Production Planning Questionnaire: 1 Enterprise Structure

Production Planning Questionnaire

Instructions
This questionnaire is an online tool that you can use to collect information about your business that will then be used for tailoring the R/3 System to your business needs. You will need Microsoft Word for Windows to work with this document. Enter your answers in the fields after the questions, using the TAB key to move from field to field. You may save, and later change, your answers in this questionnaire just as you can with any other Word document. This document can be password-protected to allow entrance of information only in the answer fields.
1 Enterprise Structure
1.1 Plants
A plant is an organizational unit that represents a production facility, warehouse, sale office, or distribution center. In addition, MRP is executed separately for each plant.
1.1.1 List the different type of plants you will need,

and briefly describe why each should be a separate plant:
2.1 Basic Data

2.1.1 Do you use engineering change management
for your BOMs? Yes No
2.1.2 What application areas are your BOMs linked

to (for example, materials management, MRP, costing, etc.)?
2.1.3 Do you plan to use the default setting by SAP

for your BOMs validity or effectivity dates? If no, define your validity settings for your BOMs.
Yes Yes
No
2.1.4 Do you maintain your BOMs using a CAD

system? If yes, explain.
No
1997 SAP Technology, Inc.
2.1.5 Select the BOM types you maintain in your

organization with associated units of measure. (i.e., pieces, each, die, etc.)
Material BOM Equipment BOM Functional location BOM Document structure Sales Order BOM
2.1.6 BOM usage

Please select in what area(s) your BOMs will be maintained.
Production Engineering Universal Plant maintenance Sales and Distribution Costing
2.1.7 Define material provision indicators

Do your BOMs include material that is provided by the customer?
Yes
No
2.1.8 Define explosion types

Select which BOM explosion type(s) your company uses.
Phantom assembly off: you control how an assembly with the Phantom assembly is exploded. Phantom in planning: no dependent requirements are produced for materials, and the materials are not planned. Collective order off: used to control how assembly collective orders are exploded. (A collective order is a structure of planned or production orders linked over several manufacturing levels.) Long term planning off: allows you to simulate materials planning, in parallel to operational materials planning, across all low-level codes. This means that you can use the current bills of material to determine the effects of a planned production program on the material requirements and the capacity load. Individual/collective requirements: planning for dependent requirements. This controls whether individual or collective customer requirements planning is allowed for dependent requirements.
2.1.9 Will you be transforming BOM data from an

existing system into the SAP system? If yes, indicate the number of BOMs.
Yes
No
2.1.10
Are there several alternative BOMs for one material (different production processes or proportions of quantities), or is this situation planned for the future? Are there BOM items that are not kept in stock, but are externally produced for orders? What are your requirements for administering BOMs (copy functions, mass changes, and so on)?
2.1.11 2.1.12
Yes
No
2.2 Work Center

2.2.1 If you are using Work Centers, select what
business function(s) apply at your organization. Costing Scheduling Capacity Planning Printing Shop Floor Paper Shop Floor Control Confirmations
2.2.2 Will you integrate Work centers with the

Human Resources sytem? If yes, briefly describe the type of data that will be used (e.g., required skills).
Yes
No
2.2.3 List the type(s) of data that are maintained at

your work centers (i.e., costing or scheduling)
2.2.4 Work centers can be categorized according to

their relevant use, for example, by maintenance or inspection. Indicate how your work centers are categorized and give the number of work centers for each category.
2.2.5 List the type(s) of parameters you use for your

various work center(s). (e.g., WC1=setup, machine & labor, WC2=labor only)
2.2.6 What are the name(s) of the person or group of

people responsible for maintaining the data in your work center(s)?
2.2.7 If you are in a Kanban/JIT environment, list the

number of supply areas you have, including a brief description. (A supply area is used for material replenishment and is situated on the shop floor.)
2.2.8 Select what default value(s) you plan to

maintain for your work center(s). (Default values help to simplify the maintenance of work centers.)
Basic Data (General data) Default operation Scheduling Capacity data
2.2.9 Control keys allow you to determine the

business functions you want to carry out with an operation and how the operation is to be processed. Which business function(s) will be processed at your operations?
Scheduling Capacity planning Costing External processing Completion confirmation (whether the operation is confirmed) Printing of time tickets
2.2.10
If you are using the HR module in SAP or if you are not planning to maintain wages or salaries of your employees, skip this question. The wage and salaries of employees can be calculated based the wage type (e.g., hourly, salary and bonus) What wage type(s) do you maintain at your company? In the SAP system, performance efficiency rates are used in costing and in capacity planning. What are the expected efficiency rates that typically occur at several work centers in your company? (e.g., 90, 100, or 110%)
2.2.11
2.2.12 Define capacity categories

What capacity categories are maintained at your work center(s)? (e.g., machine, labor, setup crew, emissions)
2.2.13 Determine capacity planner

List the name(s) of people or groups of people responsible for planning capacity at your
company.
2.2.14
Define shift sequence
Using the table below, indicate what shift definition(s) are common for several work centers at your company. Shift Description Start (e.g.)Day1 Normal Day 08:00:00
Finish 16:00:00
Break Noon
Wrk. Hrs. 8.00
2.2.15
Indicate the work center formula(s) that you use in the following areas. (e.g., Machine Requirements = Machine* Operation Qty. / Base Qty.) Setup time Machine time Labor time Setup Requirements Machine Requirements Labor Requirements
2.3 Routing
2.3.1 If you choose not to use the number range
assignment in SAP, list your number range(s) for internal and/or external routings.
2.3.2 Skip this question if you are not using repetitive

manufacturing. If you choose not to use the number range assignment in SAP, list your number range(s) for internal and/or external routings. (Rate routings are used in repetitive manufacturing.)
2.3.3 Profiles with default values are proposed when

you create a new routing. This data can either be saved or overwritten. To assist when creating a routing profile, fill in the data. Unit of measure Status (select one) Created Released for Production
Operation increments (e.g., 10, 20, 30) Base quantity Currency
Finished products: materials that are produced and sold to the customer Semi-finished products: materials that can be sold to the customer, or used in a higher assembly Trading goods: materials that you buy and sell without any manufacturing Configurable material: the selectable items form a BOM that are used to make a Finished product in various combinations. (i.e., a car) Non-stock material: material that you buy and track qty., but in value is not kept. Raw material: material you buy to produce something with
2.3.4 Select which material type(s) will be used in

your organization.
2.3.5 What are the name(s) of people or group of

people that are responsible for maintaining your routings?
2.3.6 The control key for an operation is used to

carry out business functions and dictate how an operation is to be processed by the system. What business functions are processed at the operation level in your organization? (Select where applicable.)
Scheduling Costing Inspection characteristics Print operation External Processing Automatic goods receipt Capacity Planning Time tickets Rework Confirmation Print Confirmation
2.3.7 Reduction strategies are used to determine how

the opeation lead time can be reduced step by step. Do you use reduction strategies in manufacturing at your company?
Yes No
If yes, please explain.
3 Sales and Operations Planning

3.1 Master Data
3.1.1 If currency conversion is required, which type
of exchange rate will be used? Average rate Buying rate Selling Rate
3.1.2 Should capacity information be displayed?
Yes No
3.1.2.1
If yes, which type of resources will require resource leveling?
Work Centers Materials Production Resources and Tools Costs
3.1.3 Will SOP data be transferred from any nonSAP systems/sources?
Yes No
3.1.4 Which plant should be used as the planning

plant when no other plant is identified?
3.2 Functions
3.2.1 Will sales quantities be transferred from the R/3
Sales Information System (SIS)? Yes No Direct from the sales plan From the sales plan as a proportion of the product group of which it is a member Direct from the production plan From the production plan as a proportion of the product group of which it is a member From an Information Structure
3.2.2 Which transfer strategy will be required when

transferring SAP data to Demand Management?
3.2.3 Application Link Enabling (ALE)

Will Sales and Operations plans (information structures) be distributed to remote systems? Yes No
3.2.4 Maintain planning types

Will more than one view of the planning table be required? If Yes, define the following for each user: Planning Start Date Number of time periods to plan Sales Information System Profitability Analysis (CO/PA) Yes No
3.2.5 Where will planning quantities be copied from?
3.2.6 Will non-SAP data be copied into the SAP

planning table?
Yes No
4 Master planning
4.1 Planning Strategy
4.1.1 What type(s) of Planning Strategies are used
your company? (e.g., make-to-stk., make-toorder, repetitive, etc.)
4.1.2 What planning time fence duration is required

for planned independent requirements?
Yes No
4.1.3 Will planned independent requirements be

transferred from the legacy system?
4.2 MPS
4.2.1 What individuals or groups of individuals will
be responsible for the monitoring of material availability (MPS)? Identify the materials that will be managed by each individual or group.
4.2.2 What is the desired planning time fence for

MRP processing? Should out-of-date planned orders and firm planned orders in future periods
Yes No
be deleted before each material planning run?
4.2.3 What evaluations (on-line reports) need to be

provided for the analysis of MPS results? How should the report be structured?
5 Material requirements planning

5.1 Master Data
5.1.1 Define MRP controllers
What individuals or groups of individuals will be responsible for the monitoring of material availability (MRP)?
5.1.2 What individuals or groups of individuals will

be responsible for the processing of missing parts (MRP)?
5.1.3 Will any of the following conditions exist for

materials produced in-house?
phantom assembly production in an alternative plant external reservation (withdrawal from an alternative plant) independent requirements
5.1.4 Will any of the following conditions exist for

materials procured externally?
consignment subcontracting stock transport
5.1.5 In what time bucket is your horizon? (i.e., days,

weeks, months)
Yes No
5.1.6 What is the required duration of the planning

time fence for each plant?
5.1.7 For each plant, what percentage of safety stock

should be available for material planning?
5.1.8 Should stock in transfer and/or blocked stock

(material that is not available) be included in the net requirements calculation as available stock?
5.1.9 For each plant, what is the desired maximum

number of purchase order proposals that should be created during the material requirements planning run?
10
5.1.10
utilized?
Which lot-sizing procedures will be
static lot-sizing period lot-sizing optimizing lot-sizing
5.1.11
Will the proposed lot-sizes for any materials need to be adjusted to match the deliverable/transportable units? For example, a material can only be delivered in crates of 10 pieces. Should the system continue to utilize the backward scheduling procedure even when a planned start date lies in the past? What is the maximum number of days allowed between MRP runs? Will R/3 be interfaced to an external assembly cord system?
Yes No
5.1.12
Yes No Yes No
5.1.13 5.1.14
5.1.15
Will the hardware system environment allow the splitting of the MRP planning run process among multiple R/3 application servers?
Yes No
6 Production Orders
6.1 Master data
6.1.1 Define order types
6.1.1.1 Do you use order settlement (planned vs.
actual) for production orders? Yes No
6.1.1.2 What type of number assignment do you

use for production orders?
Internal (assignment automatically by the system) External (assigned by the user)
6.1.1.3
Define the length and format of your production order numbering scheme. processed automatically or manually?
6.1.1.4 If routing selection is required, will it be
11
6.1.1.5 Will batch determination be required prior

to releasing a production order to the shop floor?
Yes No
6.1.1.6 Do you use the same scheduling data from

your planned orders for your production dates?
Yes No
6.1.1.7 Do you use external processing in your

operations? If so, would you prefer to use one purchase requisition per operation or one collective purchase requisition per order?
6.1.1.8 Indicate below where you would want to

record change status to a document. The document records: which status changed who changed the status when the status was changed
Order Status Operation Status Material Status Production Resources Tool (assigned to an operation, e.g., tools, jigs and fixtures, inspections, devices and drawings)
6.1.1.9
Indicate at which point(s) you conduct material inspection.
Goods receipts inspection Deliver to customer
6.1.1.10 Do you document goods movements with

reference to an order? If so, select where applicable.
Good receipt for a purchase order Good receipt for a completed order Planned goods issue Unplanned goods issue
6.1.2 If you choose not to use the predefined number

ranges in SAP, list your order types and their number range(s).
6.1.3 Define number ranges for confirmations

If you choose not to use the predefined number ranges in SAP, list your number range(s) for operation confirmations.
6.1.4 Define number ranges for reservations

If you choose not to use the predefined number ranges in SAP, list your number range(s) for component reservations. (Only internal number
12
assignment is allowed for reservation number within production orders.)
6.1.5 Define number ranges for operations

If you choose not to use the predefined number ranges in SAP, list your number range(s) for operations.
6.1.6 Define number ranges for capacity requirements

If you choose not to use the predefined number ranges in SAP, list your number range(s) for tracking capacity requirements.
6.1.7 Define control key

Indicate which business functions you will use in your routing.
Scheduling External processing Capacity planning Printing shop papers Inspection characteristics Costing Automatic goods receipt Processing of confirmations
6.1.7.1 Are setups used in capacity planning?
Yes No
6.1.7.2 Are formulas used for variable size items?
Yes No
6.1.8 Define (standard) trigger point usage

Trigger points are used to trigger certain functions, (i.e., operation release, insertion of reference operation sets) when the status of operation changes. A trigger point can be assigned to an order or routing.
Yes No
6.1.9 Are you planning to use trigger points?

If yes, please give some examples as to how
13
you will use trigger points.
6.2 Operations
6.2.1 Select which criteria you use for routing
selecting. When creating a routing using the copy function At the time of order creation (prior to release) During scheduling During costing
6.2.2 Select automatically

Will you use automatic routing selection for alternative routing?
Yes No
6.2.3 If yes, what type of criteria will you use? 6.2.4 Availability check
How do you process availability checks for material/components when creating production orders? Select where applicable.
All material must be available prior to creating/releasing order Create/release with shortages (not all material available) User decides on whether to release Check material in groups (grouping material based on material and/or MRP type) Material quantities confirmed in the availability check are to be locked Check ATP quantities Check accumulated ATP quantities Take into account replenishment lead time Take into account stock categories Take into account purchase requisitionsMRP Take into account purchase orders-MRP Take into account planned orders-MRP
6.2.5 What process do you use for checking

backorders?
Yes
6.2.6 Are capacity requirements (work orders,

14
planned orders) taken into consideration when scheduling?
No Forwards Backwards Only capacity requirements Current dates (The system schedules backwards from the basic date and then forward from the current date.)
6.2.7 Specify scheduling type

When scheduling production orders, what criteria does your organization use? Select where applicable.
6.2.8 Define time units

Do you use time units for scheduling (i.e., second, minute, decade, etc.)? If yes, list time units.
Yes No Yes No
6.2.9 Define key for performance efficiency rate

Do you use performance efficiency rates (actual work done by an employee vs. average work done)?
6.2.10 Define scheduling margin key

Select which type(s) of floats/buffers you use when scheduling order(s).
Float before production: This is the time between the order start date and the schedule start date. Float after production: This is the time between the order finish date and the scheduled finish date. Release period: Number of working days in the release period of an order.
6.2.11 Define move time matrix

Does your organization use move time between work orders?
Yes No
6.2.12 Define reduction strategies

Will you use reduction strategies reduces lead time if the basic dates given are not adhered to, or schedule dates lie outside of the basic dates? If you are currently using reduction strategies, what is your process?
Yes No
15
6.2.13 Define confirmation parameters

Confirmations are used for order monitoring. They can be performed at the operation and sub-operation level. Partial confirmation is the confirmation of an order that can still be processed. Select the area(s) in which your organization uses confirmation control.
Check dates Logs only warning messages or information messages Goods movement system to display all components assigned to the operation. Variances: Scrap on a quantity basis Excess consumption of activities Longer execution time
6.2.14
What inventory valuation does your organization use?
Price control (standard cost) delivered quantity is valuated with the standard cost. The difference between inventory valuation and credit posting to order is posted to the cost differences. Moving average cost.
7 Kanban
7.1
Will any stock points be situated directly at the production line or work center(s)? If yes, how many are there are how and they identified/named? Yes No
7.2 Replenishment Strategies

7.2.1 Which of the following will be used to control
the production of Kanban materials? Kanbans (cards) and a cost collector Planned orders and a cost collector Production orders
7.2.2 How will stock transfers need to be carried out?
using a stock transfer reservation using a direct transfer posting
16
7.2.3 For each status change, which of the following

should occur?
Automatic goods receipt Print Kanban card
8 Repetitive Manufacturing
8.1 Basic Settings
8.1.1 Define number ranges for run schedule headers
If you choose not to use the predefined number ranges in SAP, list your number range(s) for run schedule headers.
8.1.2 Define number of the number ranges for backlogs

If you choose not to use the predefined number ranges in SAP, list your number range(s) for backlogs.
8.1.3 Define number of number range for document log

If you choose not to use the predefined number ranges in SAP, list your number range(s) for document logs.
8.1.4 What repetitive manufacturing profile(s) does

your organization use or will use?
The data and costs incurred in production are assigned to the run schedule header and are settled. All the costs incurred in production are assigned to the cost collector where they are settled. (Production orders are not required.)
8.1.5 Select how cost collectors are created at your

company.
Automatically, when creating the run schedule header Manually, in the CO system.
17
8.1.6 Specify control data for repetitive manufacturing profiles.

Select the repetitive manufacturing profiles your organization plans to use.
Activities are automatically backflushed to the cost collector Discrepancies in backflushing are corrected manually The withdrawal of an item with a discrepancy is refused Master plan is reduced after a goods receipt Planned orders are recreated when reversing a backflush Reporting points for backflushes Goods receipt is automatically posted at the last reporting point backflush Goods receipt and a goods issue is posted when backflushing Only post goods receipt
8.2 Planning
8.2.1 Define planning periodicity
Select which planning period or buckets your organization uses when creating a run schedule header. (A run schedule header is an order in repetitive manufacturing for the production of finished products or semi-finished products that are produced on a repetitive basis over a longer period). Day Week Month Posting period
8.2.2 If you do not use capacity planning in repetitive

manufacturing, skip this section. You have two options for executing capacity leveling. Select which option(s) you plan to use in your organization.
via the planning table (spreadsheet format) via the graphic table that you access via the planning table
8.2.3 How will requirements be distributed?

Select one only.
Continuously (lineraly) Discretely to defined points
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8.2.4 Define distribution according to usage time

The distribution of orders is based on operating time that takes available capacity into account and shifts. Do you use operation time to distribute orders? If yes, what is your process?
Yes No
withdrawal of unrestricted stock-use stock withdrawal of consignment stock withdrawal of pipeline material
8.2.5 When backflushing, what sequence for material

withdrawal do you or will you use in your organization? Indicate using 1 3
8.2.6 Select which movements type you plan to use

in repetitive manufacturing. (Movements types are automatically used for backflushing.)
goods receipts goods issue scrap by-products movements referring to individual customer orders
8.3 Cost Object Controlling

8.3.1 Define generation of cost log
Does your organization log costs in repetitive manufacturing when backflushing activities? Yes No
8.3.2 Select which distribution rule for settlement

you will use.
full settlement settlement by period specifies variance calculation is done out by period cost collector is created automatically by the system, no search is required use search strategy to define which cost collector is used. If selected, choose one option below: on material is settled to one cost collector one material and one production version are settled using several cost collectors
8.3.3 Select which cost collector your organization

will use for backflushing in repetitive manufacturing.
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Production Planning Questionnaire