mrp & production planning - erpdb · mrp list use the mrp list to analyze the planning result...
TRANSCRIPT
MRP & Production Planning
Course Objectives
Understand the principles of Demand Management (DM)Define the Materials Requirements Planning (MRP) processDescribe how to valuate MRP planning runsPerform DM and MRP transactions
Module 1: Master Data
Module 2: Demand Management
Module 3: Material Requirements Planning
Module 4: MRP Planning Runs
Course Map
Module 5: Summary
Table of contents
PP flow & Integration
Sales & Ops Planning MRP
Capacity Req.Planning
Long TermCapacity Planning
Demand Management
Production Execution
CO(Cost
Control)
MM – LE(Stock
Control)
QM(QualityControl)
FI /CO MM
Master Data Related Transactions
Practice the following transactions
MM03 – Display Material MasterCS03 – Display BOMCR03 – Display Work CenterCA23 – Display Rate routingMM03 – Display Production Version
Module 1: Master Data
Module 2: Demand Management
Module 3: Material requirements Planning
Module 4: MRP Planning Runs
Course Map
Module 5: Summary
Table of contents
What is Demand Management?
Demand Management is used to determine requirement quantities and delivery dates for finished products Demand Management provides a demand program which is used by MRP to generate production plansDepending on the planning strategy chosen in the material master, the demand program can use forecasts of demand, actual demand, or combinations of bothActual demand is created in sales order management (customer orders) and materials management (warehouse replenishment)Forecasts of demand are represented by ‘planned independent requirements’ which are copied from the Sales and Operations Plan
What is the DM Process (1)?
SOP plans are transferred to Demand Management as ‘Independent Requirements’ for end products
The actual sales orders are for information purpose only and are not considered in planning.
In case the sales orders significantly vary from the forecasted demand; Planners revise the demand before running MRP to generate manufacturing orders and purchase requisitions
Who is Responsible for DM?
Planner (DEM)Responsible for managing the demand by comparing the actual demand with the forecast and manipulate the plan based on the actual demand before executing MRP
DM Related Transactions
Practice the following TransactionsMM03 – Display StrategyMD63 - Display Independent RequirementsMD04 - Display Stock Requirements ListMD74 – Reorganise Independent Requirements
Module 1: Master Data
Module 2: Demand Management
Module 3: Material Requirements Planning
Module 4: MRP Planning Runs
Course Map
Module 5: Summary
Table of contents
Materials Requirements Planning
MRP compares the requirements for end products, from Demand Management, with the current stocks and creates planned manufacturing orders
ManualManualentryentry
SOPSOPSalesSales PlanPlan
SOPSOPProductionProduction
PlanPlanMaterialMaterialForecastForecast
CopyCopyanotheranother
planplan
DemandProgram
MRPPlanning levels:
MaterialProduct groupVersions
Planning options:HorizonPeriod splitsHistory
MRP stands for: Materials Requirements Planning.
The function of MRP is to provide material availability, that is, it is used to procure or produce the requirement quantities on time. This process involves the monitoring of stocks and demand, leading to the automatic creation of procurement proposals for purchasing or production.
The main objective of MRP is to determine which material is required, the quantity required and by when it is required.
What is MRP?
What is the MRP Process (1) ?
MRP compares the requirements for end products, from Demand Management, with the current stocks and planned manufacturing orders
MRP chooses a Production Version which indicates the Bill of Material and Routing to be used
MRP then explodes the product BOM’s to determine the ‘dependent requirements’ for intermediate products and purchased raw materials
What is the MRP Process (2) ?
MRP will normally be run weekly.
The MRP process assumes infinite capacityThe Rough-Cut Capacity Planning check in SOP ensures that the loading is broadly correct before MRP runs.
MRP Type For the MRP procedure, use MRP type PDPD in the material masterMRP creates planned orders or requisition receipts to balance the demand planSafety stock can be used to cover unplanned requirements
Time
Receipts
Requirements
Who is Responsible for MRP?
MRP ControllerResponsible for running and operating the material requirement planning to check and track the planned requirement for both finished products and raw material in order to generate Production Orders and Purchasing Requisitions
Module 1: Demand Management
Module 2: Material requirements Planning
Module 3: Master Data
Module 4: MRP Planning Runs
Course Map
Module 5: Summary
Table of contents
Evaluations
There are several options for analyzing the Planning runMRP list
By materialCollectively
Stock requirements listBy materialCollectively
Printed MRP list
Planning Result
MRP list
MRP list
Use the MRP list to analyze the planning resultThe MRP list displays the future stock/requirements situation at the time of the last planning run By using the collective display, you can select a specific MRP list based on plant and MRP controllerAnalyze the exception messages in the MRP list, judge and or solve problemsUse the processing indicator to indicate that you checked the material
Planned order
Is the output of an MRP runAre automatically createdPlanned orders may be converted to production / process orders or purchase requisitions
MRP
Planned Order102030
Requirements
MRP Related Transactions
Practice the following exercise
MD01 Total Planning Run OnlineMD02 Single-Item, Multi-LevelMDBT Total Planning in BackgroundMD07 Stock Requirements List CollectiveMD05 Evaluate MRP ListMD44 Planning Situation Material