02_LO525_General Information.doc

8/12/2019 02_LO525_General Information.doc

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Chapter 1 Materials Planning: General

Information

Materials planning - complete overview

Master data

Basic information on consumption-based planning

Executing the planning run

Evaluating the planning run


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Chapter 1 b!ectives

"ou will have learned the position of materials

planning in the logistics chain and important #$P

terminolog" for materials planning

"ou will %now the master data re&uired for materials

planning

"ou will have learned the business basics of

consumption-based planning as well as the

procedure and the environment of this t"pe of

planning

"ou will %now how materials planning is carried outand the possibilities available for evaluating the

results

B" the end of this chapter:


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Materials Planning - 'omplete verview

'onvert

Planned

order

Indep(re&mts

)epedent re&mts

#ales and

distribution

processing

Reservations

Purchasing

functions

Purchase orders

#chedule lines

Purchase

re&uisition

*arehouse

Production

order

Invoice

verification

Materials

planning)emand

management

The main task of materials planning is to determine which material is required, the quantity required and when

it is required.

The internal planning elements of materials planning and of purchasing are the planned orders and thepurchase requisitions. Internal planning elements are known as order proposals.

The main focus of this course LO525 is external procurement.


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PurchasingPurchasingdatadata

Material Master RecordGeneral dataGeneral data

#torage location#torage locationdatadata

+orecast data+orecast data

'onsumption data

$ccounting$ccountingdatadata

MRP dataMRP data

Material number

)escription

,nit of measure

echnical data

MRP t"pe

Planned deliver".in-houseproduction time

/ot si0e

MRP controller

Procurement t"pe

Purchasing group

Goods receiptprocessing time

1aluation price

1aluation procedure

MRP indicator forstorage location

#pecial procurement t"pefor storage location

The data required for consumption!ased planning is stored in the material master record at plant le"el.


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MRP Procedures

MRP procedureMRP procedure

$utomatic reorder$utomatic reorder

point planningpoint planningManual reorderManual reorder

point planningpoint planning

MRPMRP'onsumption-based'onsumption-based

planningplanning

Reorder pointReorder point

planningplanning+orecast-based+orecast-based

planningplanningime-phasedime-phased

planningplanning

#s opposed to $%&, consumption!ased planning procedures are !ased on material consumption.

In reorder point planning, the system checks whether the a"aila!le stock le"el falls !elow the reorder pointdefined for the material. If it does, procurement must !e triggered. 'ou can determine the reorder pointmanually or, it can also !e calculated automatically using the material forecast.

In forecast!ased planning, historical data is used in the material forecast to estimate future requirements. Theserequirements are known as forecast requirements and are immediately a"aila!le in planning.

In timephased planned, historical data is also used in the material forecast to estimate future requirements.(owe"er, in this procedure, the planning run is only carried out according to predefined inter"als.

)or all consumption!ased planning procedures, sales orders, planned independent requirements, reser"ations,and so on are not rele"ant to planning.

In $%&, sales orders, planned independent requirements, reser"ations, and so on are planned directly asrequirements.

The $%& procedure is defined per material and plant. Therefore, the same material can !e planned in differentplants using different $%& procedures.


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'onsumption-Based Planning

+uture re&uirements are calculated from past

consumption values

It is assumed that the re&uirements are either

constant or linear

Irregularities in consumption are buffered b" a

safet" stoc%

*onsumption!ased planning procedures are especially useful+

for materials procured externally

for trading goods

for * materials #-* analysis

for operating supplies

for goods that are not directly procured for an order, !ut are always required in large quantities


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BM Explosion for 'onsumption-Based

Materials

$ssembl"

'omponents planned b"

MRP

)ependent re&mts.dependent reservations

Reorder pointReorder point

'omponents planned b"

consumption-based

procedures

/o dependent requirements are created for materials planned using any of the consumption!ased planning

procedures.


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'onsumption-Based Planning: Procedure and

Environment

MRP

2et re&mts calculation

/ot-si0e calculation

#cheduling

Inventor" mgmt

Material master+orecast

$$

MaterialMaterial

$

B B '

B

33Purchasing

)efine procurement

The main task of the planning run is to determine which material is required, how much of the material is

required and when it has to !e a"aila!le.

)or each requirement date, the system compares a"aila!le stock with requirements in the net requirementscalculation. If the requirements cannot !e co"ered !y existing stocks, the system calculates the shortagequantity.

In the lotsi0e calculation, the system groups the net requirement quantities according to the lotsi0ingprocedure selected.

These order quantities are then scheduled.


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'arr"ing ut the Planning Run

Planning run for one plant - online 4total planning5

Planning run for one plant - bac%ground processing

4total planning5

Planning run for one material - online 4single-item planning5

$$

MaterialMaterial

Plant


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Evaluating the Planning Result

Planning result with interactive processing options

2/6 $//*E) +R #I2G/E-IEM P/$22I2G BE+RE #$1I2G 7

MRP lists 4individual evaluation . collective evaluation5

'urrent stoc%.re&uirements list 4individual evaluation .

collective evaluation5


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MRP /ist /a"out for 'onsumption-Based

Planning

MRP listMRP list

Material information

2umber of exception messages

Processing indicator

'onsumption values

)ate

Exception message

Receipt.Re&mt &uantit"

$vailable &uantit"

1ariable header1ariable header

MRP elementsMRP elements

Planned orders

Purchase re&uisitions

Production orders

Pruchase orders

Plant stoc%.

#torage location stoc%

'ontents'ontents

+orecast re&uirementsPlanningPlanning

runrun

(

(

(

#ales orders

Reservations

The $%& list displays the results of the last planning run. *hanges to receipts, issues or stocks that occur

!etween planning runs are not displayed.

In the header of the $%& list, you can display "arious data for the material using the 1etailed header3 !utton.

The system creates exception messages for the e"aluation of critical situations. 'ou can search for theseexception messages in the $%& list.


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#toc%.Re&uirements /ist /a"out

'urrent stoc%.re&uirements list'urrent stoc%.re&uirements list

Material information

'onsumption values

)ate

Exception message

Receipt . re&mts &uantit"

$vailable &uantit"

1ariable header1ariable header

MRP elementsMRP elements

Planned orders

Purchase re&uisitions

Production orders

Purchase orders

Plant stoc% .

#torage location stoc%

'ontents'ontents

+orecast re&uirements

(

(

(

'ontents'ontentsre-read onre-read on

accessaccess

#ales orders

Reservations

The current stock4requirements list always displays the uptodate situation of receipts, issues and stocks. That

is, the contents of the stock4requirements list are reread each time the list is accessed.

The layout of the list is similar to that of the $%& list.

hen processing the stock4requirements list, you can always refresh the display.


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Evaluating the Planning Run ,sing the MRP

/ist

#election b" exception messages

#election b" MRP controller

#election b" stoc% receipt ranges of coverage

#election b" MRP date.processing date

#election b" materials with new exceptions

#election b" procurement

'ollective evaluation'ollective evaluation

#earch function- Exception messages

- Planning segments

- )ate of the MRP elements

Material memo

Period totals

Individual evaluationIndividual evaluation

The mass e"aluation of materials is carried out using the collecti"e display of the $%& list.

# series of selection criteria is a"aila!le for selecting the desired $%& lists.

'ou can define the layout of the collecti"e display per user using the sort functions.

# search function is a"aila!le for searching for exception messages or certain dates.


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Evaluating the #toc%.Re&uirements /ist

#election b" product group

#election b" class

#election b" MRP controller

#election b" vendor

'ollective evaluation'ollective evaluation

#earch functions

- Exception messages

- Planning segments- )ate of the MRP elements

Material memo

Period totals

Individual evaluationIndividual evaluation

The mass e"aluation of materials can also !e carried out using the collecti"e display of the current

stock4requirements list.


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Priority: if several exception messages exist for one MRP element, the system

will display the message allocated the highest priority

Creation of the MRP list depending on the exception message created

Splitting into exception gro!ps for the selection

Exception Messages

"he following settings can #e made in 'ustomi0ing:

Exceptions indicate:

2ew order proposals created in the planning r!n

$ates in the past%start, finish or opening date&

Pro#lems in BM explosion

Pro#lems in scheduling

Rescheduling


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/a"out of the Planned rder

Planned order

8eader

Material data.Plant

Procurement t"pe

#torage location

)ates

+irming

The planned order is the $%& controller3s planning tool for managing dates and quantities as well as the

procurement dates for co"ering requirements.

The system ad6usts planned orders automatically to suit changed dates or quantities.

To a"oid automatic ad6ustments, you can firm planned orders. )irm planned orders are not changedautomatically in the planning run.


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Chapter 1 Review 495

Materials planning relieves the MRP controller of routinewor% and automaticall" plans procurement proposals tocover material shortages(

In consumption-based planning the s"stem useshistorical data to forecast future re&uirements(

Materials planning can be executed as a total planning runfor all materials relevant to planning 4online or inbac%ground mode5 and as single-item planning for onematerial onl"(

6ou can evaluate the planning run using the followingevaluation tools:

MRP list 4displa"s the situation at the time of the lastplanning run5

current stoc%.re&uirements list 4up-to-date situation5

planning result 4interactive processing option beforesaving the results of the planning run5


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'hapter 9 Exercises: Executing the Planning Run

A new raw material is to #e planned in plant 1''' of the

company (or this p!rpose, the material master record is createdand the material is planned !sing the single)item planning r!n

1 Goto the main men! of the material master record:

Logistics Materials management Material master

* Create the material master record

+n the material master, select the f!nction:

Material Create (special) Raw material

nter the material n!m#er -./*/MM)00nter the indicator for mechanical engineeringSelect the p!sh#!tton for displaying the views and select thefollowing:

asic data

P!rchasing

MRP 1 and *

Acco!nting

Select the p!sh#!tton entitled, organi2ational levels and enterthe plant 1''', the storage location '''1 and the MRP profile-/*/

nter the #ase !nit of meas!re PCin the asic $ata screenand maintain a material description of yo!r choice

"he p!rchasing gro!p ''1 is responsi#le for p!rchasing "hematerial #elongs to the material gro!p ''1

Chec3 the data on the MRP screen 4hy is it not possi#le tooverwrite the planned delivery time5

66666666666666666666666666666666666666666666666


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Monthly cons!mption val!es are to #e created for thismaterial Starting from the MRP screen, select ExtrasConsumption +n the screen that appears, enter the periodindicator Mand the following cons!mption data

Previo!s month 78'

Previo!s month 1 7''

Previo!s month * 89'

Previo!s month 8 8'

Previo!s month 7 8/'

Previo!s month / 87'

Previo!s month ; 8/'

Previo!s month 8;'

Previo!s month < 87'

Previo!s month 9 8/'

Previo!s month 1' 87'

Ret!rn to the MRP screen #y selecting Back

+n the acco!nting screen, enter the val!ation class 8'''Select the standard price val!ation and enter a standard priceof =1'


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8 Save the material master record and then carry o!t materialsplanning for the material:

Access the MRP men!:Logistics Materials management Materials planning MRP

"o carry o!t the planning r!n, select,

Planning run Sng-item, Sng-level

+n the planning r!n, the system is only to create planned

orders An MRP list is always to #e created for the res!lts ofthe planning r!n

After the planning r!n, display the MRP list "o do this, select,

Evaluations MRP list!n"ivi"ual "ispla#

$isc!ss the res!lts of the planning r!n $isplay the detailedheader and scroll thro!gh it "o do this, select the p!sh#!tton,

$etaile" %ea"er"hen, access the stoc3>re?!irements list "o do this, select,

Evaluations Stock&re'mts list

+ncrease the ?!antity of the planned order #y 1'' pieces "odo this, position the c!rsor on the planned order and select,

Environment C%ange element

Change the ?!antity in the header of the planned order andret!rn to the stoc3>re?!irements list #y selecting, Back


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"hen refresh the display of the stoc3>re?!irements list "o dothis select:

ListReres%

@ow do yo! 3now that the planned order is firmed and whatdoes this mean5

66666666666666666666666666666666666666666666666

Convert the changed planned order into a p!rchasere?!isition

"o do this, position the c!rsor on the planned order and select:Environment Convert Pln"r"purre'

Chec3 the data in the following screen and save the p!rchasere?!isition Ret!rn to the stoc3>re?!irements list #y selecting,Back

After having done this, access the MRP list again 4hy canyo! not see the changes here5

66666666666666666666666666666666666666666666666


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'hapter 9 #olutions: Materials Planning in General

Executing the Planning Run

-o ;( *h" can "ou not overwrite the planned deliver"time3

"he planned delivery time cannot #e changed as it wasdefined Cannot #e overwrittenB in the MRP profile +f amaterial is created !sing an MRP profile, then the val!esthat were defined Cannot #e overwrittenB can only #e

changed #y changing the MRP profile

-o re?!irements sit!ation"o prevent man!al changes from #eing adE!steda!tomatically #y the planning r!n, yo! can firm orderproposals and sched!le lines (irmed elements are nolonger changed a!tomatically @owever, they can still #e

changed man!ally, and yo! can also reset the firmedindicator

*h" can "ou not see the changes between twoplanning runs in the MRP list3

"he MRP list contains the res!lts of the last planning r!n"his list is not !pdated !ntil the planning r!n is carried o!t

again"he stoc3>re?!irements list is availa#le for chec3ing c!rrent


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changes "he data in this list is !pdated every time it isaccessed

Documents

02_LO525_General Information.doc