MRP Concepts SAP
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Transcript of MRP Concepts SAP
8/10/2019 MRP Concepts SAP
http://slidepdf.com/reader/full/mrp-concepts-sap 1/28
MATERIALS REQUIREMENT PLANNINGCompares
available stock + scheduled receipts
with
planned independent requirements +reservations+sales orders
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MRP inputs and outputs
MRP
Planned Orders
Rescheduling Messages
Demand
Stocks
Bills of Material
Item Parameters• Exception
Messages
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MATERIALS PLANNING PROCEDURES
• CONSUMPTION BASED PLANNING• MASTER PRODUCTION SCHEDULING• MATERIALS REQUIREMENT PLANNING
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CONSUMPTION BASED PLANNING• REORDER POINT PLANNING
– manual – automatic
• FORECASTE BASED PLANNING• TIME PHASED PLANNING
–
for B & C class items – no in house production – uses historical consumption data for planning
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Reorder Point Planning
Reorder Point
Safety Stock
Order Date Delivery DateTime
Stock
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Regenerative Planning vs NetChange
• Regenerative Planning processes all items in the database.
• Net Change Planning only processes those items that had changes sincethe last planning run.
• Example of changes: - stock increase/decrease• - new requirements by planned orders• - change of lot size parameters• - etc., etc.
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MRP Prerequisites
Activated for MRPPLANT LEVEL
MATERIAL LEVELValid MRP Type
Valid Material Status
MRP Views MaintainedMRP Controller Planned Lead TimeMRP GroupLot Size Data
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Material Master – MRP Key FieldsBasic, General, and Lot Size Data
Procurement Type indicates if the material is externally procured, orproduced internally or both.
Special Procurement identifies special planning rules which may beused for in-house production or external procurement
MRP Type determines how the material is planned such as MRP, MPS,or consumption based planning
Material Lead Time identifies for material planning the planneddelivery days or in-house production days
Lot Size determines which lot-sizing procedure the system uses tocalculate order quantities
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Material Master – MRP Key Fields• Scheduling Parameters • Planning Time Fence: defines a period during which MRP/MPS will not
automatically add or reschedule orders• Scheduling Margin: controls the release period, opening period for a
material and scheduling floats for production
– Release period is the number of working days in the release period – Opening period is the number of working days between the order
creation and planned start date – Order floats allows for safety margin before and after production
• Planned Delivery: lead-time for purchased material• In-house Production: lead-time for manufactured material• GR Processing Time: goods receipt processing time
– Example: dock-to-stock time
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Material Master – MRP Key FieldsPlanned Delivery: lead-time for purchased material
In-house Production: lead-time for manufactured material
GR Processing Time: goods receipt processing timeExample: dock-to-stock time
Availability Check indicates whether the system generates individual orsummarized requirements for sales orders for this material and for planning,
which MRP items the system includes in the availability check.
Mat./PPC Status is used to limit the usability of materials for certain activitiessuch as, purchasing, bills of material
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• Material Master MRP Key Fields• Consumption Mode: controls consumption of planned independent
requirements by customer requirements Selections: backward, forward, or both
•
Consumption Periods Backward/Forward: specifies the number ofperiods of forward or backward consumption – Used in conjunction with consumption mode
• Storage Location MRP • MRP Indicator: determines whether or not requirements, for a
specific storage location, are planned separately from the overall plan• Reorder Level: used for storage location MRP• Replenishment Quantity: used for storage location MRP
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Requirements date
Scheduling Margin Key :-
Indicator in the material master record that refers to a group of time intervals that are relevant to
material requirements planning.(Defines Various Floats)
ProductionTime
Float after
Production Float Before
Production
Opening Period
Release period
Requirements date TODAY
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MRP TypesVB
VM
VV
PD
M0
Manual Reorder Point Planning :MRP produces order proposals when stock falls below a “reorder point”. Thereorder point and safety stock levels are entered manuallyAutomatic Reorder Point Planning :The reorder point and safety stock level are calculated based on the forecastresultsForecast Planning The latest forecast is copied as requirements which are used to create orderproposals
Deterministic PlanningMRP produces order proposal(s) to match the exact quantity of therequirements based on independent and dependent demandsMaster Production SchedulingSimilar to PD but used for master schedule items
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LOT SIZING PROCEDURES static lot-sizing procedures- lot for lot order quantity- fixed lot size- replenish up to maximum stock level
period lot-sizing procedures- daily lot size, weekly lot size, monthly lot size- lot size according to flexible period lengths
(based on accounting periods)- lot size according to a planning calendar
(freely definable periods)
optimum lot-sizing procedures- part period balancing- least unit cost procedure- dynamic lot size creation- Groff reorder procedure
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NET REQUIREMENTS
Safety stock
Shortage
Comparison
Warehouse stock
Lot size
Forecast requirements
Material reservations
Sales orders Fixed receipts eg Purchase
orders Firm order proposals
(planned orders
purchase requisitions) Safety stock
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Net Requirement for MRP
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Net Requirements-Grossrequirement
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Net Requirement-Reorder Point
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Back ward scheduling-In house production
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Back ward scheduling – EX Procurement
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Forward scheduling –EX Procurement
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Calculating Prod. Dates (Lead Time Scheduling)
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PLANNING FILELIST OF MATERIALS FOR WHICH A CHANGE RELEVENT TOREQUIREMENT PLANNING
TYPES OF PLANNING RUNS
REGENERATIVE PLANNING (NEUPL)(ALL MATERIALS WITH VALID MRP TYPES)
NET CHANGE PLANNING (NETCH )
NET CHANGE PLANNING IN PLANNING HORIZON (NETPL )
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MRP RUN
• Total Planning• Online• Back ground•
Single item – Multi level• Single item – single level
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MRP List MRP Controller
Group of Materialsfor which controller
is responsible
Controller’s MRPListing
Goods ReceiptGoods Issues
MRP Order Proposalsand Planner Messages
from MRP Planning run.
Planner can drill downto review material
movement activity
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Stock Requirements List
Date MRP Element Supply/Demand Ref EM Quantity Available
01/01 STOCK 10001/08 ORDER Sales Order 25 7501/15 PL ORD 1000 120 05 100 17502/01 -----------------------------------------------------> Planning Time Fence
Stock Requirements List brings together all the supply orders, independentand dependent demands and stock balances for the material. MRP makesorder proposals to balance the supply/demand position for the material
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MRPPlanningResult
MRP List vs Stock Requirements List
• The MRP List displays the result of the last planning run
• The Stock Requirements List displays the most up-to-date stock andrequirements situation
MRPPlanningProcess
Last planningrun results
Stock RequirementsList uses current data
Current Stock,Rqmts, Balances,planned Receipts,Issues