requirement class in OMPO. Check the independent requirement and consumption of requirement class in OMPC. Maintain the message for invalid requirement type in OMPJ. You define the strategy group in SM30 - V_T461P. You define the Plant to MRP group in SM30 - V_T438M_S. Maintain the consumption mode and period of adjustment in SM30 - V_T438M_V. Listed here are some common used planning strategies :Strategy 10 in summary :1. Sales Order creation - no impact. 2. Goods Receipt - reduce the planned independent requirement during MRP run For e.g. if PIR is 100, quantity remained as 100 in PIR, however during MRP run, 100 will not be included in the MRP planned as stock is available. 3. Delivery - minus the quantity for the oldest planned independent in demand management. For e.g. if PIR is 100 and delivery 90, PIR becomes 10 (withdrawal 90).

10 LSF Make-to-stock production

KSL Sale from stock without independent requirement reduction

Choose this strategy if you want production to be determined by a production plan (Demand Management) and if you do not want sales orders to influence production directly. You must maintain the following master data for the finished product: Strategy group 10 on the MRP screen. Item category group (for example, NORM) on the Sales Organization screen.

Availability check field in Customizing so that you perform an availability check without replenishment lead times (in the standard system, you must enter 02 here). In net requirements planning according to strategy 10, the order does not create a requirement; the sales order is displayed, but does not generate planned orders. The planned independent requirement is reduced during processing of the goods issue. Old quantities can still be retrieved by using either Goto -> Schedule line history in Demand Management, or by using the total requirements list (Evaluations -> Display total requirements from the Demand Management menu). The quantities issued are displayed in the Withdrawal quantity field. The system always reduces the oldest planned independent requirements unless the consumption fields (Consumption mode, Fwd consumption per., Bwd consumption per.) are maintained in the material master or in the MRP group.

11 BSF Gross planned independent requirements KSL Sale from stock without independent requirement reduction Strategy 11 in summary :1. Sales Order creation - no impact. 2. Goods Receipt - minus the quantity for the oldest planned independent in demand management. For e.g. if PIR is 100 and delivery 90, PIR becomes 10 (withdrawal 90). 3. Delivery - no impact as delivery is issue from sales order. This strategy is particularly useful if you need to produce, regardless of whether you have stock or not. For instance, steel or cement producers might want to use this strategy because they cannot shut down production; a blast furnace or a cement factory must continue to produce, even if this means having to produce to stock. You need to maintain the following master data for the finished product: Maintain strategy group 11 on the MRP screen. Set the Mixed MRP indicator to 2 on the MRP screen. Maintain the item category group (for example, NORM) on the Sales Organization screen. Maintain the Availability check field so that you perform an availability check without the replenishment lead time (checking group 02 in the standard system).

Strategy Stock is taken into account

10 Yes

11 No

Reduction of planned independent requirements takes place during … … goods issue for ... goods receipt for a production the delivery order (discrete production), for a planned order (repetitive manufacturing), or for a purchase order (trading goods).

20 KE

Individual sales order without consumption

Strategy 20 in summary :1. Sales Order creation is the only impact. 2. Demand management not in used. In make-to-order production, a product is produced specifically for an individual sales order. This planning strategy is used when planning of the (parent) product is not required or not possible. Neither Demand Management is involved in this process, nor is there an allocation mechanism. Orders are taken as they come. This strategy represents a production procedure in which each product is only produced once, although over time the same or similar production processes are repeated. Each product is specifically produced for an individual customer so that the finished product is rarely placed in stock. You also must maintain the following master data settings for the finished product: Strategy group 20 on the MRP screen Item category group (such as NORM) on the Sales Organization screen Sales Order -> MRP -> Customer Stock Finished Product -> Delivery ----+ ^ | | | +-------------------------------------------------------------------------+ Reduction

40 VSF Planning with final assembly

KSV Sales order with consumption

Strategy 40 in summary :1. Stocks on hand reduces the PIR during MRP run. e.g. if stock is 100 and PIR is 100, MRP run will not prompt 100 for procurement. if stock is 0 and PIR is 100, MRP run will prompt 100 for procurement. 2. Sales order creation reduces the PIR. e.g. if PIR is 100, sales order 90, PIR becomes 10 (withdrawal 90). 3. Delivery reduces the Sales Order.

This strategy is probably the most widely used make-to-stock strategy. It makes sense to use this planning strategy if you can forecast production quantities for the final product. Planned independent requirements are consumed by incoming sales orders so that the master plan is always adjusted to suit the current requirements situation. This means that the important feature of this planning strategy is that you can react quickly to customers’ requirements. The smoothing of the master plan is less important. You must maintain the following master data for the finished product in the material master: Strategy group 40 on the MRP screen. Consumption parameters (Consumption mode, Bwd consumption, Fwd consumption) to allow

consumption of independent requirements. If no consumption parameters are maintained in the material master, the system uses default values are taken from the MRP group. To control consumption, you maintain a consumption mode as well as a consumption period. Item category group (for example, NORM) on the Sales Organization Data screen. Four important points :1. Planned independent requirements are used to trigger the procurement and production of the necessary assemblies and components before receipt of the sales orders. 2. As soon as the sales order is received, it consumes the planned independent requirements. 3. An ATP (available to promise) logic during sales order processing will checks whether sufficient planned independent requirements have been planned to cover the sales order. 4. Requirements from the sales orders are passed on to production and can lead to changes made to procurement if the requirements from the sales orders exceed the planned independent requirement quantities. If there is insufficient coverage of components (the sales order quantities exceed the planned independent requirement quantities), the sales orders cannot be confirmed. The system therefore automatically adjusts the master plan. Planned independent requirement quantities that are left unconsumed increase the warehouse stock of the finished product. Why Planning file entry still Exists Anyone know why a planning file entry would exist for NETCH or NETPL when there has been NO activity on the material since the last planning run? No movements, no PO's created, no Orders taken, no activity whatsoever and MRP ran, created a planned order, which was converted to a requisition and then a PO. This PO was converted for a date earlier than what MRP recommended. Now each time MRP runs, we get exception #15 - delay the order until later (gives date). We don't change it and the planning file entry doesn't go away, even after the run. Found a note that seemed to apply, but I guess it doesn't really. "If the planning run terminates for a material with planning file entry on account of an error message, the planning file entry is not deleted if this is not explicitly set in customizing. In transaction OMDY, you can set for which errors (message number) you want the planning file entry being deleted." I thought this was my answer. However, after looking in OMDY - the message #015 = Dates incorrect (start date > finish date). And message #15 = Enter value for version number increment (VersNumIncr.). Neither of these defines my MRP List exception message 15 = "Postpone process (28.06.2012/26.06.2012)" - on a current date of 03/06/2012. It's CLOSE, but not the first message. So if I set the field for the deletion of the planning file entry, it still wouldn't affect my real problem - trying to get this entry to 'go away' after doing what it was supposed to do. Answer Please Check CS15 - where used list. May be this material has been added to a BOM of a product/Assy, which has caused an entry in planning file. Check MD04 for the source of reqt. Also check MD63, if a PIR exists.

If not, delete from planning file. Try report RMMDVM10 - consistency check. Notes Planning File entries can be set manually for each material or using a batch job using T.Code MD20 / MDAB. Consistency check for the planning file: Since the entries in the planning file are permanent, you must check their MRP relevancy regularly. If, for example, a plant is subsequently excluded from material requirements planning, its materials will still be included in the planning file. The same applies for materials that are subsequently flagged with the MRP type No MRP and are thus excluded from MRP. In such cases, you should delete the entries in the planning file. The same can checked by running the batch job through scheduling it in T.Code MDRE. Further Notes On completion of the Planning run, the system deletes the appropriate indicator from the planning file. 1. The system deletes the NETCH Planning indicator and NETPL indicator for a regenerative Planning run and NETCH Planning run. 2. The system deletes only the NETPL Indicator for NETPL Planning run in the Planning Horizon. If termination occurs when planning a material, the indicators for the materials remain in the planning file so that material is planned again. Planning File Entry Not Created Explain why planning file entry is missing for materials? Answer The most common reason a planning file entry is not created is that the material was created before MRP was turned on for that plant. Another reason is that Materials created by certain batch SAP programs do not trigger the creation of a planning file entry automatically, the way a MM01 normally does when you create a material interactively. Regardless of the cause, SAP supplies a transaction that will automatically create all required planning file entries. Transaction is MDAB. This will create rows in the planning file, where none existed previously. MDAB searches for Materials that are MRP relevant (all MRP configuration settings are in place, and the material has an MRP type that indicates that MRP is to be utilized). If it finds such a material, and the planning file entry does not already exist, it will create an entry. In many companies, this transaction is run regularly, in batch. Now, once the planning file entry exists, it must still be tagged for an MRP run or Netch MRP runs will ignore them. The normal way that a material's planning file is tagged for the next MRP run is that the system detects an MRP relevant change. The system then automatically tag the planning file for the next MRP run. There are many events that can trigger the system to do this: Most material movements, and also any changes in supply or demand elements. If no changes have been made, the planning file will not be updated. If you are running one of the Net Change MRPs, it will completely bypass these materials. You can force an MRP run in background against a material (providing there is a planning file entry) by running NETUPL. When someone tells me background MRP doesn't work, but interactive MRP DOES work, then I normally assume that the planning file entry does not exist, and I run MDAB. It really doesn't matter why it came to be missing. It is also a good idea to run MDRE periodically. These steps are cheap insurance.

After MRP Run Planning File After the MRP run, planning file entry should be deleted. if not deleted what will be the reasons for that? Answer The planning file controls which materials are to be planned for the different types of planning run. The planning file contains all materials that should be included in the planning run. The system enters materials automatically into the planning file and marks them with a total change indicator if a change is carried out which is relevant to the material, for example, changes to active purchase orders. If a change concerning the planning horizon occurs (for example, creating a purchase order within the planning horizon), the material is automatically given another indicator, that is, the net change planning indicator. During the planning run, the system now checks every entry for a material in the planning file: Once the planning run has been carried out, the appropriate indicator is automatically deleted in the planning file. If a termination occurs when planning a material, the indicators for this material are left in the planning file so that the material is taken into account again in the next net change planning run. Notes: Planning File Entry for Termination The purpose of this activity is to set up error handling in the planning run. Procedure 1. Access the activity choosing one of the following navigation options: IMG Menu - Production -> Material Requirement Planning -> Planning -> MRP Calculation -> Define Error Processing in the Planning Run (Transaction Code: OMDY) 2. On the Change View “Error Handling in the Planning Run”: Overview screen, make the following entries: Plant

Plant Name

BP01

Best Practice Mfg Plant

BP0X

Best Practice Inter-company Plant

Max.Pur.Ord.Prc 50

MPRG 001

00

3. Save your entries. Result Error handling in the planning run is set up. Total Planning & Netch, Netpl, Neupl What is the difference in between total planning & netch, neupl, netpl? By : Sankaran 1. Regenerative planning (NEUPL): System plans all the materials that are contained in the planning file 2. Net change planning (NETCH) or Net change planning in the planning horizon (NETPL): The system only plans materials that have undergone a change relevant to MRP since the last planning run. NETCH: In net change planning only those materials are planned for which the net change planning indicator in the planning file has been set as a planning file entry. The system usually sets the indicator automatically as soon as a change is made to the material that is relevant to MRP. NETPL: The system only plans materials that have undergone a change that is relevant to the planning run within the

period which you defined as the planning horizon. The system sets the net change planning horizon indicator automatically for these materials Remember the following point : The changes cause an entry in the planning file to be made: 

Changes to stock, if these change the stock/requirements situation of the material



Creation of purchase requisitions, purchase orders, planned orders, sales requirements, forecast requirements, dependent requirements or reservations



Changing to fields that are relevant to the planning run for these receipts and issues or in the material master



Deleting receipt or issue quantities

How The MRP Planning File Works How this planning file works? I have created a material with MRP type PD for netch and netpl, both entries are showing in the planning file (MD21). How the system know which scenario to considers, netch or netpl or neupl? The first process when you run MRP is that it check for the materials in the planning file enty with the relevant indicators(NETCH / NETPL). When the materials are created with the relevant mrp data, then an entry is created automatically in the planning file(MD21). In order to create (or to get the entry automatically) in planning file the basic prequisite is that you need to activate the MRP for the required plant (OMDU). With respect to the selection criteria you take during the MRP run (MD02) like NETCH / NETPL, this indicator is checked for the material. if the material is marked for the relevant indicator than that material is planned. So in order to plan a material PLANNING FILE ENTRY is must. If you do not activate MRP (OMDU) then there will not be any entry in MD21. So as soon as this is activated and you create any new material than the entry of this material is created automatically in the planning file. So if you want to create any entry in planning file manullay you can go with transaction MD20. The difference between NETCH / NETPL & NEUPL is: When you select NEUPL (Regenerative planning), the system plans for all the material which are in the planning file. This is mostly used when you run the MRP for the first time or in case like after major changes of master data or after mass upload of the materials. When you go for NETCH planning, MRP first check for this indicator in the planing file and plans. This indicator is checked if the material has undergone some changes with reference to the previous plan. Changes like: 

Changes in stock or in MD04



Changes in purchase requisition, purchase order, sales order, reservations, dependent requirement, forecast requirement...



Deleting reciepts and issue element



Changes in material master concerned to planning run.

When you go for NETPL (net change planning in planning horizon), those materials are only planned which has undergone changes for the planning run in the specified horizon. This is mentioned in the planning horizon. Processing Keys In TC MD02 Explain about processing keys in tc md02 ie netch, netpl etc. By : Jia Processing Key :MD02 1. Regenerative planning (NEUPL) : System plans all the materials that are contained in the planning file 2. Net change planning (NETCH) or Net change planning in the planning horizon (NETPL) :The system only plans materials that have undergone a change relevant to MRP since the last planning run . NETCH: In net change planning only those materials are planned for which the net change planning indicator in the planning file has been set as a planning file entry. The system usually sets the indicator automatically as soon as a change is made to the material that is relevant to MRP. NETPL:The system only plans materials that have undergone a change that is relevant to the planning run within the period which you defined as the planning horizon. The system sets the net change planning horizon indicator automatically for these materials Remember the following point : The changes cause an entry in the planning file to be made: 

Changes to stock, if these change the stock/requirements situation of the material



Creation of purchase requisitions, purchase orders, planned orders, sales requirements, forecast requirements, dependent requirements or reservations



Changing to fields that are relevant to the planning run for these receipts and issues or in the material master



Deleting receipt or issue quantities 

Planning Strategy Selection

Selection priority for planning strategy is: First material, second MRP group and last plant parameters. E.g. System first checks for material, if strategy is defined there, that is used, if it's not maintained there, then it checks if it's defined in MRP group. That is the same for all MRP parameters, not only strategy. If you wanna test how it works, try this: 1. create an mrp group, say 0001, and assign strategy group "40 - planning with final assembly" in the MRP group parameters. 2. create a material, say product1 and define planning strategy as "20 - make to order". And also enter the MRP group 0001 in material master.

3. Create a sales order and create an order item for product1. 4. In the sales order header, go to the Procurement tab. There, you will see the requirement type for product1, which is automatically selected by system according to the planning strategy it uses. That requirement type should be "KE" if strategy 20 is selected, or it should be "KSL" if strategy 40 is selected by system. 5. In my test, system selected KE requirement type, which indicates that system used strategy 20, and which I have entered in the material master. It didn't select KSL, which indicates that system uses strategy 40, which is entered in the mrp group. Finally, this test shows that system takes the planning strategy in material master (if it's entered), not the strategy in MRP group. I think you can now make another test how system uses MRP group's planning strategy. (hint: Delete planing strategy from the material master and repeat the previous test steps. That would end up using strategy 40, which is selected using the MRP group parameters.) With Compliment: Osman Karslioglu

When do we use planning without final assembly strategy? We have mainly MTS, MTO, planning with final assembly and planning without final assembly. Now when we are dealing with planning with final assembly, we would usually produce subassemblies (HALBs I guess) using make to stock, so do we use a planning strategy 70 for subassemblies and do a MRP run. To my knowledge I thought we run MRP only for final products (with final assembly) so in that case how would we plan for subassembly products. I get to understand you are using strategy planning with final assembly. So you are using strategy 40 for the finished product. Just to clarify certain things, MRP can be run for any material...be it finished or semi finished or raw material. Actually when you run a MRP for the finished product using MD02, you are doing a multilevel run. Secondly, when you are using 40 for the finished product you may or may not use any strategy for the semi finished goods. It depends on your business. If you are going to produce semi finished goods independent of the finished goods, you may have a make to stock strategy 10 (one of the many options) and produce them independent of the finished good requirement. Now when a requirement will be generated for the finished good and a MRP run will be taken, it will show that the Semi Finished is either in stock or a planned/production order exists and thus only the remaining quantity will be planned for (there is a better strategy existing for this type of a scenario..... However if you do not put any strategy for the Semi Finished, then planned orders will be created for the Semi Finished for the same quantity as the orders created for the Finished goods. MRP Monthly lot size Appreciated if some guide can be provided. MRP lot size has been set to MB (Monthly lot size)

It is known that with this setting, material are always bring in on the first working day of the month. Ex: Dep requirement 26-10-04 100 pcs Dep requirement 30-10-04 190 pcs When MRP completion, the PR item shown 1-10-2004 290 pcs, is that any possible to bring in material just right before dependant requirement 26-10-04 say about 24 or 25 of the month. Because. we dont tend to keep more stocks until actual requirement. Any comment are welcome. In that case you might like to consider lot size key WB (weekly). It will bring in material at the first working day of the week. In your case it is Oct 25, 2004 But in this case, I will have increase administrative cost on monitoring the material lot weekly. I want to have monthly lot size that group all the requirement, but bring in material as close as possible on the first requirement. Any comment are welcome.. How about manually change delivery date in PO item Check your config. in OMI4 - scheduling may by ''1'" for Lot size of MB. Change to Blank. Friend PPS is correct, Schedule the "REQUIREMENTS DATE = DELIVERY DATE" option in Customizing for Lot Size MB (use Blank instead of 1) & your reqt 'll be met... Reservation Not Created During MRP Run I have created a planned order thro MRP run, but reservation for raw material is not created, even though stock is available. After conversion to Production order reservation is created. After confirmation and goods reciept MB31 final product is updated in storage location, but raw material quantity is not reducing. Can any one give solution for this. Gururaj Hebbar PART I After MRP run, based on the demand Planned order will be created and for the BOM components sytem will create dependent requirement if stock is available. If stock is not available system creates a planned order or a purchase requistation. Once the planned order of the Header material is converted into a production order , then system converts the dependent requirement into reservations. PART II After confirmation and goods reciept if the item components are not consumed, it means you have not defined backflush process. If you want to issue manualy to the order u can use T-CODE MB1A, for the same. K. Prasobh 1. Check backflush indicator either in routing /workcenter or in material master. 2. In customization production control -operations-confirmation ( general individual entry screen ) check-- post open reservation . It will post open reservation while confirmation. 3. After doing this cross check failed goods movements. How to Configure Range Of Coverage Profile I am trying to configure the range of coverage profile to provide a 6 months safety stock, in which the 'target cov' field should be populated with 180 days, but the that field only accepts 2 characters max. Is there another way of accomplishing this or am I doing something wrong. Please let me know. The current setup is: - Period Indicator = M (Month)

- Type of Period = 1 (Workdays) - Range of coverage in the first period: - Min = blank; Target = 90; Max = blank In this Target value accepts only digit numbers. Muthu Chinnadurai Yes the system accepts only two digits. But since you want stock coverage for 180 days. Use target as say 60 and the number of periods as 3 . Try it and keep us posted. But the one other issue is the system calculates the dynamic safety stock. It easy to calculate the stock for the first period but for the later periods its difficult. So if later there is a problem with the quantity then its difficult to calculate or cross check what system has proposed. Raj Using target as 60 and number of periods as 3, only results in system maintaining safety stock for 60 days for first 3 periods. I found out that there is no way out of this. Strange that SAP wouldn't let the companies plan for inventory coverage more than 99 days. This is a pharmaceutical client whose procurement lead times are more than 5 months for some of the materials, where they want to maintain a 6 month coverage and SAP wouldn't allow to achieve it. Am I doing something wrong here. Is there another way of maintaining dynamic safety stock for 180 days requirements coverage? Please share your knowledge. Muthu Please let me know in details how the profile coverage works in SAP. In details means how it is being calculated and what is being considered. As I am figuring how I could make use of this function that my customer require us to keep 15 days inventory and customer forecast flucuates drastically every week. Thanking all in advance for your kind advice and help. Alicia In customizing in MRP calculation menu , you have Range of coverage. Define the range of coverage you want , as you said 15 days for a period of 3 months. Then in the profile first fill the Avg. daily req data and then the range of coverage data. Use this profile in the material master mrp II view(I think), in range of coverage. As far as calcualtion are concerned its very to calcualte the Qty for the first period and then for the later periods its difficult. May be I am wrong, just try and keep us posted. Raj The Range of Coverage profile is define specific to a plant in IMG and then assigned to materials in master data MRP 2 view. To define the profile, use menu path IMG->PP->MRP->MRP Calculation->Define Range of Coverage Profile. In the definition, there are two sections of data that you need to fill in. 1. Parameters for calculation of average daily requirements and Period indicator. 2. Minimum, Target, and Maximum stock calculation parameters. PARAMETERS FOR AVERAGE DAILY REQUIREMENTS CALCULATION: Choose the period indicator as Month, Period, or Week. Specify the number of periods. This is used by system to calculate the average daily requirements. Select the "Type of Period Length", ie. as workdays or calendar days or standard days (days per period). If the type of period length is selected as standard days, they you have to specify the "days per period". Using these three parameters, the system calculates average daily requirements using the formula: average daily requirements = Sum of requirements in the number of periods / number of days in the number of periods.

PARAMETERS FOR TARGET STOCK AS DAY'S OF SUPPLY Then you have to specify how many workdays of supply you want to maintain as target stock, in your case 15 workdays. If you wanted to maintain a constant 15 days of supply as inventory through out the planning horizon, just specify the target stock as 15 days and leave rest of the fields as blank, i.e min, max, and number of periods. The number of periods in this section simply maintains the target stock for that many periods from the date of MRP run. This way you can tell the system to maintain different target stock levels for three different period intervals. For example, if you wanted to maintain 15 days stock for first 3 periods, then specify the target stock as 15 days and number of periods corresponding to it as 3. The system then will maintain 15 days supply as inventory for first 3 periods from the date of MRP run and subsequent months zero inventory will be maintained. This will allow you to maintain your 15 days supply constantly for 3 periods. Lose of link between sales order and production order Issue with production order confirmation Due to lose of link between sales order and production order due to credit check problem The production order for higher level component lost link and was hanging out in limbo status. Now the production order at lower level component also loose track and they were already released where as production orders at higher level were not released So now lower level production orders were tecoed with BDC program as there were 1200 production orders to be tecoed at lower level . So once I deleted lower level, I saw that there were planned orders for same component and same sales order and item, this was because MRP was running at same time . So this MRP generated planned orders as the production orders at highrt level were still hanging there and to full fill those production orders lower level component planned orders were generated So now cleared the production orders in top level and ran MRP in display mode and found that there were no planned orders for lower level component. But still there were two more planned order created at higher level has I previously tecoed them and did zero confirmation due to some other reason, So I had to unteco them to delete these planned orders and also cancel confirmation to get the production order element on to MD04 screen. Once Iam done with that it show a message 26 So It should be clear that if the exception message is 20 ie cancel process then that production order must be deleted as there is no requirement to consume this order. As all this context was made in MTO stock product. Batch Characteristics while Running MRP Can batch characteristics be considered while running a MRP? I have a finished good that has acid value as its batch characteristics. Based on this acid value I am trying to pick up a certain batch of raw material that is also batch managed and has its characteristics as acid value. While running MRP qty requirements are transferred and stock is reserved but the required batch qty (having the acid value required) of raw material is not picked. MRP does NOT use batch data. Because, while entering PIR, there's no field to enter batch number. When system creates planned order, also there's no field to enter batch number, both for the header material and planned order components. There's one exception in PP-PI, where you can use batch specific unit of measure. That is, you can define batch level alternative unit of measure. For example, you may have a liquid, and it may have Liters as base unit of measure, and

it may also have the percent based active ingredient, that is Liters of the Active Ingredient can be an alternative unit of measure. So, every movement of material in the system will be done using 2 unit of measures at the same time. e.g. goods receipt of 100 Lt liquid (which is also 80 Liters of Alcohol, because of 80% alcohol potency), for the first batch. also goods receipt of another 100 Lt liquid (which is 60 Liters of Alcohol this time, because of 60% alcohol potency) When you look at your stock, you will see 200 LT liquid, which is equivalent to 140 LT Alcohol ingredient. What's the use of this active ingredient data during MRP? When you define the batch unit of measure, you define limits for it. Say, our liquid in previous example can only be between 50% and 90%, therefore we define it like that. Every time we receive this material from vendor, we make the quality inspection and determine the Alcohol percentage. however, while running MRP, system will create purchase requisitions, but it doesn't know the percentage of the liquid our vendor will send. How will it determine the correct quantity? In this case, we define a percentage for MRP, and MRP will use that percentage for calculation. e.g. if there's an industry standard that all vendors of that liquid produce it at 75%, or if we are always working with a vendor who produces 68%, then we can enter this data (per material) and MRP will calculate with that percentage. What is Firming Type in the MRP Types The firming type dictates the behavior of planning with PTR (Planning Time Fence), i.e. whether the system should automatically firm the unfirmed planned orders and purchase requisitions, which are outside the PTF as they move to fall within PTF as days progress and also if new planning proposals are needed to be created to cover the shortage within PTF. There are five firming types, viz. 0, 1, 2, 3, and 4. Listed below are the characteristics of these four firming types: 0 - PTF has not effect on planning. The system does not firm procurement proposals automatically. 1 - All unfirmed planning proposals (planned orders/purch reqs) moving into PTF will automatically be firmed by the system, thus protecting them from anymore automatic changes due to subsequent planning runs). At the same time, if the MRP engine identifies any shortage within PTF, the system will create new planned orders, but schedule them to lie JUST outside the end of PTF, thus leaving them as unfirmed elements. 2 - All unfirmed planning proposals (planned orders/purch reqs) moving into PTF will automatically be firmed by the system, thus protecting them from anymore automatic changes due to subsequent planning runs). BUT, the system will NOT create any new planning proposals to cover the shortages identified within PTF. The shortage is left as a ve qty for the planner to deal with manually. 3 - No automatic firming of any unfirmed planned orders, even if they move into PTF. They will be moved out to lie JUST outside the PTF. The system will create new proposals to cover the shortage but schedule them outside the PTF and keep them as unfirmed. 4 - No automatic firming / No automatic creation of planning proposals to cover shortage. Procurement proposals that move into the planning time fence are not firmed automatically by the system. The system does not create any new procurement proposals within the planning time fence; that means, the system does not balance the shortage situation in the planning time fence. Dependencies

If you enter a manual firming date then the firming date is automatically extended until this date. You can manually enter a firming date in the initial screen of the planning run and in the stock/requirements list in MRP and long-term planning. How MRP Type In MM MRP View 1 Works Explain how the MRP type works. MRP Type The MRP type is a key that controls the MRP procedure to be used for planning a material. The MRP type belongs to the plant-specific data (in other words, the MRP area data of a material). The MRP type controls which planning parameters must or can be entered when maintaining the material master record. You can customize the parameters of the MRP types delivered with SAP R/3 according to your own requirements. You can also add new MRP types. MRP Type From SAP Help Menu Key that determines whether and how the material is planned. You have the following options: - Manual reorder point planning - Automatic reorder point planning - Forecast-based planning - Material requirements planning with forecasts for unplanned consumption - Master production scheduling (MPS) How to create storage location for MRP area? To create storage location MRP area, do the following steps: 1. Create MRP area by SPRO -> MRP -> Master data -> MRP area -> Define MRP area. Select MRP type 02 - storage location 2. Define scope of planning by tcode OM0E Insert your Plant. 3. In MM02 assign MRP area in MRP1 view. 4. In SPRO -> Define parallel processing in MRP. 5. While MRP run select parallel processing in the initial screen. What exactly is the use of transaction code OM0E? In scope of planning you can define 1. Several plants 2. For One MRP area 3. Plant with MRP area 4. Several MRP area.

If you want to run MRP for a plant, you can enter a plant as normal. But if you want to run multiple plant or other option, you have to create scope of planning. So that MRP plan for Multiple plants. MRP Types Procedure Description MRP Type You use the MRP type to assign the procedure to be used to plan a material and to control which MRP parameters can be maintained for the material in the material master record. You enter the MRP type in the material master record. The following parameters of the MRP type are relevant for MRP: MRP procedure MRP procedure

Short Description

B

Reorder point planning

D

Material requirements planning

N

No MRP

S

Forecast-based planning

M

Master production scheduling

R

Time-phased materials planning

W

Replenishment (IS Retail)

X

Without MRP, with BOM explosion

The MRP procedure defines which of the following MRP types is to be used: 

MRP



Consumption-based planning (reorder point)



MPS

Indicator Firming type The firming type determines how order proposals are firmed and scheduled if you work with a planning time fence in the planning run. Configure Path: SPRO -> Production -> Material Requirements Planning - Master Data - Check MRP Types (tcode OMDQ) Key that determines whether and how the material is planned. You have the following options: 1) Manual reorder point planning - While you are using manual reorder planning you have to maintain a reorder point manually in MRP 1 view of the particular material.

2) Automatic reorder point planning - While using the automatic reorder point you have to maintain the forecasting view in material master and you have to give forecasting model. So here system will automatically consider the reorder point depending upon the forecasting technique. 3) Forecast-based planning Steps: a. Maintain Forecasting view in material master and enter the historical data and forecasting period within the Forecasting view. b. Maintain MRP type VV in MRP-1 view c. Carry out MRP in transaction MP30 for Individual material and MP38 for total Forecast at Plant level. The procurement proposals will be generated d. No PIR , NO sales orders r considered. e. After MRP run, planned orders are created for the forecast requirements. 4) Material requirements planning with forecasts for unplanned consumption. Unplanned consumption is updated only for materials planned using MRP. This occurs in the following cases: a. If goods are withdrawn from the warehouse without a reservation. b. If goods are withdrawn on the basis of a reservation, but the quantity actually withdrawn exceeds the reservation. 5) Master production scheduling (MPS) MPS is executed for selected material only based on business decision. Maintain MRP TYPE as M0 to M4 based on your business requirement. Use T-Code MD40 for foreground execution. For background, create variant in MDBS and use this variant to create a job. Functions of Production Version Can somebody enlighten me on the functions of production version and some tips on its configuration? Production Versions are used to describe the production process to be used for planned / production order. You can use the production versions based on: 1. Lot size qty 2. Bom explosion dates 3. Based on MRP Group Why is it required? Suppose you have 2/3 production lines and 2/3 alternative BOMs to produce one FG. How system will come to know which BOM and Routing to be used. This is done thru Prod.Version. In production version we maintain the combination of BOM and routing. Also it can be designed with lot size or validity period. Go to MM02--->MRP4 / Work scheduling view ----> Prod.Version. Enter the validity period and lot size. After entering the reqd. routing no. and BOM alternative , carry a check. After getting the Green signals ,Continue. Thus you have saved the prod. version. Mass processing TCode- C223.

Does this mean that I have to activate all the BOM’s if in case I have 3 alternative BOM’s? if yes, then, will it these 3 BOM’s be exploded in MRP? I’m just worried ‘coz I might bloat our inventory if there are three active BOM’s. No.First of all need not worry about the BOM explosion. As I told you earlier which BOM and which Routing is decided by Prod.Version. So in MRP the active prod.version only will be considered. Thus active BOM and active Routing will be used for MRP. The question comes: How to deactivate the alternative BOMs and Routing? Two Ways: 1. You lock all other non-relevant Prod.Versions in MM02 of the FG/SFG material.(Every alternative BOM and routing forms a Prod.Version) Thus even if there are 2/3 prod.versions System will go and check for Unlocked prod. version and use it. 2. If you don't want to do this business of "Lock & Unlock" just place the required version at the first place in list of prod.versions in MRP4 view of the material. Once system finds the first prod.version it will not spend energy in searching other alternatives. Also please.don't forget to maintain the selection value of "2" in MRP 4 view for BOM selection. This will enable you to start the use of prod. version functionality in SAP-PP.(very good tool for practical purposes, costing and MRP). Steps To Do Repetative Manufacturing By : Baskaran Repetative manufacturing is period based planning and not based on orders. Normally same products will be manufactured over longer period of time..products will not change frequently. Confirmation is from backflushing and settlement is through from product cost collector for the period. Confirmaton will be without ref to planned orders. Planned orders are sufficient to carry out shop floor activity. In master data production versions and cost collector is must where this is not mandatory in discreate. You do these steps for rem production: mm01 : Material Master - MRP - 4 view you click rem cs01 : Create Bom cr01 : Create Work Center ca21 : Create Rate Routing mm02 : Prodn Version md61 : Create PIR mc74 : Transfer PIR to Demand kkf6n : Create Product Cost Collector mb1c : Create Stock md02 : MRP run mfbf : Rem Back Flush The detailed sequence of T.Codes for REM including Std cost estimate. Material master - MM01

BOM - CS01 Price Planning - KP26 Work Center - CR01 Rate Routing - CA21 Material Master Change, enter production version - MM02 (MRP 4 View) Product Cost Collector - KKF6N Costing - CK40N Backflushing - MFBF What The Use of Reorder Planning What the use of reorder planning? How to create reorder planning? By : Supriyo Sengupta Reorder planning, when plant stock falls below reorder point procurement is triggered. Planning can be done by manual or automatic. We maintain reorder point in Material Master when warehouse stock reaches this level, MRP will trigger procurement for the same. AND reorder point planning is used for consumption based planning. For re-order point planning, you have to put some field in MRP1 View of the Materail Master. MRP Type: VB (manual reorder point planning) Reorder Point: for example 100 ( the level of stock at which u want to trigger replenishment) Lot Size: HB (maximum replenishment) / or u can maintain EX / FX also. but it advisable to go with HB Maximum Stock Level: for example 400 (as per ur requirement) For re-order point planning, you can leave blank strategy. What Is Planned and Unplanned Consumption Define what is planned and unplanned consumption? What is difference between MRP strategies and consumption based planning ? Unplanned consumption is updated only for materials planned using MRP. This occurs in the following cases: 1) If goods are withdrawn from the warehouse without a reservation. 2) If goods are withdrawn on the basis of a reservation, but the quantity actually withdrawn exceeds the reservation. Planned consumption is not displayed in the material master record. However, you can calculate it yourself by subtracting unplanned consumption from total consumption. The system normally updates the consumption values in the material master record automatically whenever stock is withdrawn from the warehouse. Material requirements planning is carried out using current and future sales figures. Consumption-Based Planning uses past consumption data to calculate future requirements with the help of the material forecast or statistical planning procedures. The consumption based planning means: If you are planning your Raw Material not by MRP run, then use Consumption based planning with reorder point. For this the MRP type is VB. The system will not generate PR during MRP run. When ever you issue a RM the system will look for reorder point and if the stock is less than this it will run in planning file entry. The system will raise PR at that point of time only.

In which Tables can I find: 1. Consumption of material 2. Stock of material 1. Consumption of material: MARC-VMORD MSEG - MENGE S026 - ENMNG 2. Stock of material: MARD Table Choose the following filed Unrestricted: LABST Restricted use: EINME Blocked: SPEME Return: RETME Max stock MARC-MABST

Planning separately via Storage Location or Vendor with MRP Area ERP SAP Modules ==> PP In SAP Steps 1 :You must convert the existing planning file (table MDVM) to the new planning file (table DBVM) in order to be able to use MRP areas in materials requirements planning. Transaction OM0F. 1. During the conversion, the system creates a plant MRP area for every plant. 2. The existing planning file entries are copied from the planning file used up to now into the new planning file. 3. The system deletes the planning file that had been used up to now after the conversion has taken place. 4. At client level, the indicator Planning file entries for MRP area converted is set in a system table. This indicator causes material requirements planning to be carried out using planning file entries at MRP area level from this point onwards. 5. The report also converts the individual customer planning file entries at plant level to individual customer planning file entries at MRP area level. Steps 2 :Activate MRP Area in SM30 - T000MD. (Material requirements planning with MRP areas cannot be reversed once activated). Steps 3 :During conversion in Steps 1, SAP will automatically create a MRP area for all your existing Plants. Now, you can start creating the MRP area for storage location or vendor to be planned separately. That's is the whole purpose for using MRP area. Define MRP Area in SM30 - V_MDLV. Here you define whether the MRP area type :01 - Plant 02 - Storage Location 03 - Vendor

Steps 4 :In Material Master MRP 1, the MPR area section will appear once you successfully complete the above Steps. Assign MRP Areas to Materials You assign the MRP areas to the materials by creating an MRP area segment for each MRP area in the material master. You can assign several MRP areas to one material. MRP with MRP areas for the material is not activated until an MRP area has been assigned to a material. If you have not assigned an MRP area to a material, that is, you have not created an MRP area segment in the material master, the material will continue to be planned in the plant MRP area only. If you have assigned an MRP area to the material, the system can plan it in the plant MRP area and in the assigned MRP area. You can display an overview for all materials in an MRP area. To do this, you go into Customizing for MRP and choose the IMG activity Define MRP areas. Call up an MRP area by double-clicking and choose Material overview for MRP area. Steps 5 :Check Storage Locations If you have already entered a storage location in the BOM (BOM item), in the work center (supply area) or in the production version, you should check whether this storage location is the storage location for the MRP area that you have assigned in the material master. The materials are assigned to an MRP area via the storage location that the system determines during the planning run. You should therefore check the storage locations that you have maintained in the material master. The storage location in the material master must be a storage location for the MRP area, for which you have created an MRP area segment in the material master. You can therefore ensure that material requirements planning will be carried out for the correct MRP area

The MRP area represents an organizational unit for which material requirements planning is carried out independently. Basically, there are three types of MRP area: Plant MRP Area The plant MRP area initially contains the plant together with all its storage locations and stock with subcontractors. When you have defined MRP areas for storage locations and for subcontractors and you have assigned the materials, the plant MRP area is reduced by exactly this number of subcontractors and storage locations. This is because they are now to be planned separately.

MRP Areas for Storage Locations You can define an MRP area that consists of a particular storage location, by creating an MRP area and assigning the storage location to it. Material requirements for this storage location are then planned separately from the rest of the plant. You can also group several storage locations into one MRP area, by creating an MRP area and assigning the storage locations to it. These storage locations are then planned together. A storage location of a plant may be assigned to only one MRP area. MRP Areas for Subcontractors You can also define an MRP area for each subcontractor. A subcontractor may be assigned to only one MRP area. An MRP area of the subcontractor type may also only contain one subcontractor. MRP areas of the storage location or subcontractor type are only suitable for: 1. components that are planned and produced for stock 2. finished products that are planned and produced for stock. By assigning a storage location in a sales order or by entering an MRP area when creating the planned independent requirements, you can define whether a material is planned in the plant MRP area or in the MRP area of the storage location.

Material requirements planning for each MRP area allows you to have specific control over the staging and procurement of parts produced in-house and purchased parts for each shop floor and assembly area. If, for example, you define an MRP area for the production storage location of an assembly line, the system plans the material requirements for the assembly line separately from all other requirements. Example: Subcontractor You can also carry out planning for components to be provided in subcontracting using an MRP area by defining an MRP area for every subcontractor and assigning the components to be provided to the MRP area of the subcontractor. You therefore plan the requirements to be provided for these components for one subcontractor separately from all other requirements. Depending on the requirements situation, the system creates either stock transfer reservations from the plant to the stock of material provided of the subcontractor or it creates purchase requisitions within subcontracting/third-party order processing, according to the special procurement key settings.

The planning run takes into account the planning with MRP areas as follows: If you do not enter a separate scope of planning, the system plans the whole plant, that is, all MRP areas in the plant, during the total planning run. If you want to carry out a total planning run for a particular MRP area only, you must specify the required MRP area in the scope of planning. During single-item, multi-level planning, the system plans the selected material in the MRP area entered. In addition, the system takes into account planning file entries from other MRP areas, for example, if the material is to be procured using stock transfer. During single-item, single-level planning, the system plans the selected material in the MRP area entered only. You define the MRP areas in Customizing for MRP. You can thereby assign the following to an MRP area: one or more storage locations (example: you want to carry out planning for a particular assembly line and therefore assign a production storage location to the MRP area) a subcontractor. You assign the various MRP areas to the materials in the material master. For this, you create an MRP area segment for a material for every MRP area, in which it is used. In this MRP area segment, you can define MRP parameters such as, for example, the lot size or MRP type. This allows you to plan the material differently in the MRP area from how you plan it in the plant MRP area. MRP with MRP areas for the material is not activated until the material has been assigned to an MRP area. If you have not assigned a material to an MRP area, that is, you have not created an MRP area segment in the material master, the material will continue to be planned in the plant MRP area only. If you have assigned an MRP area to it, the system can plan it in the plant MRP area and in the assigned MRP area.

MRP Area Customizing and Mass Updating ERP SAP Modules ==> PP In SAP I have created my storage location as MRP area in the customizing. Now when I am trying to enter in the MRP 1 view in material master, it is showing the following error. Error: MRP area is not assigned to Plant. But in customizing I have assigned plant while creating the storage location as MRP area. To create storage location MRP area, do the following steps: 1. Create MRP area by SPRO -> MRP -> Master data -> MRP area -> Define MRP area. Select MRP type 02 - storage location 2. Define scope of planning by tcode OM0E. Insert your Plant. 3. In MM02 assign MRP area in MRP1 view. 4. In SPRO -> Define parallel processing in MRP.

5. While MRP run, select parallel processing in the initial screen. If you want to run MRP only for one MRP area then only enter the MRP Area there or If you want to run MRP for Plant with MRP area, several MRP area you can select there. Run MRP with MD01 then. What exactly is the use of transaction code OM0E and What is the use of defining scope of planning. In scope of planning (OM0E) :- you can define: 1. Several plants 2. For One MRP area 3. Plant with MRP area 4. Several MRP area. If you want to run MRP for a plant, you can enter a plant as normal. But if you want to run multiple plant or other option, you have to create scope of planning. So that MRP plan for Multiple plants. Do you know of a program/transaction (like MASS) that will enable me to update Material master MRP Area data (table MDMA)? Try report RMMDDIBE - Fill in the MRP Area Data - Fill in the Forecast Data What is MRP Area And How Is It defined What is MRP Area. How it is defined? What are the points to be considered while defining a MRP Area? The MRP area is an organizational unit for which material requirements planning can be carried out independently outside of total plant level MRP run which is done using MD01 for entire plant. by creating a specific scope of planning and is maintained in the MRP view of the material master But first you need to create it in SPRO and if needed assign the storage locations or materials masters to the mrp area and MRP with MRP areas for the material is not activated until the material has been assigned to an MRP area. If you have not assigned a material to an MRP area, that is, you have not created an MRP area segment in the material master, the material will continue to be planned in the plant MRP area only. Basically, there are three types of MRP area: 1. Plant MRP Area The plant MRP area initially contains the plant together with all its storage locations and stock with subcontractors. When you have defined the other 2 types of MRP areas for storage locations and for subcontractors and you have assigned the materials, the plant MRP area is reduced by exactly this number of subcontractors and storage locations. This is because they are now to be planned separately. 2. MRP Areas for Storage Locations You can define an MRP area that consists of a particular storage location, by creating an MRP area and assigning the storage location to it. Material requirements for this storage location are then planned separately from the rest of the plant.

You can also group several storage locations into one MRP area, by creating an MRP area and assigning the storage locations to it. These storage locations are then planned together. 3. MRP Areas for Subcontractors You can also define an MRP area for each subcontractor. A subcontractor may be assigned to only one MRP area. Advantages of using MRP area and highlights. 1. You can carry out MRP specifically for the determined MRP areas. This enables you to carry out differentiated material requirements planning. 2. Finished products and important assemblies intended for make-to-order or engineer-to-order production are always planned in the plant MRP area 3. The planning run takes into account the planning with MRP areas as follows: 4. If you do not enter a separate scope of planning, the system plans the whole plant, that is, all MRP areas in the plant, during the total planning run. If you want to carry out a total planning run for a particular MRP area only, you must specify the required MRP area in the scope of planning. 5. During single-item, multi-level planning, the system plans the selected material in the MRP area entered. In addition, the system takes into account planning file entries from other MRP areas, for example, if the material is to be procured using stock transfer. 6. During single-item, single-level planning, the system plans the selected material in the MRP area entered only. Now, for running the cycle for MRP areas, we need to define in SPRO. IMG -> Production Planning -> MRP -> Master data -> Define MRP Areas Specify Area types 01 - Plant MRP Area, 02 - Storage Location MRP Area 03 - Sub contractor MRP Area. After defining MRP area, assign the material to the specific MRP area in the MRP1 view of the Material master and define the MRP1 & 2 views specific for those areas. Enter the requirements for the specific MRP areas, if you do not enter the MRP area, MRP area by default will be picked as Plant MRP area. Also, need to run MRP, by entering appropriate MRP area. Stock/Rqmts list to be selected by entering the MRP area in the selection screen. MD04 - Inconsistencies after PGI - SDRQCR21 What is the use of SDRQCR21 (SAP note 1166713) standard SAP program? I have got a issue with this program. The issue (problem) stated is as follows: Program SDRQCR21 was ran on material XYZ for plant ABC. It did not work. The item is still on MD04. Unable to use material as it is being held on the MD04 screen. This program is used for to regenerate the sales/delivery requirements. Example: sales order 1000 is created on some date. Now may be you have put the reason for rejection to the sales order but the stock requirement list MD04 is still holding the qty against to the sales document.

Execute SDRQCR21 program by selecting data Transfer option. MD04 will remove the Hold qty against to the sales order. I have a sales order, sales order is fully delivered and MD04 doesn’t have this record displayed. You can see it has no sales orders by using the Find in List function (Cnt-F) in mdo4. The find MRP Elements tab shows you no sales orders exist for this material plant (sales order item ). So don’t understand why it shows up as an error. Why does the program think it needs to delete this sales order entry from md04, when it has nothing in MDO4 . Run the program SDRQCR21 in SA38. In the ensuing selection screen, Give the inputs of material number, plant and if possible document number, and execute. You have to schedule this job before MRP run at plant level (creating variant from SE38). After executing this, the completed delivery will disappear and MD04 will have real data only. SDRQCR21 report doesn't update MD04 result. We had quite a lot customer orders be re-scheduled everyday for some reason. According to OSS note : 25444 & 998102 we have to run the report SDRQCR21 with option "data transfer" to correct stock /requirement list. But nothing happen after run the report. Go through the OSS Note: 547277 It may be useful. From the OSS Note:25444 Below write-up may be useful: Item Material Index If you enter the 'Material' or 'Plant' selection criteria, the report returns correct results only if the document items affected are contained correctly in the relevant material index (VAPMA, VLPMA). This prerequisite is usually met. Only if you have good reason to suspect that the index is inconsistent, that the report has returned incorrect results because of inconsistencies, or that the report terminated with SAPSQL_ARRAY_INSERT_DUPREC because of inconsistencies, check the TVIND Customizing table and see Note 128947 and/or 33267 for information about correctly reconstructing the material index. MD04 MD05 MD06 MD07 Differences Some information for their differences : MD04 - MRP Display Stock Requirements List MD04 provides a display of the existing, immediate availability of a single material within a plant. The display will show on hand inventory, open requisitions, open purchase orders, open stock transport orders and reservations made against a material. Every time the list is displayed or refreshed, it will update with the most current information. MD05 - Individual Display of MRP List MD05 provides a snap shot of the condition of a single material within a plant as of the last time MRP was run. The display will show on hand inventory, open requisitions, open purchase orders, open stock transport orders and reservations made against a material.

MD06 - Collective Display of MRP list MD06 provides a collective list of all materials run during the MRP process. Parameters may be set to view certain criteria across all materials. The same detailed information detailed in MD05 may also be obtained by using the drill-down features. MD07 - Stock Requirements Collective Display MD07 provides a collective list of all materials within a plant. Parameters may be set to view certain criteria across all materials. The same detailed information provided in MD04 may also be obtained by using the drill-down features. In Summary: 1. MD05 and MD06 is related. MD05 display single, MD06 display collective. – This 2 display the Last MRP run result. 2. MD04 and MD07 is related. MD04 display single, MD07 display collective. – This 2 display the “real time” stock requirement result. Example of differences: Plant: P100 Material: CTESTMAT1 Run MD04 and MD07 you will be able to see : 1. Sales order 1257000566 – Qty -20 2. Purchase order 4556000819 – Qty +30

Run MD05 and MD06 you won’t see it because this 2 orders were created after I run the MRP .

What Is Safety Stock In MRP ERP Safety Stock or Buffer Stock exists to counter uncertainties in supply or demand. For example, a supplier may deliver their product late, the warehouse may be on strike or a number of items may be of poor quality. In addition, a

competitor may be sold out on a product, increasing demand. Safety stocks enable organizations to satisfy customer demand in the event of these possibilities. In short, a minimal level of inventory that a company seeks to have on hand at all times is called safety stock. Safety stock as the name suggest is the stock level till which the dead stock or stock out situation will not arise (probable figure based on past data maintained in master). As such this figure is not stock, it is cut-off figure maintained in master which is used for Planning and once the stock level dips below this value, you can configure system to generate PR, orders automatically. It has its relevance in MRP and CBP. Safety Stock is the quantity of stock held to satisfy unexpectedly high requirements in the stocking-up period. The purpose of the safety stock is to prevent a material shortage from occurring. In order to determine the safety stock level, you must first specify the risk of a material shortage and also the desired service level. Usually the safety stock will not be used in production. The purpose of the safety stock is to prevent a material shortage from occurring. In order to determine the safety stock level, you must first specify the risk of a material shortage and also the desired service level. The safety stock depends on the service level that you specified in the MRP 2 view of the material master record and on the accuracy of the forecast. The more accurate the forecast, the smaller your safety stock can be. You can specify a minimum safety stock. If the result of the safety stock calculation is lower than this limit, the safety stock is then automatically set to this minimum value. You enter the minimum safety stock in the material master record ( MRP 2 screen ). What are the precautions to take to adjust safety stock in material master? You can change safety stock at any time; it will only effect during next mrp run output subject to your lot size selection. How to configure once the delivery is created, the available stock is reduced? Go to OPJJ -> There for there for combination of Checking Group "01" or "02" as per material master and Checking Rule "B" i.e. SD delivery, Check whether "Include Deliveries" is active OR not. It should be active then System will consider the quantity of delivery document during availability check even if PGI is not done. Explain Rounding Profile In MRP Can you explain rounding profile in mrp. You can customize the Rounding Profile in OWD1 Rounding profile - Key that the system uses to adjust the order proposal quantity to deliverable units. In Customizing, enter a threshold value from which the system should round up to the next value per deliverable unit: - If the requirements value exceeds the first threshold value, the system always rounds up to the next multiple of the level found - If the requirements value falls below the first threshold value, the system copies the original requirements value. Two other types of rounding exist: - Dynamic rounding profile:

These profiles are used to round up quantities to logistical units of measure (for example, layers). The contents of a logistical unit of measure does not have to be know when creating the rounding profile. It is determined by the master data from the material master. - Rounding profile with quantity to be added/subtracted With these profiles, the given quantity is changed either by adding a percentage or subtracting a percentage. Only static rounding profiles are taken into account in requirements planning. Neither dynamic rounding profiles not quantity addition/subtraction are taken into account. Examples : A material's base unit of measure is 1 unit; the purchase order is to be delivered in layers (1 layer corresponds to 5 units) or in pallets (1 pallet corresponds to 8 layers which contains 40 units). You maintain the profile as follows: From a requirements of 2 units, the system is to round up to 5; from a requirement of 32 units, the system is to round up to 40. This results in the following order proposal quantities: Requirement from 1 -> 1 requirement from 31 -> 30 Requirement from 2 -> 5 requirement from 32 -> 40 Requirement from 6 -> 10 requirement from 74 -> 80 Requirement from 7 -> 10 If no rounding profile has been entered, the system uses the rounding value entered in the material master record for the planning run. Difference Between MTO and MTS By: Sankaran The difference between MTO and MTS is MTO--> Make to Order Production is the process where the production order is triggered from a Sales Order. Ex: The Prod process will start only after receiving the sales order from the customer. In this case the product could be customer specific only (Variant) MTS--> Make to Stock MTS scenario can be accomplished by the following settings: - Need to use strategy group 20 in material master MRP view-Strategy group 20 is assigned to strategy 20 Strategy 20 is assigned to Requirement type KE (Individual customer requirement) - Requirement type KE is assigned to requirement class 040 (Indiv.cust.w/o cons.) - Requirement class has all the parameters where we can define Production order type that will be used to create th prod order. The above link needs to be established. Also the MTS can be achieved using Sales Order schedule line category which will be assigned to Requirement type/class. Item category is assigned to Reqtype/class and the Item category is maintained in the material master. You can use any of the above Config settings. For MTO --> you just need to have all PP cycle settings in place nothing special needed as it is a plain PP cycle. 1. Make-to-order production is a process in which a product is individually manufactured for a particular customer. In contrast to mass production for an unspecified market where a material is manufactured many times, in make-to-

order production a material is created only once though the same or a similar production process might be repeated at a later time. 2. You can use make-to-order production in two scenarios (a) For branches of industry or products where a small quantity of products with a large number of different characteristics are manufactured (Variant Configuration). (b) When a product has to be assembled particularly for a sales order (Individual Customer Requirement). 3. Stock keeping is not usually carried out for products that are made to order. In companies using make-to-order production, the demand program only determines the production area, in which various variant types are produced. Depending on how you track the costs associated with make-to-order production, there are two ways to process make-to-order items during sales order processing. (a) Make to order using sales order (b) Make to order using project system (not relevant for SD application) 4. For make to order production using the sales order, all costs and revenues involved for an order item are held collectively at that item. A particular rule is used that can be changed manually to transfer costs to profitability analysis. 5. Make to order production is largely a production planning configuration. It is also controlled by the requirements type, which is determined by three things the strategy group (MRP 3) in MMR the MRP group (MRP1) in MMR the item category and MRP type (MRP 1) 6. Make-to-order production is controlled by the requirements type. The requirements type is determined on the basis of the MRP group (MRP1) and the strategy group (MRP3) in the material master record. In addition, a plant must be assigned for make-to-order items in the sales order. Checking Groups and Checking Rules Explain the definition of the checking groups (CG) and checking rules (CR) in the availability check in the customizing of the Production orders. This is about CR and CG : CG : Specifies whether and how the system checks availability and generates requirements in material planning. The value you enter for use is a default value which defines: Which MRP elements (for example, purchase orders, reservations) the system includes in the availability check. Whether the system checks availability only until the end of the planning or whether it checks availability over the entire period for which MRP elements exist. Whether the system generates individual requirements or summarized requirements if you enter sales orders or deliveries for the material. CR : Defines the checking procedure to be used for the availability check (or in Inventory Management, the missing parts check) in individual applications. Overall you can say, checking rule and group to determine: Which receipts (for example, purchase orders or production orders) should be taken into account in the availability check. Which issues (for example, sales orders or dependent requirements) should be taken into account in the availability check.

Path : SPRO-----Shop floor control---Availability check-Define CG/CR I have created a process order-1, and assigned say a raw material x of certain batch. Material x got reserved for that process order. Now my requirement is system should not allow the material x of the same batch to assign for another process order-2, since it got reserved for process order-1. Availibility check for the material X has given 01 in material master. To solve the problem: Go in OPJK and check the checking rule for your plant and order type. Default - It will be pp checking rule. Go in OPJJ and check your setting against reservation and change it with do not check. MRP Not Creating Purchase Requisition When running MD01, purchase requisition was not created to a certain material, but when using MD02, purchase requisition was created. Answer: MD01 requires a planning file entry, MD02 does not. Check/create appropriate entries in MD20. For all materials in background use MDAB. Might also have to fix inconsistencies using MDRE. Depending on how your master data is being maintained, you may not automatically get a planning file entry when a material is made relevant for planning. As a backstop measure, many companies rebuild the planning files regularly just prior to the MRP runs, using the batch program noted earlier.

Checklist when purchase requisition not created: - Check whether you have maintained the purchasing view for that raw material or not. - Check if already there is stock of the raw material maintained in the system. If the available stock is sufficient for the order quantity, then the system will not generate purchase requisition. Run MD04 /MD05 and check order tree for the material for which you are doing the MRP run. System will show if there is stock available. - Check whether the Material is defined for "F" - External Procurement in MRP2 view of the material master. - Check whether the material type used for the material is enabled for "External Purchase orders". Transaction 'OMS2'. - Check purchase requisition number range is not exhausted. Tcode 'OMH7'. Notes: If you have updated MD20 you cannot revert back the changes made. Reverting this entry is not standard SAP functionality. In the most common business scenarios, if one wishes to be able to plan a material using MRP, they also need to have a planning file entry. SAP will normally create this entry automatically under most standard conditions that require it. Certain uncommon scenarios will leave a material/plant in a condition where planning is required, but SAP has not created the appropriate planning file entry. For these instances, SAP provides the transactions I mentioned previously.

Archiving (physically deleting a material from the database and copying it to long-term storage) will remove planning file entries. Changing a material to non-planable (ND) will remove the entry. I can't think of any other standard MRP process that will remove a planning file entry. The usual business requirement is, "how can I ensure that all planable materials have the appropriate planning file entry".

What code to display all Purchase Requisition generated by MRP LIST? You need to use ME5A report with dynamic selection. In dynamic selection (it will appear next to variant button) you need to choose creation indicator. Give creation indicator as "B" which material requirement planning and execute the report. How And When To Use MDAB Transaction Explain how and when to use MDAB transaction. At the beginning of the implementation when we are done with the organization structure (define Plant.. etc.), we have to activate the MRP in the TC: OMDU This will take care of all planning file entries for all the materials created afterwards and that are relevant for planning. If some materials are created before the activation of MRP, in that case we use this transaction MDAB, for those material to be entered in the planning file. MDAB is for creating the planning file entries in background. So when you go-live you can schedule this job and it will create planning file entries for all the material in that plant. If required you can also schedule this job to be run once in a month to take care of all the new materials. (if you create them by batch jobs). Also you can use this transaction along with consistency check for the planning file MDRE

1. What do MDAB does? This creates a Planning file entry 2. Why do we run this for first time when MRP is started? As the system needs to identity what all the materials that has to be included in the planning run. This Transaction creates a planning file entry to make the mrp run at background to pick the materials and to include in the MRP run. 3. Do we need to run regularly? The answer is No. Once the mrp is run the planning file entry will be removed and again it will be populated when a stock change occurs, a sales order gets created, etc.

Can we get a list of materials for those planning file entry is generated through background job using t-code MDAB ? You will get that list from accessing database table MDVM or DBVM

Notes: Planning File creates all the materials relevant for the planning run. The planning run and the scope of the planning run (which materials are planned in which planning run) are controlled by the planning file. For planning file entry use the following transactions, MD20 : Create planning file entry MD21 : Display planning file entry MDAB : Set up planning file entry in background MDRE : Check planning file entry Please run this in it will solve your problem All materials assigned with MRP are automatically entered in planning file entry. Depends on changes in material planning or in proposal, system will create planning file entry. When MRP run, system will consider only which materials having entry in above contents of planning file entry. After MRP run, system delete the planning file entry. And again, when material have changes like GI GR on any other demand, then system generate planning file entry again. Step by Step Process Of MRP Flow From Demand management, how the MRP flow starts. Since MRP is contributing with many inputs in material master, how are the importance data taken. Explain clearly the Step by Step flow. Answer: The Process Flow: 1. The system calculates net requirements for all the requirement quantities that are to be planned. The system thereby compares available warehouse stock or the scheduled receipts from Purchasing and Production with planned independent requirements, material reservations and incoming sales orders. In the case of a material shortage, that is, if the available stock (including firmed receipts) is smaller than the quantity required, the system creates procurement proposals. 2. The system calculates the quantity recorded in the procurement proposal according to the lot-sizing procedure that you specified in the material master. Various lot-sizing procedures are supported by the system. You can define a lot-sizing procedure for each individual material. 3. The procurement proposal is also scheduled which means that, for materials procured externally, the delivery and release dates are determined, and for materials produced inhouse, the production dates are calculated. 4. For materials produced in-house, the dependent requirements of the components are determined during the BOM explosion. For each component, the dependent requirements date is displaced by the in-house production time of the higher-level material.

5. Additional requirements (unplanned goods issues, excess consumption of components in production, and so on) can be covered by using the materials forecast within MRP. The historical values of unplanned requirements form the basis of the forecast. These requirements are then taken into account along with the exact requirement quantities.

The whole production process takes place in the following steps. 1) Forecasting of the future demand. 2) Demand Planning (Flexible planning / Standard SOP). 3) Transfer Demand Planning data to Demand Management. 4) Demand Management. 5) MRP - Material requirement planning will happen in the following steps: a) Net requirements are calculated b) based on the various configuration parameters like the requirement type, planning strategy & MRP type...etc, planned orders are generated with schedule dates & quantities. 6) Capacity Planning. 7) Conversion of Planned Orders to Production Orders & execution. In short this is the whole process of planning. Usage Probability For MRP Run Explain usage probability. Let us say if I specify two comp A and B. For A Priority 1 Strategy 2 ( 100 %) Usage prob. 30 For B Priority 2 Strategy 2 ( 100 %) Usage prob. 70

Do I need to maintain usage probability?

How system will behave, will it ignore usage probability? Answer: Usage probability is for MRP run. Priority is the order in which stock is checked in order to reserve. If either 100% of A or 100% of B can fulfill the demand then it will pick that component based on priority (A first, B second). Let us make it a little bit more detailed. Component A Priority 1 Strategy 2 ( 100 %) Usage prob. 30 Qty reqd in BOM : 20 EA Component B Priority 2 Strategy 2 ( 100 %) Usage prob. 70 Qty reqd in BOM : 10 EA If Available stock A: 20 B: 10 Component A is picked to make reservation. If Available stock A: 4 B: 6 (After MRP run) pur req for A: 2 EA and pur req for B: 1 EA

If Available stock A: 0 B: 0 (After MRP run) pur req for A: 6 EA and pur req for B: 7 EA If either 100% of A or 100% of B cannot fulfill the requirement then MRP run will look at the usage probability and generate purchase orders based on the probability and available stock. But you want to purchase either component A or component B (according your requirement where you want to make one of them primary), it makes little sense to set one at 30% and other 70% so you set that component usage probability for primary as 100% and rest of the components in the group 0 so that pur reqs are generated only for the primary. Example, you always want the system to look for A if it's in stock and can fulfill demand but you always want to purchase B first, so you set priority 1 for A and probability 0 and usage probability 100 and priority 2 for B. MRP To Generate PR Once In No Of days Question: I have a requirement to fulfill the needs to generate a collective PR for requirements pending for next 45 days. PIRs are maintained for around 90 days based on the forecast. Materials are ordered based on their ABC category. For all A class materials PR generation is dynamic. For all B class materials the requirement needs to be clubbed and a single collective PR is required for 45 days and for all C class materials one PR for requirement pending for 6 months, There is no PP here and all the materials are externally procured and sold. Solution: Well, I can only think of the lot-sizing procedure in MRP 1 view. You can configure your own lot-size to accommodate your requirement. You need the new period lot sizes for the materials B and C classes. Please go to customization transaction OMI4 then create new lot sizes as below and assign to the material master. Class B: Lot size for short-term period. Lot-sizing procedure P Period lot-sizing procedure No. of periods 45 Lot-size indicator T Daily lot size Class C: Lot size for short-term period. Lot-sizing procedure P Period lot-sizing procedure No. of periods 6 Lot-size indicator M Monthly lot size

Question: The client has an requirement as follows. For a certain X material system has to generate PR after every two months for 100 KG. Please guide how it can be achieved using MRP or any other functionality. Solution: Maintain the MRP data for the material and maintain the MRP profile for the material as fixed quantity and then whenever you run the MRP for the Material system will create a firm 100 quantity, you can convert that for creation of PR. To include the Period factor: Maintain the MRP Type as VB and lot Size as FX and maintain the fixed quantity. MDBT Create a variant and give the transaction code MD02 and maintain the plant & create purchase req. as 1 and schedule it for every two months, then automatically it will create for every two months. This is the way you can achieve it. Planned Order Split For Material During MRP RUN My client is using strategy 50 MTO. There is a sale order for 100 qty. Run MD50 and generated planned order for some material (HALB). My client require that during planning, it need the system to generate split planned order for each material by dividing the sale order qty (i.e.) each planned order 20 qty. Client require this material to create five planned order irrespective of sale order quantity, planned order qty should be always 100/5. --You can define a production version for the material and in that version specify a distribution function which distributes the requirement in 20% splits. Distribution functions are defined in customizing under: Production -> Basic Data -> Bill Of Material -> Item Data -> Item Data from Related Application Areas -> Define Distribution Keys

If you want to split the planned order by percentage, you can use quota arrangement (MEQ1). Alternatively, you can distribute requirement quantity by defining a lot sizing procedure with the time in OMI4. However this type of splitting requires specifying min, max or static lot sizes in material masters. If you want to split order by capacity, then you might want to use fixed lot size, and finite capacity with option “changing production version on error”. Splitting Of The Forecast Requirements The purpose of this configuration is to define splitting forecast requirements. Here, you will define: - the periodicity in which forecast requirements are taken into consideration and are split on the time axis in MRP - for how many periods the forecast requirements are taken into consideration in the net requirements calculation The splitting indicator is defined depending on the period indicator. The period indicator defines the periodicity used to record the historical values for the forecast and the periodicity to be used to output the forecast values. However, this periodicity may be too large for the planning run. Therefore, you can use the splitting indicator to: - split monthly values into daily and weekly forecast requirements, and to - split weekly forecast values into daily forecast forecast values. In this step, you can also limit the number of forecast requirements for which the net requirements calculation is to be carried out. To split the forecast requirements for a material, the splitting indicator defined here is assigned in the material master record. Notes: The splitting of the forecast requirements is only relevant for copying forecast values to MRP. It has no influence on the forecast execution. Step-by-step action: 1. Access the activity choosing one of the following navigation options: IMG Menu - Production -> Material Requirement Planning -> Forecast -> Define Splitting of Forecast Requirements for MRP 2. On the Change View “Splitting Forecast Requirements”: Overview screen, choose New entries. 3. On the New Entries: Details of Added Entries screen, make the following entries: Plant

SI

Period ind

BP01

A

M

1

BP01

A

W

4

4. Save your entries. Outcome

No.days

No.wks

Pds

2

4 16

The standard settings for process messages have been copied. Notes: Field description for Step 3: Define the following in the field entitled, "No. of days": - How many periods are to be calculated to the day in MRP? Define the following in the field entitled, "No. of weeks": - How many periods are to be calculated 'to the week' in MRP? Define the following in the field entitled, "No. of periods": - For how many periods - in addition to the periods to be split - is the system to carry out the net requirements calculation in the planning run? Pre Requisites Before Running MRP What are the requisites before running MRP? The following are the Pre Requisites before running MRP. Define MRP types Path: SPRO -> IMG -> Materials Management -> Consumption-Based Planning -> Master data -> MRP Types This will determine the MRP procedures, forecast usage and select automatic calculation of either safety stock / reorder point

Define MRP areas Path: SPRO -> IMG -> Materials Management -> Consumption-Based Planning -> Master data -> MRP Areas -> Define MRP areas We define this for combination of plant, SLoc and Vendor. Note: MRP area and plant must be the same. Maintain MRP relevant data at Plant/SLoc level using TCode MM01 - MRP 1, MRP 2 and MRP 3 are for plant level data: You need to maintain here the MRP Type, forecast model and the period indicator. In MRP1, you can maintain the Re-Order point and Lot Size. In MRP2, you can maintain Safety stock and planned delivery time parameters. - MRP 4 is for SLoc level data. Create MRP profiles (using Tcode MMD1) Using this, you can maintain general parameters for materials. The MRP parameters defined here will be independent of the material master. Set material status for cross site / plant in material master.

Material status for Cross site will be assigned in the u2018Basic datau201D view whereas Material status for u201CPlantu201D will be assigned in MRP 1 view. After having all these pre-requisites maintained, you can run the MRP as Single Item or Multi Level. Check TCode MD01 / MD02 / MD03 / MD04 Creating Planning Scenario MS31 What is the use of planning scenario MS31 in SAP PP? Planning scenario is used in Long Term Planning. LTP is just a simulation of the entire planning process. It is used by the planning department, finance persons and other top level management persons to check the effect of demands on inventory, capacity, budgets, profitability etc. Based on the results they will either adjust the demand or on the flip side they will decrease or increase the inventories , capacities etc. The steps are as follows: 1. A planning scenario has to be created for a plant in Tcode MS31 and for the same Planning scenario configuration settings has to be made in OPU5 for the planned orders for LTP. User SAP Menu - Production -> Production Planning -> Long-Term Planning -> Planning scenario -> Create 2. Requirements has to be given in MD61 in an inactive version and also after giving the requirements. Kindly remove the tick mark against version - active check box. 3. Assign this plan to the planning scenario in MS32, release it and ensure the planning file entries are entered or created, the same can be checked using MS21. 4. After taking LTP simulation run in MS02 (individual material) or MS01 you can see the simulated planned orders obtained in MS04 Tcode. 5. These Simulated planned orders can't be converted into production orders or it can’t be used for any business confirmation purpose. 6. For capacity planning analysis, use Tcode CM38 Before that Ensure for all the work centers in CR03 which are used for operation under capacity header you have included the check box for Long term planning, otherwise in CM38 you can't see any capacity requirements data. 7. Before executing CM38, ensure under settings -> general, you have giving the period settings properly. Notes: In MS32, after releasing, there is one tab by name "Activate Independent Requirements". What is the purpose of this tab? When you want to activate that inactive version requirements, you can mention the source version (in active version) and the target version say 00 (To active version). Again there's test mode to check the execution and a create List mode. Also, check Tcode MS64, to copy the requirements data from one version to another version. MRP And SOP Definition And Flow Definition of Material Requirement Planning (MRP) and Sales and Operations Planning (S&OP) MRP

MRP is a tool which helps in planning the requirement quantities and schedules of a given material. It not only ensures availability of the material for which MRP is carried out, but also ensures availability of the components (of all the BOM levels) below in the BOM structure. It is DEMAMD driven. S&OP SOP is a forecasting tool enabling you to set up sales, production, and other supply chain targets based on existing, future, or historical data. SOP is most suitable for planning finished goods, and not for material component planning. SOP is made up of two application components namely, Standard SOP and Flexible Planning. SOP plans are passed on to Demand Management (DEM) in the form of independent requirements, which in turn is fed into MPS (Master Production Scheduling) and MRP (Material Requirements Planning). The results of SOP can be passed on to profitability analysis, cost center accounting, and activity-based costing.

SCHEDULING

Rescheduling date does not take into account the GR Processing Time If you look at MD04, the rescheduling date is based on the Stocks Requirement date. It does not take into account the parameters in Procurement and Scheduling in the Material Master. In the net requirements calculation, the system checks whether warehouse stock or firmed receipts are available to cover requirements. If a material shortage exists, the system usually creates a new procurement proposal. The rescheduling check is used to change the dates of already existing firmed receipts not planned on the same day as the requirement to suit the requirement date. For this purpose, the system displays the appropriate exception messages with rescheduling proposals for these firmed receipts to be processed by the MRP controller. You defined the rescheduling parameters in Customizing for MRP. An important parameters is the rescheduling horizon period to be included. 1. OPPQ per plant to Carry out overall maintenance of plant parameters. 2. OPPR per MRP group to Carry out overall maintenance of MRP groups. You can also define tolerance values for the creation of exception messages. These values define a time period in which no exception message is to be created, despite the fact that a rescheduling proposal may exist. The MRP controller can thus avoid a situation where too many exception messages are created if a certain buffer has already been planned for scheduling basis dates. Rescheduling Exception Proposal Bring process forward (reschedule in) Within this rescheduling horizon, the net requirements calculation checks whether, after a requirement, a firmed receipt exists, which can be used to cover this requirement. Then the system displays a rescheduling date as well as the exception message Bring process forward for this receipt. The net requirements calculation then uses this receipt and the system will only create another procurement proposal if the receipt quantity is not sufficient to cover the complete requirement. Several firmed receipts can be used to cover one requirement. The rescheduling horizon is always calculated from the MRP date.

Postpone process (reschedule out), or cancel process The net requirements calculation checks over the complete time axis whether availability could still be guaranteed without the receipt in question. If this is the case, the system checks whether the receipt planned here could be used to cover a future requirement. If the system can find such a requirement, it then displays a rescheduling date as well as the exception message Postpone process for this receipt. If the system finds no future requirement, for which the receipt is required, the system displays the exception message Cancel process.

Schedule Margin Key in Production Scheduling I want to know impact of schedule margine key in production scheduling in following changes in mateial master 1) if I have schedule key where all floats are zero but I enter in-house prodution time as e.g. 7 days . 2) if I have key where floats before prodution is 5 days and same values in next floats and in house production time as 1 day. All above with MTO what is impact of above cases in scheduling. While "Basic Scheduling" in MRP... Scheduling margin key is not considered. It takes the "In house production" days for fixing up the start date. This is only exact to "days". Lead Time scheduling is carried out on request from the scope of MRP. Target dates are calculated from routing and Capacity requirement calculations are also done. The calculations are exact to the seconds (time). SCHEDULING MARGIN KEY takes effect only for Lead Time Scheduling. For this you have to configure for "scheduling horizon" to limit the period for which lead time scheduling and capacity planning should be carried out. scheduling horizon is the period in working days. If a planned order has its basic start date within this period in future, lead time scheduling is carried out using the selected routing. The production times are calculated from the float times of the scheduling margin key in the material master record and the time from the individual operations. If the planned order has its basic start date further in the future than this scheduling horizon, the basic dates are calculated from the in-house production times in the material master and are transferred to the production times. Could you explain what's function of opening period in Sched Margin key. Opening period is like a "release window". The length of the opening period is the window of opportunity a planner has to convert the planned order to a purchase req. For example - Component A has a lead time of 14 days and opening period of 5 days. Requirement on 12-22-03 Opening Date - 12-01-03 Start Date - 12-08-03 Finish Date - 12-22-03

Now the planner can convert the order starting Dec. 1st, instead of Dec. 8. It basically is a buffer in the lead time to get things on order a little sooner than needed. What's the function for Plan order convert to production order? As your example, Requirement on 12-22-03 Opening Date - 12-01-03 Start Date - 12-08-03 Finish Date - 12-22-03 But I can convert plan order to production before 12-01-03 at random, so I wonder what is the opening period real function? it looks useless to restrict when to convert plan order to production order. CO41 and MD15 are used for the conversion process. Here you enter the opening dates you wish to convert. Of course the opening period will not stop you from converting planned orders - hopefully your planner is not randomly converting orders or you have much bigger issues!!!! The opening period is basically just to get the planned order to show up on the CO41 or MD15 lists in case you wish to convert it sooner than the lead time suggests. Your answer make me clear to understand the opening period. BTW,could you explain the release key ,float after production and float before production parameter in SchedMargin key? I know the parameter affection in production,but I am not sure why to define how many days in each parameter. for example, release key defined for 10 workdays,but you can release production order out of the release period randomly.any way to stop release out of the release period? For example - Component A has a lead time of 14 days and opening period of 5 days. Requirement on 12-22-03 Opening Date - 12-01-03 ??? Start Date - 12-08-03 (from requirement date - lead time ?) Finish Date - 12-22-03 (from requirement date ?) Why Openning date = 12/01/2003 how system calculate , Could you please explain to me.. I know that when we run MRP system will check if the opening date is out of open period system will generate Plan order instead of PR . The times in the sch. margin key are in workdays. That's how it gets the dates. The component I was describing originally would have been a purchased part, where lead time is in calendar days.

The order start date and the order finish date form the framework within which a production order is to be executed. Since malfunctions and disturbances in the production process can never be fully prevented, the system uses particular floats in a production order. The system takes into account so-called "before and after production floats" when scheduling an order. The float before production is a start float. It has two functions: It can compensate for delays in the staging of the material components. If there is a capacity bottleneck at the work centers involved, the production dates can be moved forward in the future. In this way it serves as a float for capacity leveling. The float after production is a finish float. It is used to compensate for unexpected disturbances in the production process, so that they do not delay the scheduled finish date. The floats before and after production are defined for each material using a scheduling margin key. This scheduling margin key is automatically transferred from the material master when an order is created. However, you can change the times in the order. The system calculates the scheduled start of the order by adding the float before production to the order start date. It calculates the scheduled finish of the order by subtracting the float after production from the order finish date. The system deducts the number of days defined in the release period from the scheduled start of the order and thus determines the scheduled release date of the order. This date can be used for collective release. Work Scheduling View in Material Master What is the importance of work scheduling view in material master and the standard values in Routing? If I am maintaining Lot size dependent information such as set time, Interoperation time, Processing time in work scheduling view in material master and also Total in-house production time in MRP view under scheduling tab, what will effect on the system? Means how will the system behave in this scenario? In house production time in MRP2 view, specifies the time in workdays needed to produce the material in-house. In-house production time is independent of the order quantity. The system requires the in-house production time to determine the planned dates for planned orders in materials planning. You can define work scheduling times in the material master record in one of two ways: -Either you enter the in-house production time. If required, you can get the system to update this value from the routing. -Or you enter the setup, teardown, processing, and interoperation times. If you maintain these values, the system determines the in-house production time on the basis of lot size. SAP PP Tips by : Brajesh What is the basic fundamental of "Independent lot size" and "Dependent lot size" in work scheduling view of a material master. I am jumbling a lot between this two to understand the basic requirement of my client. Second thing is that you are saying that - You can define work scheduling times in the material master record in one of two ways: -Either you enter the in-house production time. If required, you can get the system to update this value from the routing.

-Or you enter the setup, teardown, processing, and interoperation times. But how the system update this first option. I mean to say , is there any setting in configuration so that the system will update workscheduling time values from the routings? You need scheduling data for 2 types of orders, planned orders and production orders. And you can have the scheduling data in 3 ways: 1. Lot size independent in-house production time, in material master, MRP2 view. ex: if in house production time is 2 days, it will schedule the order for 2 days, and it doesn't matter if the order size is 1 or 1000, they are both produced in 2 days. (I never met any case that fits this situation) 2. Lot size dependent in-house production time, in material master, Workscheduling view. ex: if you have 5 day setup time, and 1 day production time for lot size of 10, then your order will be scheduled according to the order size. if your order is for 10, then your total production time will be 5 day + 1 day x 10 / 10, which is 6 days. If your order is for 100, then your total production time will be 5 day + 1 day x 100 / 10, which is 15 days. 5 day setup time will not change when the order quantity changes, because you make the setup once at the beginning of the production, and use the same setup during whole production. 3. Lot size dependent in-house production time, in routing. The same calculation of above will be used for this. So, which of these data is used for the 2 order types? For the planned orders, for default, system uses the times in number 2 above. If that data is not entered, system will use the time in number 1 above. If you want the system to use the routing data, then you should use lead-time scheduling parameter in MRP run, then system will use data in number 3 above. (The idea behind this is, MRP run always takes long time, and if you want it to use routing data, that will also increase this run time. Therefore, you can use routing but take results after long MRP run time, or you can use approximate times but take the results after short MRP run. This was very crucial before, because at those times hardware technology was not enough to process too much data in short time, when MRP run was taking days and days. But now is not that crucial, that's my personal opinion. As I said before, you can use routing data but take results after long MRP run time, or you can use approximate times but take the results after short MRP run, however, there's one other way which is a combination of these two: You can use the system to update the data in number 2 using the data in number 3, which is called the update of material master from routing. In that case, the approximate production times in material master will be as close as possible to the actual production times. In that case, not only MRP run will not take long time, but also we will get much better results.) For the production orders, always the routing data is used for scheduling. Now, I am cleared that what is independent and dependent lot size. but still there is one confusion in my mind that where did we mentioned this lot size i.e 10,100 as per your example in case 2. Secondly, I didnt understand your second last sentence (i.e.the approximate production times in material master will be as close as possible to the actual production times). Can you please clear me this sentence with suitable example. You enter the lot size on the Work scheduling view of material master, for the lot size dependent times, for my example you enter 10 as lot size. And the approximation is like this: In the material master, you enter the production times as DAYS, but in the routing you can use MINUTES, even seconds. Therefore the most detailed and accurate production times can be entered in routing, in material master you can enter only days, which will be the approximate value. If your routing is, for lot size of 10, setup time is 3 hours and production time is 50 minutes, when you update the material master from routing, system will write 3/24 days for the setup time, and 50/1440 minutes for the production time, because it has to convert it to days.

But still I dont understand that where I have to mentioned that lot size 10 or 100? And second thing is that, If I have to use routing data for planned order what should I have to do? Shall I have to mentioned lead time scheduling in MD02? You enter lot size in material master, on workscheduling view. and yes, you have to mention on md02 screen that you want lead-time scheduling. You mean to say I have to enter that 10 or 100 in base quantity of work scheduling view of material master? Yes. Scheduling Background Jobs for MRP Transaction code : MDBT click Create Variant button (specified a variant name and click continue). Then fill in the following fields :Scope of Planning : Optional (refer to Note if you want to specify a plant grouping) Plant : Your company Plant Processing Key : NETCH Create PUrchase Req. : 1 Schedule lines :1 Create MRP lists :1 Planning mode :1 Scheduling :1 Planning date : default date Click the Back button and you will be prompt Save Values. Type in a Description and click the Save button. After creating the variant, park your cursor at the variant and click the Schedule job button. Fill in the Date and Time value. Click Schedule periodically and you are prompt to choose the period. Click the Create button and you are done. To check, you can click the Show Scheduling button. Note : Define Scope of Planning for Total Planning in 'OM0E'. 1. Choose New entries. 2. Enter a key and a description for the scope of planning that you would like to define. Save your entries. 3. Select the scope of planning and choose Sequence of plants/MRP areas. 4. Choose new entries and enter the plants or the MRP areas in the sequence in which they are to be planned. The counter determines the sequence. 5. Save your entries. What is Finite and Infinite Scheduling What is finite and infinite scheduling? How it is carried out? What is to be done for each one? What are their significance? Differences between planning and scheduling, finite and infinite

Finite Scheduling Scheduling type within capacity planning that takes account of the capacity loads which already exist. Finite scheduling calculates the start and finish dates for operations in the order. It is a detailed scheduling strategy with which you schedule orders and operations, taking into account the existing resource load. A resource overload cannot occur. Infinite Scheduling A detailed scheduling strategy with which you schedule orders and operations, without taking into account the existing resource load. It is therefore possible for resource overloads to occur. R/3 does planning without consideration for capacity situations. So if MRP says you need 500 parts on 3/1/04, it schedules them all to be built at the same time, even though you can only do 100 at a time. Assume you have a fixed lot size of 100, you'll get 5 planned orders for 100 to start on the same day. This is "Infinite Planning". APO would recognize that constraint, and instead schedule out the 5 orders over time. The important part of that is that it also will schedule out the deliveries of the components for 5 different days. This is "Finite Planning". Now, assume old fashion MRP. It schedules all 5 orders for the same day, and the buyers go out an get all of the components for the same day. Then the planner realizes he can't do all 5, and manually changes the schedule, and manually spreads out the 5 orders. The buyers will recieve rescheduling notifications, but not until the scheduler does the manual rescheduling. You could call this "Infinite Scheduling", but that only means the same thing as Infinite Planning. But, SAP has "Capacity Leveling". What that means is you run another program after MRP (CM27 and CM28), which can be run in batch mode overnight. (There is a ton of configuration and thinking that will be required to do this!). The capacity leveling program will recognize the constrant at the work center level, and fill up the first day, then reschedule the next order to the next available capacity, then the next order searches for available capacity, and so on. This is called "Finite Scheduling". The problem with this is the opposite of Infinite Planning, which is it doesn't take Material availablity into consideration! The system will re-schedule a production order without thinking about whether the materials will be available or not. Finite Planning does Finite Scheduling at the same time. If there is no capacity available on the desired date, the system looks for when capacity IS available. Then it stops to see if Materials will also be available (usually based on the lead-time for those components). If there is a material problem, then the system figures out when the materials WILL be available, and then checks to see if capacity is available on THAT day, and if so, it blocks off capacity, and allocates the materials for that day. What Is Mean By Schedule Lines What is mean by schedule lines? Explain the schedule lines in md02? 1. no schedule lines 2. schedule lines in opening period 3. schedule lines Schedule lines are created against schedule agreements. Say if you have a material which is procured from subcontract. If you want the delivery in particular days with schedule you can maintain schedule agreeement. In source list you will maintain vendor, schedule agreeement with validity dates and which agreement is relevant for mrp. If you maintain 2 against the sch agreemetn mrp will generate schedule line which you can see in md04. Also this delivery schedules are updated in scheduling agreement (t cod ME33). When running mrp in initial screen delivery schedules--you have to maintain 3 create schedule line

Schedule line in opening period - Opening period is maintained in Configuration of "Schedule Margin Key" which is getting assigned to Material master in MRP2 view. Your understanding of the result after MRP is needed. Define Floats (Scheduling Margin Key) In this step, you specify the floats for determining the basic dates of the planned orders. The floats are allocated to the material via the release period key in the material master record. Opening period The opening period represents the number of workdays that are subtracted from the order start date in order to determine the order creation date. This time is used by the MRP controller as a float for converting planned orders into purchase requisitions or into production orders. Float before production The float before production represents the number of workdays that are planned as a float between the order start date (planned start date) and the production start date (target start date). On the one hand, this float is intended to guarantee that delays in staging a material do not delay the production start. On the other hand, the production dates can be brought forward by means of the float to cope with capacity bottlenecks. Float after production The float after production should provide a float for the production process to cope with any disruptions so that there is no danger that the planned finish date will be exceeded. You plan the float after production between order finish date (planned finish date) and scheduled end (target finish date). Release period The release period represents the number of workdays that are subtracted from the order start date in order to determine the production order release. The release period is only relevant for production order management. Recommendation The opening period should reflect the processing time the MRP controller needs to convert planned orders into purchase requisitions or production orders. The opening period should be at least as long as the interval between two MRP intervals, so that all planned orders can be taken into account during the conversion. Difference Between Basic and Lead Time Scheduling What are the difference between basic scheduling and lead time scheduling? Basic Scheduling 1. Separate Scheduling for planned orders 2. Exact to days 3. Basic dates are calculated (Order start date opening date and finish date) opening date is a date in future were that planned order should be converted to production order 4. No calculation of Capacity requirements Lead time scheduling 1. Used for production orders and Routing 2. Exact to seconds 3. Targets dates are calculated 4. Capacity requirements are calculated 5. In house production time and float before production and float after production time is taken (schedule margin key) 6. Lead time scheduling is calculate using time from routing

7. With in Lead time Scheduling there are two type of scheduling - Back ward Scheduling - Forward Scheduling 8. Customizing setting for lead time scheduling is - go for IMG activity and there “ Define scheduling parameters for planned orders” When do planning in MRP with single–item, multi-level planning in the initial screen and in that if you go to MRP Control Parameters and then to scheduling if you Select = 1 (basic dates will be determined for Planned Orders) Select = 2 (lead time scheduling and Capacity Planning) Please note when you do lead time scheduling you need to maintain: 1. Queue time 2. Wait time 3. Setup time 4. Operation time 5. Teardown time and also you need to maintain in-house production time in material master. What Is Work Scheduling Explain briefly about work scheduling and use of Forward and backward scheduling? A routing can be scheduled using the following scheduling types: Forward scheduling: The system schedules forward starting from the basic start date. Backward scheduling: The system schedules backward starting from the basic finish date. "Today" scheduling: The system carries out forward scheduling using the current date as a basic start date. No scheduling: The individual operations are not scheduled. Based on the floats before and after production, the system calculates the scheduled start and finish and enters these dates in all operations. The scheduling type determines which basic dates you have to enter. The following table shows the dates you must enter for the individual scheduling types as well as the dates that are then calculated using scheduling. If you enter both basic dates, the system will make sure that the dates determined using forward or backward scheduling are within the specified period. If necessary, it will apply reduction measures. Example Data Material shortage date 01.08 (Friday) Planned delivery time of the material 10 days (calendar days) Processing time for purchasing 1 day (workdays) Goods receipt processing time 2 days (workdays) Opening period 10 days (workdays) Workdays = Monday to Friday, no bank holiday Scheduling

Material shortage date plus processing time for purchasing plan plus planned delivery time = delivery date 01.08. (Friday) plus 1 workday + 10 calendar days = 14.08. (Thursday) Delivery date plus goods receipt processing time = availability date 14.08. (Thursday) plus 2 workdays = 18.08. (Monday) What Is The Rescheduling Horizon The planning horizon is the number of days where MRP will be running. Now, in the IMG, in the Maintain plant parameters there is a button for Rescheduling for specific plant. What is the rescheduling horizon? There are certain elements such as firm planned orders, PO, firm purch reqs. etc that are considering in here but what is the rescheduling horizon? What does it do? By: Sankaran The below info will help you to understand the Rescheduling Horizon concept: Rescheduling Check An important group of the exception messages mentioned above are the rescheduling proposals. In the net requirements calculation, the system checks whether warehouse stock or firmed receipts are available in sufficient quantity to cover requirements. If a material shortage exists, the system usually creates a new procurement proposal. The rescheduling check is used to change the dates of already existing firmed receipts not planned on the same day as the requirement to suit the requirement date. For this purpose, the system displays the appropriate exception messages with rescheduling proposals for these firmed receipts to be processed by the MRP controller. Prerequisites You have defined the rescheduling parameters in Customizing for MRP: per plant in the IMG activity Carry out overall maintenance of plant parameters per MRP group in the IMG activity Carry out overall maintenance of MRP groups. The rescheduling horizon, which defines the period for bringing forward the receipts, and the receipt elements, which should be taken into account in rescheduling, are included in these. You can also define tolerance values for the creation of exception messages, in Customizing. These values define a time period in which no exception message is to be created, despite the fact that a rescheduling proposal may exist. The MRP controller can thus avoid a situation where too many exception messages are created if a certain buffer has already been planned for scheduling basis dates. Process Flow Bring process forward (reschedule in): Within this rescheduling horizon, the net requirements calculation checks whether, after a requirement, a firmed receipt exists, which can be used to cover this requirement. Then the system displays a rescheduling date as well as the exception message Bring process forward for this receipt. The net requirements calculation then uses this receipt and the system will only create another procurement proposal if the receipt quantity is not sufficient to cover the complete requirement. Several firmed receipts can be used to cover one requirement. The rescheduling horizon is always calculated from the MRP date. Postpone process (reschedule out), or cancel process: The net requirements calculation checks over the complete time axis whether availability could still be guaranteed without the receipt in question. If this is the case, the system checks whether the receipt planned here could be used to cover a future requirement. If the system can find such a requirement, it then displays a rescheduling date as well as the exception message Postpone process for this receipt. If the system finds no future requirement, for which the receipt is required, the system displays the exception message Cancel process.

What is Discrete Manufacturing, REM and Demand Management? 1. What is Discrete Manufacturing? 2. What is REM? 3. What is Demand Management? Here are difference between Discrete and REM and small explanation about discrete and repetitive manufacturing: - A typical characteristic of discrete manufacturing is the frequent switching from one manufactured product to another. The products are typically manufactured in individually defined lots, the sequence of work centers through production varying for each one of these. Costs are calculated on the basis of orders and individual lots. - In Repetitive Manufacturing, products remain unchanged over a longer period and are not manufactured in individually defined lots. Instead, a total quantity is produced over a certain period at a certain rate. - Discrete manufacturing typically involves varying the sequence of work centers through which the products can pass during production. The order of work centers is determined in routings, which can often be very complex. There can be waiting times between the individual work centers. Also, semi-finished products are frequently placed in interim storage prior to further processing. - Repetitive Manufacturing, on the other hand, normally involves a relatively constant flow on production lines. Semi-finished products are usually processed further immediately without being put in interim storage. Routings tend to be relatively simple. - In discrete manufacturing, component materials are staged with specific reference to the individual production lots. Completion confirmations for the various steps and processes document the work progress and enable finetune controlling. - In Repetitive Manufacturing, components are often staged at the production line without reference to a particular order. Completion confirmations are less detailed, and the recording of actual data is simplified. - The function of Demand Management is to determine requirement quantities and delivery dates for finished products assemblies. Customer requirements are created in sales order management. To create a demand program, Demand Management uses planned independent requirements and customer requirements. To create the demand program, you must define the planning strategy for a product. Planning strategies represent the methods of production for planning and manufacturing or procuring a product. Using these strategies, you can decide if production is triggered by sales orders (make-to-order production), or if it is not triggered by sales orders (make-to-stock production). You can have sales orders and stock orders in the demand program. If the production time is long in relation to the standard market delivery time, you can produce the product or certain assemblies before there are sales orders. In this case, sales quantities are planned, for example, with the aid of a sales forecast. Discrete Manufacturing - The Made To Order Cycle In sap there is specific transaction flow for a particular Mfg. Process.it all depends upon the req. of client and process. Here is the basic flow of transactions which is req. for creating master data, planning and order processing... The Made TO Order Cycle: The sale department passes on the Made to order-Sales Order to the Material department so that material requirement is analyzed. This is done in SAP by carrying on an MRP Run for all the levels of the product BOM. This MRP Run would create Planned Orders for the shortages. Here the planned orders for fert sub assemblies, Components etc, are created. This planned orders for materials produced in house are converted in to Production order and planned orders for materials

procured from outside are converted in to Purchase order. The creation of Production order through the planned orders will convert all the dependant requirements in to dependant reservations. The dates of production or purchase are decided through the total replenishment time mentioned in the material master, If it is, in-house production, then the Route times precede over the total replenishment time entered in the material master. And the availability of all the components is ruled by the availability checking rules and by availability checking scopes. Thus whenever the system declares a product to be ready or available by a date it implies that the system has checked the availability of the material with respect to the Ware house stock, in coming stock (Receipts) and all other planned orders already existing for the product or material. In the Made to order production, sales order produced for Fert and Sub assemblies are converted in to production order during MRP run. The production orders created have a specific quantity, specific Basic start date and a specific Basic Finish Date, a set of operations and a set of component attached from the BOM. In course of production the quantities produced in the operation for an order should be confirmed so that the current status of work is available in real time situation. The components required for production are issued to the production order through goods issue by a movement type 261 and the issue is always made to the reservations or to the order, thereby clearing the reservations. Issues of unplanned components are made as new items issue and not as order issue. The quantities, for an order which are produced completely are the put in to stock i.e. a Goods Receipt is done. Thus the made to order cycle starts with the sales orders and converting them to Production Orders through MRP Run and there off confirming produced quantities for an order and finally putting the order in to stock. The Cycle of Made to order: Steps: MTO Scenario 1. Material Creation (Made To order Material with major changes of: Item Category: 0004-make to order/assem.,or 0001-make to order) 2. Route Creation 3. Creation of BOM 4. Sales order 5. Production order Scheduling, Costing, Release and Save 6. Production order Quantity confirmations for operations, Parallel task of material issue to order or to reservations (261) 7. Fully Produced Production Quantities will be put into stock (GR) 8. Delivery against sales order 9. Invoicing. Discrete Manufacturing - The Made To Stock Cycle The Made To Stock Cycle The Made to stock scenario will start from Demand Management here we can create Planed independent requirements manually or by using data from SOP. After MRP run system will create planned orders which we can convert to Production order As the Stocks produced there off are not customer stock or the stock is not attached to any specific customer. Further confirmations are done and issues of material are carried out to the production order. Finally the production is put in to stock (GR). Here at any point of time a sales order might come in and delivery to the customer is done from the existing stock. Production Master Data The Production Master Data consists of Material Master, Bill of Material, Work Center, Route, and Production Line Design. The Material Master is created first for all components involved in making the Final product. Then these components are put in a product relationship i.e. a list of materials required to make the final product are put in a hierarchy, this is called a Bill of Material.

The next task is to identify the work centers required to produce the product; if the work centers are already created then they can be readily put in a sequence, which would be a sequence of work centers required to produce the product. This sequence of work centers one after the other (in the sequence of work to be done) is called a Route. The Cycle of Made to stock: Steps: MTS Scenario 1. Material Creation (Made To Stock Material with major changes of: Item Category: NORM ) 2. Creation of BOM 3. Route Creation 4. Demand requirements 5. MRP Run 6. Creation/conversion of Production order (Made To stock), Scheduling, Costing, Release and Save 7. Production order Quantity confirmations for operations, Parallel task of material Issue to order or to reservations (261) 8. Fully Produced Production Quantities will be put into stock (GR) 9. Sales order Creation 10. Delivery against sales order Discrete Manufacturing - The Step By Step Tcodes Step 1: Material Master Logistics > Production > Master Data > Material Master > Material > Create General > Immediately MM01 Step 2: BOM creation Logistics > Production > Master Data > Bills of Material > Bills of Material > Material BOM > Create CS01 Step 3: Work Center creation Logistics > Production > Master Data > Work Center > ( New Screen ) Work Center > Create CR01 Step 4: Route creation Logistics > Production > Master Data > Routings > Routings > Routing > Create CA01 Step 5: PIR Generation Logistics> Production>production planning>demand management>PIR>Create MD61 Step 6: MRP Run Logistics>Materials Management>Material planning>MRP>MRP>Total Planning>Online MD01 or Logistics > Production > MRP > MRP > Sng-Item, Multi-Level MD02 Step 7: Evaluation through MRP list and Stock requirement list Logistics>Materials Management>Materials Planning>MRP>Evaluations>MRP List>Individual Display MD05 Logistics>Materials Management>Materials Planning>MRP>Evaluations>Stock Requirements List MD04 Step 8: Conversion of Planned order to Production order Logistics > Production > Production control > Order > Create > With a planned order CO40 or Logistics >Production > Production control >Order > Create >With material CO01(For creating production order Without planned order) Step 9: Order management Logistics >Production > Production control >Order > Change >With material CO02 Step10: Confirmations Logistics >Production >Production control >Confirmation >Enter >For order CO15

or Logistics >Production >Production control >Confirmation >Enter >For Operation >For time ticket CO11N Step11: Goods issue 1. Logistics >Production >Production Control >Environment >Goods Movement >Goods Issue 2. Logistics >Materials Management >Inventory Management >Goods Movement >Goods Issue MB1A-261Movement type Step12: Goods receipt Logistics > Production > Production Order > Environment > Material Movement > Post Mat to Stock or Logistics > Materials Management > Inventory Management > Goods Movement > Good Receipt > For Order MB31 Step13: Techo Or Close Order. This can be done from Prd. Order Header menu. Split The Order Qty In Discrete Manufacturing Use the below settings in your SAP IMG PP Setting for above issue. Make the following settings in the order type-dependent parameters (Customizing for Shop Floor Control by choosing Master data -> Orders -> Define Order Type-Dependent Parameters) : OPL8 1. With the Cost collector indicator, you decide whether you want to collect the costs in a product cost collector. It specifies whether the costs are collected on a manufacturing order, (production order, process order), or product cost collector. 

If this indicator is turned on, the costs are collected on a product cost collector. In this case you use the functionality of Product Cost by Period. preliminary costing, simultaneous costing, and final costing are performed at the level of the product cost collector. In this case you calculate the work in process and variances by period.



If this indicator is not turned on, the costs are collected directly on the manufacturing order. In this case you use the functionality of Product Cost by Order. Preliminary costing, simultaneous costing, and final costing are performed at the level of the manufacturing orders. In this case you normally calculate work in process and variances by lot.

2. The Distribution rule must support periodic settlement. : PP2 Now, the main prerequisites for Split order are follwoing : An order split is allowed with the following system status: 

Header status: Partially released, released, partially confirmed



Operation status of the split operation and all successors: Created, released, partially confirmed

The order split is not allowed with the following status: 

Header status: Created, delivered, finally confirmed, locked, technically complete, closed, deletion indicator set.



Operation status of the split operation and all successors: Finally confirmed, dispatched, partially dispatched, capacity split, capacity requirement assigned, capacity requirement partially allocated.



Operation status of the split operation: Deleted.

Before an order split can be performed, you must first post all requested confirmations for the parent order . The posting of requested confirmations is carried out in general by scheduling the program CORUPROC1 as a background job. To ensure that settlement is performed without any additional variances, the parent and child orders must be assigned to the same Product Cost Collector. After an order split, the costs per piece can no longer be calculated for each order, since operations and goods movements are usually not distributed equally between parent and child. As a result, settlement by order is not supported. Settlement is performed through a product cost collector. What Is Repetitive Manufacturing Explain what is repetitive manufacturing. Repetitive manufacturing is period based planning and not based on orders. Normally same products will be manufactured over longer period of time. Products will not change frequently. Confirmation is from backflushing and settlement is through from product cost collector for the period. Confirmation will be without ref to planned orders. Planned orders are sufficient to carry out shop floor activity. In master data production versions and cost collector is a must where this is not mandatory in discrete. You do these steps for rem production: MM01 : Material Master - MRP - 4 view you click rem CS01 : Create Bom CR01 : Create Work Center CA21 : Create Rate Routing MM02 : Prodn Version MD61 : Create PIR MC74 : Transfer PIR to Demand KKF6N : Create Product Cost Collector MB1c : Create Stock MD02 : MRP run MFBF : Rem Back Flush The detailed sequence of T.Codes for REM including Std cost estimate: Material master - MM01 BOM - CS01 Price Planning - KP26 Work Center - CR01 Rate Routing - CA21 Material Master Change, enter production version - MM02 (MRP 4 View) Product Cost Collector - KKF6N Costing - CK40N Backflushing - MFBF SAP PP-CRP-LVL - Capacity Leveling Profile Setup Capacity leveling is used in various areas of a company and at different planning levels with the following objectives: - High capacity load - Adherence to dates

- Short lead times - Low stocks The objectives of capacity leveling include: - Leveling overloads and under loads at work centers - Achieving optimum commitment of machines and production lines - Selection of appropriate resources Show here is an example on how to customize the Capacity Leveling Profile. Define time profile in OPD2. Assuming you want to create a time profile for 2 months. Entry Type Start Date Database Read Period J -3

End Date 3

The database read period specifies the period in which capacity requirements are read from the database. All requirements are accessed which are partially or completely within the database read period. Evaluation Period

G

-1

60

The evaluation period specifies the period over which data is formatted and displayed. The evaluation period must lie within the database read period. Planning Period

G

-1

60

The planning period defines the period in which the SAP system can carry out planning. The planning period is smaller than or equal to the evaluation period. You cannot move operations outside the planning period. Equally, when automatic finite scheduling is carried out for an operation the system only searches for a new date within the planning period. Dispatch of backlog

G

Backlog dispatch Date = 0

The date for dispatching the backlog is of importance in period-related planning. You use the date for dispatching the backlog to determine the date backlogs are to be allocated. The following types of entry are available: Actual date specifications These date specifications (for example, calendar day, calendar year) are only useful in the profiles in exceptional cases. Relative date specifications These date specifications (for example, number of calendar days, number of calendar years) are always calculated from the current day. For every period, you can specify in what form you want to enter the date by using the respective field "Type of entry". Define the strategy profile in OPDB. In this menu option you define strategy profiles to control capacity leveling with the planning tables. You can copy the standard strategy profile like SAPSFCVER1 or SAP_T001.

Assuming you copy the strategy profile to ZAPSFCVER1 ticking the followings:1. 2. 3. 4. 5. 6.

Dispatch at earliest point in time. Change production version on error. Cancel dispatching due to error. Use operations floats. Use float before production. Use float after production.

and copy the strategy to ZAP_T001 ticking the Change Planning direction. Define the Overall profiles in OPD0. The overall profiles are used as follows to control capacity planning: If you select the menu options: Capacity planning -> Leveling -> Work center view -> Planning table, then the profile SAPSFCG001 is processed in the standard version. You can change the profile, but the SAP sub-profiles should remain unchanged as far as possible. You can define your own profiles and allocate them to particular users by means of user parameters. (See user parameters CYA -> CYX) For example, when you access the planning table enter using the application menu "Capacity planning" -> Leveling -> Work center view -> Planning table the user parameter "CYA" is operative. You can select any overall profile you like by entering via the application menu "Capacity planning" -> Leveling -> Variable. Your details of the profile can be as follows:Profile ZONLINE ZBACKGRD Selection profile SAPSFCS005 SAPSFCS001 Control profile SAP__C001 SAP__C002 Time profile ZTIME SAP__Z002 Evaluation profile SAP__A001 SAP__A001 Strategy profile SAP__T001 ZSTRATEGY Period profile SAP__P002 Planning table profile SAPSFCL010 Prof. Plan tab (tab) SAPSFCR011 List profile SAPSFCI001 SAPSFCI001 Rough Cut Capacity Load In Standard SOP Problem: Have created some sales & production plan synchronous to sales but when I try to see the capacity load thru: View -> Capacity Situation -> Rough Cut planning -> Show It is showing me that No Resource load exists. Resolution: Please maintain the settings as mentioned below. Then you can see the load.

Before you can carry out resource leveling in SOP, you must: 1.) Create a PP task list (a routing, a rate routing, or a rough-cut planning profile) for the material, product group, or characteristic values combination whose resources you want to plan. 2.) Configure resources planning in Customizing for Sales & Operations Planning. 3.) If you use routings or rate routings to do resource leveling, define the key figure to which the resources are tied. Do this in Customizing for Sales & Operations Planning under Set parameters for info structures and key figures. 4.) Define the planning plant of any information structure whose plant is not uniquely identifiable (that is, either your information structure does not contain the characteristic "plant" or your rough-cut planning profile covers more than one plant). Do this in Customizing for Sales & Operations Planning under Set parameters for info structures and key figures. 5.) Set the default SOP plant for Sales & Operations Planning. Do this in Customizing for Sales & Operations Planning under Set planning plant for SOP. Note: Follow these detail steps: 1. Create a product group (mc84) 2. Create a production plan (mc81). Enter a qty in sales plan row. Goto Edit->create prodn plan synchronous to sales plan. 3. Create rough cut planning profile (mc35). Here choose the resources as the bottleneck work center & enter the time to produce 1 pc. 4. In mc82, go to views -> capacity situation -> show You can see the load % in the bottom. Adjust your requirement so as to match the load for 100%. 5. Then use mc78, enter the inactive version Eg:01/02 & enter the inactive version as a00 & then click transfer/copy. 6. In mc82 screen you can see that the plan is in active mode. 7. Now in the same screen, goto Extras->transfer to demand management. Here enter the requirement type & then click transfer. 7. In md61/md62 you can see the requirement. Operation Dispatching and Deallocation

What is operation dispatching and deallocation? It is when you use the capacity planning table (CM25) to finite schedule planned or production orders. When you despatch the orders you fix in time their use of capacity and when you de-allocate them you remove them from the capacity planning table. Dispatching: While doing the capacity planning for the order you dispatch the operation. Dispatching operations is the main function of capacity leveling. Operations are dispatched to the time when there is sufficient capacity for them to be executed. You can also dispatch sub-operations and work elements. Depending on whether finite scheduling is to be carried out, operations can be dispatched based on unlimited available capacity or existing available capacity. Existing available capacity is calculated as the difference between the available capacity maintained in the capacity and the requirements already dispatched. Deallocating operation: By dragging and dropping an operation from the work center chart onto any line in the pool you can deallocate individual operations. To deallocate one or more operations, proceed as follows: - Select the desired operations. - Choose Functions - Deallocate. The system deallocates the operations. That means that they are put back into the pool. When you create a production/process order the system proposed a data/time at which the operation has to be carried out in the work center. The same can be check in CM01, CM25, CM29, etc. The MRP controller based on the priority of the order/operation/work center capacity he can deallocate the operation to some other date or time. If the work center is free at date/time proposed by the system then he will dispatch the operation. The status of the operation will be updated as DSPT(dispatched). Sample Issue: Dispatching Operation for maintenance order - CM25(Capacity Leveling). When we do Dispatching Operation for maintenance order through CM25 (Capacity Leveling). What are all the backend process do & what are the fields will change & in which table the changed datas get updated. Solution: In IW32, Extras -> Order Documents -> Changes we can see where the dispatch dates are documented in table AFVV. Guide To Mass Replace Work Center On the work center I have defined an activity type for preparation, machine work, personal work. When I modify an activity type on a work center, the routings where these work center are employed are not automatically updated.

Use Tcode CA85 with same workcenter in New work center field. Change the new activity type in default values screen. But if your activtity types don't change in the routings where ever the workcenter is used, then check the reference indicator in the workcenter itself. So whenever you change the activity type in the workcenter, routing data will also get changed automatically. The step by step guide below gave you a blow by blow account of the steps for CA85. Just ensure you only select a few materials initially, and change the mode of transfer so that it works like a BDC and you are sure that the data is correctly changed.

Set Parameter and Work Center Formula How to set parameter and formula for e.g. Power, Fuel, Repair and Maintenance? Some inputs for setting parameters and formula:: Go-to : OP7B "Parameters Overview" Define your requirements Eg. For Power – say ZELECT like that (Short Key work/Keyword – Electricity, Dimension " Energy", Std. Value Unit – KWH) Then Go-to : OP19 " Standard Value Key Formula : Overview " Select SAP1 – Normal Production and Copy as (F6) and Create new Activity Type Say eg. ZELE Then Assign this new Parameter ZELECT and save (handle the transport request) For Formula Definition : Go-to : OP54 "Formula Definition" Select SAP002 – Prod.: Machine Time and Copy as (F6) and Create ur new Formula Say Eg. ZELECT And replace SAP_02 with your Parameter – ZELECT Then it’ll look some thing like "ZELECT * SAP_09 / SAP_08 / SAP_11" Assign The Standard Value Key " ZELE" to your Work Center-Basic Data Screen Now Go-to Costing Tab Page assign your formula to your Predefined Activity Type for Power. (Otherwise – First Create Secondary Cost Element (T.Code KA06), Assign this Sec. Cost Element to your new Activity Type, then KP26 " Change Activity / Price Planning" Assign Activity Type in Work Center Costing Tab & Assign Your Formula)

You can assign max. 6 Standard Values to your WC, I.e If you want to capture Power & Fuel Consumption for an Operation you can have both parameters set as per above procedure. For costing part, please refer to your CO-person for help. Delete Or Archive Work Centers How do I do a MASS delete for all work centers under a certain plant? For Mass Delete all work centers under a certain plant, follow the below steps. You can just set "Deletion Flag" in the change mode of the resource (Extras -> Status -> Deletion Flag) and then follow the archiving method to delete from the database. For archiving and latter deleting you can use transaction code "CR41" (CRA2 and CRA1) You need to get the authorization for directly deleting from "CR02". CR41 The Archiving steps :-

Archiving object PP_WKC for work center. You can display the archived data, but not reload it. Type in a variant name and click Maintain. (Tick the Test Mode for archive simulation). Save the variant. Maintain the Start date and Spool parameters and click execute. Click Goto Job Overview to check the archive status. To do a permanent delete, goto transaction CR41and click Delete button. Maintain the Archive Selection, Start date and Spool parameters. Click Test Session for testing or click execute to start the deletion program. Click Goto Job Overview to check the delete status. Notes: You can only delete a work center if it is not in use. You cannot delete work centers that are used in objects.

Your work center is use in any routing please check. Try with tcode CA80 , for plant level and in the Task list : N Check with capacity requirements for that work center at CM01 if it is there then do TECO the order. Goto Basic Data view in the Change work center screen choose Extras --Status --Deletion flag. You can use deletion flags as a selection criterion for the work centers to be deleted in the next reorganization run. Work Center Relevant Questions and Answers 1) Operations are carried out at a work center. In the R/3 System work centers are business objects that can represent the following real work centers, for as follow: A. Machines, machine groups B. Production lines C. Assembly work centers D. Employees, groups of employees

2) You can display the following administrative data about a work center: A. Object ID that the work center is stored under in the system B. When and by whom the work center was last changed C. Locked indicator or deletion indicator

3) The system does not delete after archiving in the following cases: A. Work centers used in objects that have been logically deleted but are still in the database. B. Pooled capacities and reference capacities

4) Default values in work centers are for instance: A. Wage type and wage group B. Control key C. Standard text key D. Suitability

5) You can set a reference indicator for each default value in a work center and thus specify that the default value is referenced in the task list. This means that: A. The default value can only be changed in the work center and not in the task list. B. A change in the work center is automatically transferred to the task list, when the task list is called up.

6) The following data is entered in a capacity: A. the operating time B. the available capacity C. Formulas for calculating capacity requirements

7) Capacities can be entered and changed in work centers, but also independently. The system distinguishes between: A. Work center capacities B. Pooled capacities C. Reference capacities D. Default capacities

8) Capacities in work centers are distinguished by capacity categories Capacity categories are for as follow: A. Machine capacity B. Personnel capacity C. Reserve capacity for rush orders D. Emissions E. Energy requirements

9) The available capacity of a shift is defined by the following data: A. Shift start, shift end, break times B. Capacity utilization rate C. Number of individual capacities

10) Capacity data is maintained on the following screens: A. Capacity overview (only for work center capacities) B. Header C. Interval of available capacity D. Available capacity profile --Correct Answers 1) A, B, C, D 2) A, B, C 3) A, B 4) A, B, C, D 5) A, B 6) A, B, C 7) A, B, C, D 8) A, B, C, D

9) A, B, C 10) A, B, C, D Work Center Basic Data View And Formula Missing Fields in Work Center Basic Data Screen While creating work center with CR01, in basic data view, I could not find shift note type, shift report type, back flush tick fields were not found in sand box. Please advise where is the settings to appear the same. Suggested Answer: Go to OPFA Click on Basic data Field, you will find Modifiable fields. In that first field will be Blackflush field, please check the radio button it might be HIDDEN, make it to INPUT . For shift time, this you will find in work center -- Capacity Screen that to when you enter Capacity category you give the Labour 001. --Work Center Basic Data View 1. In work center basic data view, what are the meanings of various options of the ‘Rule for Maintenance’? 2. What do we mean by performance efficiency rate? I have the case for MRP below: ‘Company 1000, Purchasing department create PO for parts A. Design department create BOM using parts A1. Actually, A1 is A just with some version change by the vendor. While running MRP, A1 should be short of parts since there is no outstanding quantity defined for it. Will there be any solution to allow the MRP to run for such a case, without users changing their PO? Suggested Answer: The rule for maintenance is based on how you want to control the input of the standard values in routing (for an operation involving the work center). ‘Should / may not - generally means only a warning, “must” is mandatory.’ Performance efficiency rate is the rate that the work center is working at. 100% is normal working rate. If you alter the effectiveness of the work center, the standard times in capacity planning & costing are altered against the new rate. If A and A1 have been maintained as two different material items (i.e. two different material number in SAP), then it is not feasible. Instead, you can use auto-backflush to make the conversion between these two parts when receiving goods. --Work Center Formula

Why do we need different formula for setup requirements and processing time requirements in capacity tap & scheduling tab? Suggested Answer: These formulas are used for capacity planning and scheduling of orders during execution as well planning of orders and materials. One formula is used for time calculation of one piece and the other is used for scheduling that is to indicate the number of pieces. In a nutshell, capacity is used for determining the actual capacity requirements, whereas scheduling is used to determine the basic dates. A basic SAP Engineering Change Management Setup To activate "Engineering Change Management", what are the settings that are needed? Engineering Change Management is used to track and control all the changes with reference to Material master, BOM, Work Center & Routing. This are the basic IMG settings in order to used the engineering change management features. x refers to a tick. First setup the control data in OS54. Revision sections Fields :Revision level active Ext. revision level Higher revision level

x x x

Object Management Record sections Fields :Object maintenance Assign alternative date

x x

Overide value/assignment date sections Fields :Only with leading change mst. x Setting the Revision level active is to activate the engineering change management for material master. If you do not want the engineering change management for materials, remove the tick. With a tick in "Higher revision level", the new revision level has to be always higher than the old revision. Secondly, setup the external number range in OS53. If you use the internal number range, then remove the external number range.

Third, define the status for the change master records in transaction SM30 - V_T419S. Change No. Chg Status Poss 1 2 3

x '' ''

Date Chg

Dist. Lock

x '' ''

'' '' x

Description

Active Inactive Locked

Fourth, define modification parameters for the BOM in OS27. Fields :BOM Validty Maint. x EC Management Active x History Requirement '' Unit Piece PC The rest of the fields are blank. If the History Requirement is tick, every time during creation of the BOM, SAP willprompt your for an ECN number as is compulsory. Lastly, define fields selection for routing in OP5A. PP task lists: initial screen -> Change number -> Transaction code -> Tick Req. Setting the Transaction code fields Required indicate that you have make the ECN number compulsory when changing the routing. Finally, do a test by making changes to the Material Master, BOM and Routing. Some of the Standard reports in SD are: Sales summary - VC/2 Display Customer Hierarchy - VDH2 Display Condition record report - V/I6 Pricing Report - V/LD Create Net Price List - V_NL List customer material info - VD59 List of sales order - VA05 List of Billing documents - VF05 Inquiries list - VA15 Quotation List - VA25 Incomplete Sales orders - V.02 Backorders - V.15 Outbound Delivery Monitor - VL06o

Incomplete delivery - V_UC Customer Returns-Analysis - MC+A Customer Analysis- Sales - MC+E Customer Analysis- Cr. Memo - MC+I Deliveries-Due list - VL04 Billing due list - VF04 Incomplete Billing documents - MCV9 Customer Analysis-Basic List - MCTA Material Analysis(SIS) - MCTC Sales org analysis - MCTE Sales org analysis-Invoiced sales - MC+2 Material Analysis-Incoming orders - MC(E General- List of Outbound deliveries - VL06f Material Returns-Analysis - MC+M Material Analysis- Invoiced Sales - MC+Q Variant configuration Analysis - MC(B Sales org analysis-Incoming orders - MC(I Sales org analysis-Returns - MC+Y Sales office Analysis- Invoiced Sales - MC-E Sales office Analysis- Returns - MC-A Shipping point Analysis - MC(U Shipping point Analysis-Returns - MC-O Blocked orders - V.14 Order Within time period - SD01 Duplicate Sales orders in period - SDD1 Display Delivery Changes - VL22