 Backward Scheduling:

1) Backward Scheduling is process in which system carries out scheduling BACKWARDS

from customer's requested delivery date to determine material availability date (date at
which material is available) and takes into account picking/packing time etc. If sufficient
material is available on Material availability date, system confirms the requested delivery
date.
2) In backward scheduling u enter the basic finish date and the system calculates basic
start date, scheduled start, scheduled finish.

 Forward Scheduling:
1) Forward scheduling happens when system fails to confirm thru backward scheduling and
checks for next material availability date and then calculate picking/packing time etc.
forward from this date and gives confirmed dates and quantities which will be obviously
different from customer's requested delivery date.

2) In forward scheduling u enter basic start date and the system calculates scheduled start
, scheduled finish, basic finish date.

3)

1. Replenishment lead time (RLT): is the time taken for the material to become available either
internally (in house production) or externally (from a vendor) & Lead time scheduling calculates
the concrete production dates. The system uses the times in the routing to carry out lead time
scheduling.
2. Basic scheduling is done by considering the times maintained in the material master in MRP 2
VIEW & the lead time scheduling uses the times maintained in the routing.

 -----------------------------------------End--------------------------------------------------
  SAP PP SCHEDULING:

There are two methods of scheduling in SAP and especially in production planning.

1. Basic dates scheduling. Basic dates scheduling is calculated by considering the

values like goods receipt (GR) processing time, in-house production time and
planned delivery time from material master (MRP 2 view). It calculates basic start
date and basic finish date for an order.
2. Lead time scheduling. Lead time scheduling takes value from routing operation
times (setup, machine, labor, etc.) to calculate operation start date, start time,
finish date and time.

SAP PP Scheduling Types:

There are different scheduling types commonly used in Production Planning and
especially in production orders.

 Forward scheduling
 Backward scheduling
 Today scheduling
 Only capacity requirements

In forward scheduling, SAP system schedules the order based on basic start date
and determines the schedule end dates.

In backward scheduling, SAP system schedules the order based on basic end date
and try to determine schedule start date.

In today scheduling, SAP system calculates schedule end date by considering

schedule start date as current date.

In only capacity requirements scheduling, basic dates are copied as schedule dates.
Operations will not be scheduled.

Basic Dates vs Schedule Dates

Basic finish dates are calculated based on requirement date (demand). SAP system
adds lead times (GR processing time, in-house production time, etc.) defined in MRP
2 view to that to determine basic start date.

It also adds opening period defined in scheduling margin key (MRP 2 view). Opening
period is the number of days required for a planner to convert a planned order to a
production order.

Production start date/time and finish date/times are calculated by scheduling individual
operations defined in routing. Then, schedule start and finish dates are calculated by adding
floats (defined in scheduling margin key) to the production start dates.
Control Key in SAP PP Scheduling:
Control key decides that whether an operation needs to be scheduled or not. If scheduling
indicator is activated in the control key, SAP system will schedule the operation. Otherwise,
it will not.
SAP PP Scheduling Components
When system schedule an operation, it uses the following parameters from master
data.

1. Operation times and base quantity from routing.

2. Formula for scheduling from work centre.
3. Inter-operation timings from routing or work centre.
4. Break time and shift sequences.

Operation Time in Routing

In routing, each operation contains setup, machine and labour hours required to
produce the base quantity. SAP system uses this information to calculate the total
time required for that operation.

Let’s say that in routing we have entered machine time 120 mins for the base
quantity of 500 PC. When an order for the quantity of 1200 PC is created, SAP
system will calculate the total time required for this operation as follows.

Total time required for 1200 PC = (120 / 500) * 1200 = 0.24 * 1200 = 288 minutes

Formula for Scheduling Time

This calculation is maintained inside the scheduling formula in a work centre.

Operation time = (Machine time * Operation quantity /Base quantity) /Operation split

Here, operation split is defined in routing where in this example it is ‘1’.

Inter-Operation Time
Inter-operation time is time between operations in the work centres. In SAP, there
are 3 inter-operation times available.

1. Queue time. Queue time is time required before processing the material in a
work centre.
2. Wait time. Wait time is the time material must be kept after processing in a work
centre.
3. Move time. Move time is the time required to move the material from one work
centre to another after processing.

Let’s consider this example from the fastener industry which deals with
manufacturing bolts and nuts. We will consider only the final stage of operation when
after bolts are produced they will be painted and packed. Let’s say before painting
previous batches are in queue for 10 mins (queue time) due to shorter duration of
preceding operation and longer duration of painting operation. After painting, this
material must wait for 15 mins (wait time) for drying. Then, it will be moved to
packing location using trolley which takes 10 mins (move time).

Break Time and Shift Time

SAP system will calculate break time from work centre master data. If any shift
sequences are defined in the work centre, SAP system takes break time in shift
break entered in the shift sequences. Else, it will take the total break time entered in
the capacity header.
Break time entered in the capacity header is the total break hours between start and
finish time (refer to the screenshot below). Here, a total of 1 hour of break time is
from 07 AM to midnight (available capacity = 17 hours). If your operation time for an
order is 8 hours, SAP system will calculate break time as following:
Break time for 8 hours = 1/17 * 8 = 0.47 hours

Shift sequences are entered with exact break hours which will be considered for scheduling
and capacity calculations. These shift sequences will be assigned to a work centre.

Reduction Strategy in Scheduling

When SAP system tries to schedule an operation, it first tries to schedule it within the
basic dates. When schedule start date falls before basic dates, it tries to adjust the
dates by reducing the inter-operation timings except wait time. From the example
discussed above, we can reduce the queue time and move time but cannot reduce
the wait time. Because painted bolts must wait for 15 mins in order to get dry.
We can maintain standard and minimum queue time in work centre and routing. SAP
system will first consider standard queue time but if scheduling dates falls before or
after basic dates, it will take minimum queue time.

If after considering minimum time SAP system finds that dates are not within the basic dates,
it will apply reduction strategy defined in routing operation.

SAP system will apply reduction step by step for each of reduction levels.
1. Try to reduce 50% of the queue time.
2. Try to reduce 100% of queue time and move time.
3. Try to reduce 100% queue and move times and try to apply operation overlap
defined in routing operations.
4. Try to reduce 100% queue and move times and try to apply operation overlap
and operation split defined in routing operations.

Here, operation overlap and splits will reduce the lead time of the operation.

Factory Calendar in Work Centre

When system schedule an operation or production order, it considers factory
calendar from the plant and excludes the non-working days and holidays. When
there is a business scenario where the production calendar is different from the plant
calendar, we can assign a production specific calendar in a work centre. So that at
the time of scheduling SAP system considers working days from the work centre
instead of the plant calendar.

 -------------------------------------------End------------------------------------------------------

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.

 -------------------------------------------End------------------------------------------------------

For Raw materials:

Scheduling for externally procured materials:
For the externally procured materials, SAP uses the planned delivery time (lead times) and
goods receipt times in Material master to schedule the delivery & release dates for the
procurement proposals. You can either use forward scheduling or backward scheduling for
these materials. SAP uses the basic date scheduling in the case of externally procured
materials

For Finished and Semi finished products:

Scheduling for in-house manufactured materials:
For materials which are to be manufactured in house, as assemblies and subassemblies (in-
house produced materials), the scheduling is done according to the scheduling method
selected in the selection screen of the MRP run.
If the scheduling method selected is - ___Lead time Scheduling__ the scheduling for the
planned orders are done through the use of standard timings in the routings/recipes of
the material. The Standard values or the standard timings in the routings or recipes are for
a base quantity, which means that the scheduling carried out using the lead time method
is an accurate method of scheduling and gives the greatest results every time. It not only
calculates the operation lead time (operations start and finish times) but also cumulates
them to arrive at a total lead time with an order start date and order finish date._
 When you use the lead time scheduling method, the system uses the scheduling methods
configured; you can use either forward scheduling or backward scheduling method for the
MRP run. As a default scheduling type, the system uses backward scheduling but it also
switches automatically to forward scheduling if the determined start date lies in the past.
Though if you do not want the system to switch to forward scheduling automatically, you
can specify per plant in Customizing for MRP, in the IMG activity Parameters for determining
the basic dates that the system is to continue the backward scheduling calculation even if
the resulting start date lies in the past.
· Check the Lead time Scheduling example as shown below. Lead time scheduling uses the
floats in the schedule margin keys (if any) and the standard values in the operation along
with the operationu2019s interoperation times.
Order Lead time scheduling for In-house produced materials =
Opening Period from where the Planning opens as mentioned in Schedule Margin Key
+
Order Floats before Productionu2019 starts here u2013 Floats mentioned in Schedule
Margin Key. If floats = 0 then Operation start date = order start date
+
Operation 0010 Start date u2013 to u2013 Operation 0010 Finish date (calculated through
the standard values in operations)
+
Operation 0020 Start date u2013 to u2013 Operation 0020 Finish Date (calculated through
the standard values in operations)
+
Operation 0030 Start date u2013 to u2013 Operation 0030 Finish Date (calculated through
the standard values in operations)
+
u2013 u2018Order Floats after Productionu2019 ends here u2013 Floats mentioned in
Schedule Margin Key. If floats = 0 then Operation Finish date = order start date
· The selection of the Routing/Recipe is made through the u201Ctask list determination
strategies included in the configurationu201D or if the selection method for the BOM
selection is through u2018production versionsu2019 then the task list included in the
version is used.

 -------------------------------------------End------------------------------------------------------
- The customer specifies a delivery date on the schedule line of the sales order
- The business checks whether the requested quantity can be delivered on the requested
delivery date.
- When you create an order, the system can determine the required material availability
date based on the delivery date requested by the customer. The goods to be delivered must
be available for shipping at this point in time.
- Scheduling takes into account the following times:
 Transit time: Time required in order to ship a delivery to the ship-to party
 Loading time: Time required for loading the goods
 Pick/pack time: Time required for picking, packing
 Transportation lead time: Time required for organizing the transportation
- Next, the system performs backward scheduling in the order. If the result is a date in the
past, the system automatically performs forward scheduling, which requires the
confirmation of a new requested delivery date. The same happens if the material is not
available by the material availability date.
For this to happen, you should ensure
- availability check is switched on at the requirements class level as well as for each schedule
line category.
- maintain transit time & transportation lead time in route
- maintain loading time & picking time in shipping point

 -------------------------------------------End------------------------------------------------------

Q. How the Delivery lead time works in Sales Order i.e.

"From the time a confirmed Sales order is punched till the time we have delivered the material"
How to configure to use effectively

When you create sales order, system automatically proposes data based on configuration
settings.
1. Check the schedule line proposed by system in sales order. Let's say CP. Go to transaction
VOV6 and see if availability check is checked.
2. Check the requirement type proposed by system in sales order. Let's say 041. Go to
transaction OVZH and see what requirement class has been assigned to it. Let' say 041.
3. Go to transaction OVZG and see if availability check has been checked for this
requirement class 041.
4. Check the shipping point proposed by system in sales order.
Go to transaction OVLZ and check Loading time & pick pack time maintained there for this
shipping point. If there is nothing let's say we have 24 hours and 24 hours respectively.
5. Check the route proposed by system in sales order. Let's say route selected is 000003. Go
to transaction 0VTC and see Transit duration & Transportation lead times maintained there.
Let's say timings maintained are 2 days and 1 days respectively.
Now let's say a customer calls and says he wants a material delivered on Apr 25. Now what
the system does is that it does backward scheduling. i.e. it goes backward from delivery date
i.e. 25th April. It reduces 3 days for transit time, reduces time taken for loading time,
reduces days taken for arranging transport, reduces time taken for pick pack. After
calculation it arrives at date Apr 21. Now it checks whether material is available on this date
i.e. Apr 21.
If material is available, it confirms delivery date.
Otherwise, if material is not available on Apr 21, it determines date on which material is
available. Let's say material is available on Apr 23. Now, system immediately carries out
forward scheduling. So it starts calculating from Apr 23 and adds time and dates maintained
for picking & packing; transportation lead time, loading time and transit time.
Also note that system takes into account factory holidays, factory timings when it is
calculating above. If factory works 24 hours and is closed on Saturday & Sunday, system
arrives at date Apr 30. It now confirms delivery date as Apr 30 to customer.
I have given a simple example. There are many other aspects you can configure on
scheduling.

Q. how system or how we chk the stock is available or not on particular future date and in ur
answer i.e April 21st.

While creating sales order, the system does background checks to see whether material is
available based on configuration settings.
Configuration settings are done at IMG->SD->BF->Availibility check and transfer of
requirements.
ATP (Available to promise) is the process of checking the available quantities of a material.
ATP quantity is equal to plant stock plus the planned receipts (Incoming stock) minus the
planned issues (Outgoing stock). ATP takes into account all movements into and out of the
plant. In transaction OVZ9, you define checking rules for availability check. Basically you are
telling system what stock to take into account to determine whether material is available.
In brief, system does all checks to determine whether material is available.
Go to transactions
- MD04 to check availability of stock in plant.
- MMBE to check total stock by company code, plant, storage location
- CO09 to check stock on hand
You can also check stock of material while creating sales order by clicking availability check
button at bottom of screen.
In case system determines there is no stock of material, it takes MRP settings from Material
Master to determine when stock would be available.

 ---------------------------------------------------End------------------------------------------------------