[SAP] - Production Planning MRP.pdf - SAP - tedzik321

Material Requirements Planning

Release 4.6B

™

Material Requirements Planning

SAP AG

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December 1999

SAP AG

Material Requirements Planning

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December 1999

Material Requirements Planning

SAP AG

Contents

M aterial Requirements Planning .....................................................................11

Material Requirements Planning in the Logistics Chain ......................................................... 13

MRP Procedures .......................................................................................................................... 15

Material Requirements Planning ................................................................................................ 16

Material Requirements Planning Procedure............................................................................. 17

Master Production Scheduling................................................................................................... 18

Master Production Scheduling Procedure................................................................................ 20

Consumption-Based Planning ................................................................................................... 22

Reorder Point Planning ............................................................................................................ 23

Reorder Point Planning Procedure ..................................................................................... 24

Reorder Point Planning with External Requirements.......................................................... 26

Forecast-Based Planning .........................................................................................................27

Forecast-Based Planning Procedure .................................................................................. 29

Time-Phased Planning ............................................................................................................. 30

Time-Phased Planning Procedure ...................................................................................... 31

Range of Coverage Profile in Time-Phased Planning ........................................................ 33

Time-phased Planning Process with Delivery Cycle........................................................... 35

Time-phased Planning Process with Reorder Point Planning ............................................ 37

Master Data .................................................................................................................................. 38

Planning Calendar ....................................................................................................................... 39

Creating Planning Calendars with Calculation Rule................................................................. 40

Creating Planning Calendars without Calculation Rule............................................................ 42

Changing the Planning Calendar ............................................................................................. 43

Quota Arrangements ................................................................................................................... 44

Allocation Quota Arrangement ................................................................................................. 46

Example for Allocation Quota Arrangement........................................................................ 47

Splitting Quota Arrangement .................................................................................................... 48

Example for Splitting Quota Arrangement........................................................................... 49

Lot Size and Rounding Profile in Quota Arrangement ............................................................. 50

Example for Maximum Lot Size .......................................................................................... 52

Priority and Maximum Release Quantity per Period ................................................................ 53

Example for Priority and Maximum Release Quantity ........................................................ 54

Maintaining the Quota File........................................................................................................ 55

BOM Explosion Number (Fixed Key Date) ................................................................................ 56

Creating BOM Explosion Numbers .......................................................................................... 59

Changing BOM Explosion Numbers......................................................................................... 60

Assigning a New Key to the BOM Explosion Number.............................................................. 61

Assign New Project Account Assignment to Material Components...................................... 62

Planning Process......................................................................................................................... 63

Checking the Planning File......................................................................................................... 65

Individual Customer Planning File Entries................................................................................ 66

Planning Run Types and Scope of Planning............................................................................ 67

Planning Mode.......................................................................................................................... 69

Calculating Low-Level Codes ................................................................................................... 71

Displaying the Planning File ..................................................................................................... 72

December 1999

SAP AG

Material Requirements Planning

Setting Up the Planning File ..................................................................................................... 73

Creating Entries in the Planning File Manually......................................................................... 74

Check the Consistency of the Planning File............................................................................. 75

Net Requirements Calculation ................................................................................................... 76

Net Requirements Calculation for MRP ................................................................................... 77

Net Requirements Calculation for Reorder Point Planning ...................................................... 78

Net Requirements Calculation for Forecast-Based Planning................................................... 79

Gross Requirements Planning ................................................................................................. 80

Calculating Procurement Quantity ............................................................................................ 81

Lot-Sizing Procedures .............................................................................................................. 82

Static Lot-Sizing Procedures ............................................................................................... 83

Lot-for-Lot Order Quantity.............................................................................................. 84

Fixed Lot Size ................................................................................................................ 85

Replenishment up to Maximum Stock Level.................................................................. 86

Period Lot-Sizing Procedures ............................................................................................. 89

Availability Date for Period Lot-Sizing Procedure .......................................................... 90

Example for Determination of Availability Date ........................................................ 91

Delivery Date Instead of Availability Date ...................................................................... 92

Example for Delivery Date Instead of Availability Date ............................................ 93

Optimum Lot-Sizing Procedures ......................................................................................... 94

Part Period Balancing .................................................................................................... 95

Least Unit Cost Procedure ............................................................................................. 96

Dynamic Lot Size Creation ............................................................................................ 97

Groff Reorder Procedure................................................................................................ 98

Lot Sizes with Splitting and Overlapping............................................................................. 99

Short-Term and Long-Term Lot Size ................................................................................ 100

Lot-for-Lot Remaining Order Quantity............................................................................... 101

Calculating Scrap ................................................................................................................... 102

Assembly Scrap ................................................................................................................ 103

Component Scrap ............................................................................................................. 104

Operation Scrap ................................................................................................................ 105

Rounding ................................................................................................................................ 107

Rounding Profile................................................................................................................ 108

Examples for Calculating Procurement Quantities and Yields............................................... 110

Scheduling.................................................................................................................................. 112

Scheduling: In-House Production ........................................................................................... 113

Calculating Basic Dates .................................................................................................... 114

In-House Production Time: Independent of Lot Size ................................................... 115

In-House Production Time: Dependent on Lot Size .................................................... 116

Backward Scheduling for In-House Production ........................................................... 117

Example of Backward Scheduling for In-House Production ................................... 118

Forward Scheduling for External Procurement ............................................................ 119

Calculating Production Dates (Lead Time Scheduling) .................................................... 120

Levels of Scheduling .................................................................................................... 122

Determining Capacity Requirements ........................................................................... 123

Starting Lead Time Scheduling.................................................................................... 124

Calculating the Provision Date for Components ............................................................... 125

December 1999

[SAP] - Production Planning MRP.pdf

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