Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
htm
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!
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 re-schedule 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.
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.
- Reorder planning
- Forecast based planning
- Time phased planning
Production Cycle: -
The following might help in explaining the difference between MPS and its counter part MRP.
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.
(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.
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.
- 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.
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.
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.
- 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.
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.
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
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.
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 --> MM --> Consumption based planning --> Master data --> Define MRP
group.
It is procedure that you set in the system on how the Material is planned
- Reorder Point
- Seasonal requirement
- Replenishment
- Vendor Managed
- Forecast Based
Setting --> SPRO --> MM --> Consumption based planning --> Master data --> Define MRP
types
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:
Unplanned consumption is updated only for materials planned using MRP. This occurs in the
following cases:
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.
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.
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 re-schedule 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.
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
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.
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.
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. *-- Dhananjay
What are the difference between basic scheduling and lead time scheduling?
Basic Scheduling
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.
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.
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
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)
The planned delivery time from the material master record or purchasing info record
The goods receipt processing time from the material master record
Note
The planned delivery time from the purchasing info record and the GR processing time are only taken into account if
the purchase requisition was generated via materials planning.
Example
Processing time Planned del. GR processing
Purchasing time time
|----------|---------------------|--------|
For the material to be available on the date it is needed, the purchase requisition must be released on 13.09.2007
(requirement date less GR processing time, planned delivery time, and purchasing department processing time).
===========================================================
Use
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.
Examples
If the system schedules forwards, you must enter the order start date.
If the system schedules backwards, you must enter the order finish date.
If the system does not schedule the order, you must enter both the order start date and the order finish date.
Scheduled start
Use
Start date for the execution of the production order.
let the system determine this date using lead time scheduling, or
enter the date as a fixed date on the header screen of the production order.
The system automatically sets this date, as soon as the first operation is confirmed.
If, on order creation, a planned order exists for the production order/ process order, the basic dates are
copied from the planned order.
If no planned order exists on order creation, you must specify at least one basic date.
The scheduling type determines the basic dates that you must specify.
Dependencies
The order finish date is accurate to the day. However, for scheduling, production requires a completion date that also
specifies the time. To ensure that the material to be manufactured is available on the order finish date, the completion
date must be before 00:00 hours on the order finish date.
If, however, an in-house production time of 0 days is maintained in the material master, an exception is made to
this rule. In this case, it is assumed that the material can be manufactured in a single workday. The completion date
is then before 24:00 hours on the order finish date.
Example
The last operation of an order was completed on Thursday at 5 pm (17:00 hours). No float after production was
maintained for the order.
If an in-house production time greater than 0 days is maintained in the material master record, the order
finish date is Friday.
If an in-house production time of 0 days is maintained in the material master record, the order finish date is
Thursday
Scheduled finish
Scheduled finish date
Procedure
You can either
let the system determine this date using lead time scheduling, or
enter the date as a fixed date on the header screen of the order.
Lead time scheduling is performed using the routing. In this case, it calculates the start and finish dates and
times of the operations.
In MRP, lead time scheduling can be performed using the times specified in the material master. In this
case, it calculates the production start and finish dates, but does not calculate capacity requirements.
Return ->
opening period
The number of working days between the date that the order is created and the planned start date.
This time is available for the MRP controller to convert a planned order into a purchase requisition or a production
order.
Return ->
Definition: opening_period_for_planned_order
The number of working days between the scheduled finish date and the order finish date; used as a float in
production scheduling.
The number of working days between the order start date and the scheduled start date; used as a float in production
scheduling.
Return ->
Definition: float_before_production
The number of workdays between the planned start date of the production order and the date for releasing the order.
If the order release indicator is set, the production order is released by a background program that takes all dates into
account.
Return ->
Definition: release_period
Scheduling type
Key which specifies the scheduling type for detailed scheduling.
Note
With production-rate and rough-cut scheduling backward scheduling is always used.
Use
Via the scheduling type you can control, how the production order should be scheduled (for example forward,
backward).
Dependencies
The scheduling type determines, which dates you must enter:
If the system schedules forward, you must enter the order start date.
If you schedule backward, you must enter the order finish date.
The period, at operation level, between the earliest start and the latest finish of an operation and at order level the
period between the order start date and the order finish date.
The lead time of an operation is made up of queue time, execution time, and wait time.
The lead time of an order is made up of execution times, interoperation times, and order floats before and after
production.
Time span between the start date of the first activity in an order and the finish date of the last activity in that order.
Contractually agreed period of time between the buyer's notification of his/her wish to exercise the option, and the
actual exercising of a Bermuda option.
Time span in days between creation of a shopping cart and the delivery date. This time is made up of the delivery
time of a vendor (possibly detailed in a catalog) and the processing time in Enterprise Buyer up until output of the
purchase order.
Expected time interval between the shipping of a delivery in the ship-from location and the expected time of arrival at
the customer location.
The lead time equals the transportation duration of a means of transport that you have assigned to the transportation
lane between the ship-from location and the customer location.
Return ->
Describes the worksteps necessary to produce a material or perform an activity without reference to an order.
Essential objects of a task list are header, operations, material component allocations, production resources/tools and
inspection characteristics.
Together with specific dates and quantities, task list data forms an important part of the order.
routing
inspection plan
standard network
master recipe
Return ->
Definition: standard_task_list
Definition: sequence
The order in which several assets are assigned to one collateral agreement.
Using sequences, you can create structures in the routing, that are similar to networks but less complex. Sequence
categories in routings are:
Standard
Alternative
Parallel
Control structure made up of a statement block that is not defined with keywords and is executed only once
without conditions.
Several objects or sub-objects can be assigned to a collateral agreement. The sequence describes in which order the
objects are to be utilized in a fictitious liquidation.
Return ->
Definition: sequence
Definition: routing
Allows you to define certain flight itineraries to which an enterprise-specific airfare rate or discount applies.
A routing type that defines one or more sequences of operations for the production of a material.
To reduce the effort of entering data in a routing, you can reference or copy reference operation sets as many times
as required and in any sequence.
A description of the production process used to manufacture plant materials or provide services in the manufacturing
industry.
Return ->