sap pp material planning

7/22/2019 SAP PP Material Planning

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Testing: Unit Testing / User Manual Module: PRODUCTION PLANNING

ENVIRONMENT

SYSTEM : SAP R/3 ECC 6.0

CLIENT :

UNIT TESTING SCENARIO

SCENARIO NUMBER : PP01- 03

DESCRIPTION : Matera! P!a"""#

PREPARED BY

NAME : Pra$ee% D. &a!a%'re

DATE : 03/01/0(

TEAM : Pr)$'*t)" P!a"""#

APPROVED + TESTED BY

NAME : Na",e Ba' PC

DATE :

TEAM : Pr)$'*t)" P!a"""#

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T,e C)"*e%t O MRP I" SAP

MRP is the planning tool in SAP which will look at all aspects of a material and is highly based uponthe master data of the material.MRP looks at current inventory, current requirements, and open purchase requisitionorders and soon. So if a material is required to satisfy a sales order and there is no inventory, MRP will create a%!a""e$ )r$erif the item is t) e %r)$'*e$ " ,)'2e. !his planned order can then be convertedto a production order by the master scheduler."f the item is t) e %r)*'re$, then MRP will create a %'r*,a2e re'2t)"which the #uyer willconvert to a purchase order. !his is $ust one scenario, the system is highly configurable and will dopretty much whatever you tell based on config and master data.!he 4a" '"*t)"of material requirements planning is to guarantee 4atera! a5a!a!t, that is,it is used to procure or produce the requirement quantities on time both for internal purposes andfor sales and distribution. !his process involves the monitoring of 2t)*72 and, in particular, theautomatic creation of %r)*'re4e"t %r)%)2a!2 for %'r*,a2"# a"$ %r)$'*t)".

MRP O5er5e

MRP analy%es the demand from sales orders and forecasts. "f stock is needed then a planned orderis created. A planned order consists of a suggested order quantity, a start date and a finish date.!he bill of material of the planned order is e&ploded, creating dependent requirements.!hese are processed later by MRP, to determine if planned orders are needed for the components."n order to replenish stock, we must convert the planned order to a production order 'if it is for a

manufactured item(, or to a purchase requisition 'if it is for a purchased item(.MRP can create purchase requisitions directly, for purchased materials, depending on runtimesettings. "f the purchased material is part of a scheduling agreement with a vendor, MRP can create

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schedule lines. )hen the planned order is converted to a production order, the dependentrequirements for its components become reservations.

P!a"""# Pr)*e$'re

Planning procedures automatically generate order proposals to purchasing and to production. R*planning procedures can be divided into Material Requirements Planning and +onsumptionbasedplanning.

"n MRP, the system compares available stock plus planned receipts with demand. "f the availablequantity is less than the required quantity at a point in time, then an order proposal is created.

MRP at P!a"t )r MRP Area Le5e!

-ou can plan material requirements at %!a"t !e5e! or for different MRP areas. )ith MRP at plantlevel, the system adds together stocks from all of the individual storage locations, with thee&ception of individual customer stock, to determine total plant stock. !he requirements arecombined in the planning run and procurement elements are created for these peggedrequirements with unknown sources. "ndividual storage locations can be planned separately orbe e&cluded from planning."n the case of material requirements planning on an MRP area !e5e!8 only the stocks from the

storage locations assigned to the respective MRP area are taken into account.nly the requirements in this MRP area are combined and procurement elements are created forthem. !his enables you to plan material requirements specifically for certain areas.

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+onsumptionbased planning procedures use past consumption data 'history( to calculate futurerequirements. !hese procedures are sometimes used for e&ternally procured materials or for low

value low demand items.

+onsumptionbased planning can be divided into forecastbased and reorder point planning.Re)r$er %)"t %!a"""#can be divided into automatic and 4a"'a! re)r$er %)"t %!a"""#./orecastbased planning uses the SAP forecasting module to calculate future requirements fromhistorical data.

Re)r$er P)"t P!a"""#

"n reorder point planning, procurement is triggered when the sum of plant stock and firmed receiptsfalls below the re)r$er %)"t.

!he re)r$er %)"t should cover the average material requirements e&pected during thereplenishment lead time.

!he 2aet 2t)*7 e&ists to cover both e&cess material consumption within the replenishmentlead time and any additional requirements that may occur due to delivery delays. !herefore, theSafety stock is included in the reorder level.

!he following values are important for defining the reorder point0

Safety stock Average consumption Replenishment lead time

!he following values are important for defining the safety stock0

Past consumption values 'historical data( or future requirements 1endorproduction delivery timelines

Service level to be achieved

/orecast error, that is, the deviation from the e&pected requirements

Automatic reorder point planning uses the forecasting module to determine the reorder pointquantity. A reorder proposal is generated when the stock falls below the reorder point.

I" 4a"'a! re)r$er %)"t %!a"""#, you must specify the reorder point quantity in the materialmaster record.

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MRP BOM E9%!)2)"

MRP begins by calculating demand for the finished product. !his consists of sales orders andplanned independent requirements. "f we don2t have enough supply to cover this demand, MRP willcreate a planned order.

!he bill of material of the planned order for the finished product is e&ploded. !his creates dependentrequirements for the assemblies. A dependent requirement is demand that is derived from the bill of

material structure.

At the ne&t level of the bill, MRP calculates the requirement for each assembly. "f we don2t haveenough supply, MRP will create a planned order.

!he bill of material of the planned order for each assembly is e&ploded. !his creates dependentrequirements for the raw materials.

At the lowest level of the bill, MRP again calculates demand. "f we don2t have enough supply, MRPwill create a a purchase requisition.

MRP R'" Pr)*e$'re

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3. +reate requirement or demand in MD614. MRP run by MD01for !otal Planning '"t will run in background(.*. See the result in stock requirement list in MD0.

MRP R'" ;e Ca" Carr O't B

3 .MD015!otal planning for the plant !hrough user e&it a. MRP Area 5 + class b. MRP +ontroller c. MRP !ype4. MD0


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De2*r%t)" ) t,e ?e!$

Nat're )

t,e ?e!$ Va!'e ) t,e ?e!$Plant Mandatory 1110

Processing 7ey NETC@

+reate Purchase Requisition 1

Schedule 8ines 3

+reate MRP 8ist 1

Planning Mode 3 P!a"t S%e**

Scheduling .4( Second line shows the planned independent requirement is ?.*( !hird line shows the planned order created against the P"R is ?.

St)*7 Re're4e"t L2t C)!!e*t5e D2%!a

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1. Tra"2a*t)" C)$e/ Pat,

;nter the menu path of the transaction code, which is going to be tested by the user.

Me"' Pat,L)#2t*2 Pr)$'*t)" MRP E5a!'at)"2 St)*7 Re're4e"t L2t >C)!!e*t5e D2%!a

T.C)$e MD0

"n *)!!e*t5e a**e220

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o ;nter theplantand one of the following parameters0 MRP controller, product group,class orvendor.

"f you do not enter any further selection criteria, the system selects all the materialsassigned to this MRP controller, to this product group or to this vendor in therespective plant.

o "f the work with MRP areas is activated for a single client, you enter either theplant'@

all MRP areas including the plant MRP area( or only one particular MRP area, and, inaddition, either the MRP controller, theproduct groupor the vendor.

"f you do not enter any further selection criteria, the system selects all the materialsassigned to this MRP controller, to this product group or to this vendor in the selectedMRP area or in all MRP areas. Materials that are assigned to five MRP areas are

displayed, where applicable, with five MRP lists."f required, enter further selection criteria.

o Date0 for e&ample, all MRP lists that were created or processed within the last two

weeks, or MRP lists for all materials with insufficient stock for the ne&t two weeks.

o Exception groups0 for e&ample, MRP lists for all materials for which the planning run

was terminated 'e&ception group (.

o Processing indicator0 for e&ample, all MRP lists that have not yet been processed.

o

Material data0 for e&ample, MRP lists for all materials that are procured e&ternally."f required, choose a display filter

/or e&ample, a display filter that only displays the planned orders for the ne&t two weeks inthe stockrequirements list for the materials assigned to a selected MRP controller.

-ou can use 2e!e*t)" r'!e2to define which MRP elements and which stocks are includedin the quantity and stock calculation. -ou hereby define your own '2"e22 5e2.

A 2e!e*t)" r'!econsists of particular time information, MRP elements and stocks that are

grouped together in a rule, which controls the selection 'or import( of the data in thestockrequirements list and the planning table for Repetitive Manufacturing0

o !he system only displays MRP elements in the period that is defined in the selection

hori%on.

o !he system only displays the MRP elements that are selected in the selection rule.

o f the MRP elements displayed, the system only takes those indicated as affecting

availability in the selection rule into consideration for the calculation of the quantityavailable and the ranges of coverage.

o !he system only takes the stocks defined in the selection rule into consideration tocalculate the unrestricteduse stock.

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!his creates a new business view of the data in the lists.

-ou can use $2%!a !ter2to define which MRP elements and MRP segments are

displayed. !his enables you to reduce the information displayed to a *!ear 2e!e*t)".

A $2%!a !terconsists of particular time information, MRP elements, and MRP segments groupedin a filter that controls the display of the MRP list and the stockrequirements list.

o !he system only displays MRP elements in the period that is defined in the display

hori%on.

o !he system only displays segments in this period that are selected in the display filter.

o )ithin these segments, the system only displays MRP elements that are selected in

the display filter and that, if necessary, correspond to particular additional selections

'for e&ample, customer, vendor, storage location(.

!he data in the lists is thus reduced to a clear selection.

"n contrast to selection rules, the calculation of the quantity available and the ranges ofcoverage is not influenced by display filters.

-ou can define the 2e!e*t)" ,)r)"for the selection rule as well as the $2%!a ,)r)"and the a$$t)"a! 2e!e*t)"2for the display filter in two ways0

o companyspecific in +ustomi%ing

o userspecific in the respective analysis list

1. Select the With filter field 'initial screen( or choose 'main screen( in order to show theDisplay filterand Selection rulefields.

4. Select a display filter andor a selection rule.

3. +hoose and, if necessary, enter a display hori%on for the display filter or a selectionhori%on for the selection rule, which means a period to which you want to limit the display.

4. +hoose and, if necessary, enter additional selections for the display filter, for e&ample ifyou want to see MRP elements for a particular vendor or a particular customer.

"f you always work with a particular display filter andor selection rule, choose . !hesystem displays the Settingsdialog bo&.:se this to define that this display filter orselection rule should always be activated when you access the lists.

E"ter C)"tr)! Para4eter2

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De2*r%t)" ) t,e ?e!$Nat're )t,e ?e!$

Va!'e ) t,e ?e!$

Plant Mandatory 1110MRP +ontroller

Set up 8ists in back ground TIC&

Ater !!"# t,e a)5e $ata a#a"2t t,e re2%e*t5e e!$2

Press on !ab

MRP C)"tr)!!er Matera!2 P!a""er

Specifies the number of the MRP controller or group of MRP controllers responsible for material planning for the material.

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Stock Requirement 8ist as per the MRP +ontroller then get displayed

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Select the individual lines and click on tab it will show therequirements for the particular item code B the planned orders generated against the requirementqty.

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sap pp material planning

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