361 bpp en us forecasting of make to stock products with configured materials

EHP4 for SAP ERP 6.0June 2010English

Forecasting of Make-to-Stock Products with Configured Materials (361)

SAP AGDietmar-Hopp-Allee 1669190 WalldorfGermany

Business Process Documentation

SAP Best Practices Forecasting of Make-to-Stock Products with Configured Materials (361): BPD

Copyright

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Icons

Icon Meaning

Caution

Example

Note

Recommendation

Syntax

External Process

Typographic Conventions

Type Style Description

Example text Words or characters that appear on the screen. These include field names, screen titles, pushbuttons as well as menu names, paths and options.

Cross-references to other documentation.

Example text Emphasized words or phrases in body text, titles of graphics and tables.

EXAMPLE TEXT Names of elements in the system. These include report names, program names, transaction codes, table names, and individual key words of a programming language, when surrounded by body text, for example, SELECT and INCLUDE.

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EXAMPLE TEXT Keys on the keyboard, for example, function keys (such as F2) or the ENTER key.

Example text Exact user entry. These are words or characters that you enter in the system exactly as they appear in the documentation.

Variable user entry. Pointed brackets indicate that you replace these words and characters with appropriate entries.

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Contents

Purpose .............................................................................................................................................. 5

Prerequisites........................................................................................................................................ 7

Master Data and Organizational Data..............................................................................................7

Business Conditions ........................................................................................................................ 9

Preliminary Steps............................................................................................................................. 9

Roles.............................................................................................................................................. 13

Process Overview Table....................................................................................................................14

Process Steps.................................................................................................................................... 15

Product Costing (Semi-finished Products and Finished Products).................................................15

1.2Optional: SOP........................................................................................................................... 15

1.3Create Planned Independent Requirements and Evaluation (Make-to-Stock Product) ............16

1.4MRP Run (Multi-Level) and Evaluation.....................................................................................17

1.5Evaluation of Total Requirements for Make-to-Stock Product...................................................18

2Follow-Up Processes.......................................................................................................................19

Make To Stock production (multilevel) with Configured Materials..................................................19

Appendix............................................................................................................................................ 19

Reversal of Process Steps.............................................................................................................19

SAP ERP Reports.......................................................................................................................... 20

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Forecasting of Make-to-Stock Products with Configured Materials

Purpose

The planning strategy explained in this scenario is designed for planning the procurement (production or purchasing) of components by planning the components themselves. This is particularly useful in the following cases:

There is a variety of finished products (possibly with an irregular demand pattern where planning is not possible).

The finished products are consumption-based.

The purpose of planning at component level is to procure components to stock (without sales orders) in order to react to customer demand as quickly as possible.

This strategy can be used if the components are not segregated (that is, they are not uniquely linked at specific orders), and the costs should be tracked at component (material) level, not at order level.

In this scenario, the material requirements planning scenario is used to create a six-month planning basis for a Make-to-Stock product (such as YM2000-002) in a make-to-stock environment. Based on planned independent requirements and depending on warehouse stocks, planned orders (for production) or purchase requisitions (for purchasing) are created across all BOM levels.

The Make-to-Stock product is required for the production of different finished products, such as YM1000. The finished product is then produced in a make-to-order environment.

The customer requires the material YM1000 (finished products) and informs plant 1000 of this need. A sales order is created for the customer requirement. The sales order automatically leads to a production requirement.

As the finished product is produced in a multilevel production process, the whole production process is divided into make-to-order and make-to-stock production.

1. Demand ManagementThe process starts with the manual creation of independent requirements for a Make-to-Stock material. Alternatively, a SOP (Sales and Operation Planning) could be executed. This is described in the Long Term Planning with Configured Materials -scenario (351).

2. Planned Independent Requirements ProcessingAfter creating the planned independent requirements, an 18-month forecast based on sales figures is available. The planned figures are divided into monthly values or weekly values.

The semi finished product is planned with the planning strategy 70. As part of material requirements planning using the net change method, the planned independent requirements are exploded across the entire BOM structure. As a result, the system also determines dependent requirements for purchased parts and raw materials.

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3. Material Requirements Planning (MRP)The daily MRP run generates replenishment elements at each low-level code. The system automatically generates purchase requisitions for purchased parts within opening period for the planned order, for example, three months. The system uses planned orders to implement receipt elements, which are also required.

In general, the system also creates planned orders for parts, which are produced internally. When the planned opening date has been reached, the production planner converts these planned orders into production orders. Some raw materials are planned on a consumption basis (for example, raw material gold).

4. Production of Make-to-Stock Product (Semi-finished and Finished Materials)The production planner releases the production orders. After processing, the goods issue of component, the time ticket, and the goods receipt of the Make-to-Stock product is booked. The Make-to-Stock product is now available on stock for the final assembly of different finished products

5. Production of Finished Product (Make-to-Order)A customer requirement initiates the production of the finished products. A customer order is created and directly triggers production requirement. The produced material will be stored in an individual customer stock.

Evaluation of Dependent Requirements

According to customer requirements, dependent and independent requirements on component level can be analyzed and evaluated.

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Prerequisites

Master Data and Organizational Data

Essential master and organizational data has been created in your ERP system during the implementation phase, such as the data that reflects the organizational structure of your company and master data that suits its operational focus, for example, master data for materials, vendors, and customers.

This master data usually consists of standardized SAP Best Practices default values, and enables you to go through the process steps of this scenario.

MaterialsMaterial Description Plant

YM1000 YM1000,FERT,MTO,CONFIG,PD,E 1000

YM2000 YM2000, HALB,MTS,CONFIG,PD,E 1000

YM2000-002 YM2000-002,HALB,MTS,VARIANT,PD,E 1000

RM30-010 RM30-010,ROH,PD,F 1000

RM30-020 RM30-020,ROH,PD,F 1000

RM30-030 RM30-030,ROH,PD,F 1000

RM30-001 RM30-001,HALB,MTS,ND 1000

RM30-002 RM30-002,HALB,MTS,ND 1000

RM30-003 RM30-003,HALB,MTS,ND 1000


RM30-003 RM30-003,HALB,MTS,ND 1000

RM30-001 RM30-001,HALB,MTS,ND 1000

RM30-002 RM30-002,HALB,MTS,ND 1000


RM20-001 RM20-001,ROH,PD,JIT,F 1000

RM20-002 RM20-002,ROH,PD,KANBAN,JIT,F 1000

RM20-003 RM20-003,VERP,VB,HU,F, BULK 1000

Storage locationsMaterial Description Storage

location

YM1000 YM1000,FERT,MTO,CONFIG,PD,E 1020

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Material Description Storage location


YM2000-002 YM2000-002,HALB,MTS,VARIANT,PD,E

1020

RM30-010 RM30-010,ROH,PD,F 1050, 1020

RM30-020 RM30-020,ROH,PD,F 1050, 1020

RM30-030 RM30-030,ROH,PD,F 1050, 1020

RM30-001 RM30-001,HALB,MTS,ND 1050, 1020

RM30-002 RM30-002,HALB,MTS,ND 1050, 1020

RM30-003 RM30-003,HALB,MTS,ND 1050, 1020


RM30-003 SCRAP NON LAMINATED, ND 1050, 1020

RM30-001 SCRAP GOLD, ND 1050, 1020

RM30-002 SCRAP EPOXY, ND 1050, 1020


RM20-001 RM20-001,ROH,PD,JIT,F 1050, 1020

RM20-002 RM20-002,ROH,PD,KANBAN,JIT,F 1050, 1020

RM20-003 RM20-003,VERP,VB,HU,F, BULK 1020

Bill of Material StructureThis overview shows the bill of material structure for the finished products YM1000, F234-1 and F234-2

MaterialLevel

Materialtype

Unit Characteristic of material

Optional Enhancements

YM1000 0 FERT EA Configurable materialYM2000 .1 HALB EA Configurable material Variants can be used as componentsYM2000-002 .1 HALB EA Variant of configurable

material YM2000RM30-010 .1 ROH EARM30-020 .1 ROH EARM30-030 .1 ROH EARM30-001 .1 ROH EARM30-002 .1 ROH EARM30-003 .1 ROH EAYM3000 ..2 HALB EA Configurable material Variants can be used as componentsRM30-003 3 ROH EA

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MaterialLevel

Materialtype

Unit Characteristic of material

Optional Enhancements

RM30-001 3 ROH EA

RM30-002 3 ROH EA

YM4000 3 HALB LB Configurable material Variants can be used as components

RM20-002 .1 ROH EA KANBAN external procurementRM20-003 .1 ROH EA using dependencies to calculate qty

Sales DataMaster data Value Master data

detailsComments

Material YM1000

Sold-to party 100003

Ship-to party 100003

Plant 1000

Shipping point 1000

Sales organization 1000

Distribution channel 10

Division 10

Business Conditions The business process described in this Business Process Documentation is part of a bigger chain of integrated business processes or scenarios. As a result, you must have completed the following processes and fulfilled the following business conditions before you can start any activities in this scenario:

Business Condition Scenario

You have completed the step Roll MM Period to Current Period, described in the Business Process Documentation Prerequisite Process Steps (154). Perform this activity if the MM period in the system is not set to the current period. Usually, this activity has to be done once a month.

Prerequisite Process Steps (154)

Preliminary StepsThis Business Process Documentation (BPD) contains process steps that have to be performed as prerequisite before you can start to work through the standard Business Process Documentations of selected logistics scenarios.

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1.1.1 Optional: Remove Batch Management Requirement for Finished Product, Semifinished Product and Raw Materials

This step can only be done if there is no stock movement or any open transactional document. For more information, see Note 533383.

In this step, the process runs with batch management (default). Batch management can be deactivated for this process.

UseThe batch management requirement for all materials is optional in this scenario.

If you do not want to execute the batch management requirement, you must carry out the following steps.

Procedure 1. Access the transaction choosing one of the following navigation options:

Option 1: SAP Graphical User Interface (SAP GUI)

SAP ECC menu Logistics Materials Management Material Master Material Change Immediately

Transaction code MM02

Option 2: SAP NetWeaver Business Client (SAP NWBC) via business role

Business role Engineering Specialist (SAP_NBPR_ENGINEER-S)

Business role menu Engineering Master data Material Master Change Material

2. On the Change Material: initial screen, make the following entries and choose Enter:

Field name Description User action and values Comment

Material YM1000

3. On the Select View(s) Screen, select the Purchasing or Work Scheduling view and choose Enter.

4. On the Organizational Levels screen, make the following entry:


Plant 1000 Production Plant

5. Choose Enter.

6. On the Purchasing or Work scheduling tab page, make the following entry:


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Batch management

Deselect remove existing value

7. Save your entries and go Back (F3) to the SAP Easy Access Screen (SAP GUI) or:choose Exit (Shift+F3) and confirm the Business client message with Yes to return to SAP Home (SAP NetWeaver Business Client).

ResultThe batch management requirement is removed.

1.1.2 Create User Settings for Requirement Planning

UseIn this step, you set up the user settings necessary for requirement planning.

Procedure1. Access the transaction choosing one of the following navigation options:


SAP menu Logistics Materials Management Inventory Management Environment Stock-Stock/Requirements List

Transaction code MD04


Business role Production Planner (SAP_NBPR_PRODPLANNER-S)

Business role menu Production Evaluations Reports Stock/Requirements List - Individual Display

2. On the Stock/Requirements List: Initial Screen, make the following entries:


Material number YM1000 Finished Good MTS


3. Choose Enter.

4. From the menu list, navigate to Environment Navigation Profile Assign.

5. Choose the General Settings tab page.

6. In the Navigation Profile field, choose the navigation design SAPPPMRP00 MRP Controller.

7. Choose Save and confirm the information message.8. Go Back (F3) to the SAP Easy Access Screen (SAP GUI) or:

Choose Exit (Shift+F3) and confirm the Business client message with Yes to return to SAP Home (SAP NetWeaver Business Client).

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ResultYou have created the user settings necessary for the requirements planning.

1.1.3 Assign User Parameter CORUPROF to User Master Record

Use In this step, you assign a profile to your user which defines the layout for the confirmation screen for single screen entry.

Procedure 1. Access the activity using one of the following navigation options:


SAP ECC menu Tools Administration User Maintenance Users

Transaction code SU01


Business role IT Administrator (Professional User) SAP_NBPR_IT_ADMIN-S

Business role menu Administration User Management User Maintenance

2. On the User Maintenance: initial screen, make the following entry:


User Enter your SAP-User

3. Choose Change.

4. On the Maintain User screen, choose the Parameters tab page and make the following entries:


Parameter ID CORUPROF

Parameter Value

YBDI02

5. Save your entries and go Back (F3) to the SAP Easy Access Screen (SAP GUI) or:Choose Exit (Shift+F3) and confirm the Business client message with Yes to return to SAP Home (SAP NetWeaver Business Client).

Note: If you have authorization problems using the transaction SU01, you can also maintain your own user data directly by selecting System -> User Data -> Own Profile from the menu (only in SAP ECC).

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Result The confirmation profile YBDI02 is assigned to your user.

Roles

UseThe following roles must have already been installed to test this scenario in the SAP NetWeaver Business Client (NWBC). The roles in this Business Process Documentation must be assigned to the user or users testing this scenario. You only need these roles if you are using the NWBC interface. You do not need these roles if you are using the standard SAP GUI.

PrerequisitesThe business roles have been assigned to the user who is testing this scenario.

Business role Technical name Process step

Warehouse Clerk SAP_NBPR_WAREHOUSECLERK-S

Initial Stock Posting (MB1C)Posting Goods Receipt for Production Order (MIGO)

Strategic Planning SAP_NBPR_STRATPLANNER-S

Evaluation of planning situations (MD73)

Sales Administrator

SAP_NBPR_SALESPERSON-S

Create Sales Order (VA02)Create Outbound Delivery (VL01N)

Production Planner SAP_NBPR_PRODPLANNER-S

Change Independent Requirements (MD62)

Warehouse Clerk SAP_NBPR_WAREHOUSECLERK-S

Cancel material document (MBST)

ResultYou can now process this scenario.

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Process Overview TableProcess step External

process reference

Business condition

Business role Trans-action code

Expected results

Product Costing Prerequisite process steps(154)

See scenario 154

See scenario no. 154

CK40N Standard cost estimation for semi-finished and finished products, price update

Create SOP

(optional)

Scenario Long Term Planning (351)

Demand Planning for Make-to-Stock product

Demand Planning (Make-to-Stock Product)

MTS production (multilevel) with Configured Materials (360)

See scenario 145


MD61 Demand Planning for Make-to-Stock product

Display Stock/Requirements List (Make-to-Stock Product)


See scenario 145


MD04 Review planning situation for Make-to-Stock product

Material Requirements Planning at Plant Level


See scenario 145


MD02 Multi-level MRP run for the material

Display Stock/Requirements List (Make-to-Stock Product)


See scenario 145


MD04 Review planning situation for Make-to-Stock product

Evaluation of Total Requirements for Make-to-Stock Product

Strategic Planning

MD73 Evaluation of planning situation for the Make-to-Stock product

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Process Steps

Product Costing (Semi-finished Products and Finished Products)

UseThe purpose of this activity is to perform product costing.

PrerequisitesThis is a periodic step. You only need to perform it once a month. This step should be normally executed at the beginning of every month. If you execute it for the first time, use the current date.

Prerequisite Process Steps (154)

ProcedureTo execute this activity process the following steps using the master data from this document (see also table below):

Steps to process from scenario Prerequisite Process steps (154) Product Costing: Costing Run

Master data Value Other mat.

Bus. cond.

Comments

Material type HALB For the purposes of Fabricated Metals, only the material YM2000-002 is relevant to this scenario, choose only this material. The other materials are part of Baseline.


Result The standard price of the materials is updated.

1.2 Optional: SOP

LTP with Configured Materials (351)

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UseThis procedure allows you to perform long term planning using the Sales and Operations Planning (SOP) with simulations. Once the forecasts have been created in the SOP, they will be transferred into the independent requirements.

ProcedureTo execute this activity, process the scenario LTP with Configured Materials (351) using the master data from this document (see also table below):


Bus. cond.

Comments

Material YM2000-002 Make-to-Stock product


Planning period M

Amount 100 For the next 18 months

ResultThe planned independent requirements have been created by copy of the quantities in the SOP.

1.3 Create Planned Independent Requirements and Evaluation (Make-to-Stock Product)

UsePlanned independent requirements are used to perform demand management functions. A planned independent requirement contains either one planned quantity and one date or a number of planned independent requirements schedule lines, that is, one planned quantity split over time according to dates.

Instead of creating single requirement, sometimes a requirements plan that includes one or more planned independent requirements can be maintained for mass processing. In this case, the requirements are grouped and maintained under a requirement plan number.

In this scenario, the Make-to-Stock product is planned in advance for the next six months.

This step is not required if you used the SOP to create independent requirements.

Anonymous Forecast and MRP (145)

Procedure

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To execute this activity, process the following steps using the master data from this document (see also table below):

Steps to process from scenario Make-to-Stock Production Discrete Industry (MTS) (145)Creating Planned Independent Requirements

Evaluation of the Stock/Requirement List


Bus. cond.

Comments

Material YM2000-002 Make-to-Stock product


Planning period M

Amount 100 For the next 6 months

ResultIn the Stock and Requirements List, you find the independent requirements for the Make-to-Stock goods (YM2000-002). They appear as MRP element data VSFB (Planning for assemblies).

1.4 MRP Run (Multi-Level) and Evaluation

UseMRP run is performed regularly. The run compiles the requirements from the independent planned requirements, the individual sales requirements, already existing planned orders, and available stock.

Planning is performed for the Make-to-Stock product (YM2000-002). All BOM items of the material are planned.

Prerequisites Requirement changes are made (sales order, independent planned requirements)

The MRP type PD must be entered in the material master. This can be checked in view MRP1 of the material master (as described in the step Planned Independent Requirements Prerequisites).

Anonymous Forecast and MRP (145)

ProcedureTo execute this activity, process the following steps using the master data from this document (see the table below):

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Steps to process from scenario Make-to-Stock Production Discrete Industry (MTS) (145)Material Requirements Planning at Plant Level

Evaluation of the Stock/Requirement List

Field name Description User action and values

Comment

Material YM2000-002 Make-to-Stock product (for MRP and evaluation step)

Raw material (use only in evaluation step)

Plant 1000 Production plant

ResultIn the stock and requirements list, the dependent requirements to produce the Make-to-Stock product (YM2000-002) and their components are listed. If sufficient stock is available, no requirements will be generated.

1.5 Evaluation of Total Requirements for Make-to-Stock Product

UseThis activity describes one way to analyze the planning situation of a forecasted material, in this case the Make-to-Stock product (YM2000-002).

PrerequisitesIndependent requirements and dependent requirements and/or reservations and/or customer orders exist for a material.

Procedure1. Access the transaction choosing one of the following navigation options:


SAP system Logistics Production Production Planning Demand Management Evaluations Display Total Reqmts

Transaction code MD73


Business role Strategic Planner (SAP_NBPR_STRATPLANNER-S)

Business role menu Production Production Planning Demand Management

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(DM) Display Total Requirements

2. On the Display Total Requirements: Initial Screen, make the following entries:

Field name User action and values Comment

Material YM2000-002

Plant 1000

Output List 1 Check also for entry 2

3. Choose Enter.

4. Analyze the planning situation and allocation of independent and dependent requirements.5. go Back (F3) to the SAP Easy Access Screen (SAP GUI) or:

Choose Exit (Shift+F3) and confirm the Business client message with Yes to return to SAP Home (SAP NetWeaver Business Client).

ResultYou have analyzed the planning situation for forecasted Make-to-Stock product.

2 Follow-Up ProcessesYou have finished all activities that are part of the business process described in this document.

To accomplish subsequent activities of this business process, carry out the process steps described in one or more of the following scenarios, using the master data from this document.

Make To Stock production (multilevel) with Configured Materials


UseIn this activity you run a multilevel MTS production with variants using discrete manufacturing.

ProcedureComplete all activities described in the Business Process Documentation of the scenario (360) - MTS production (multilevel) with Configured Materials using the master data from this document.

.

Appendix

Reversal of Process StepsIn the following section, you can find the most common reversal steps, which you can take to reverse some of the activities described in this document,

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Create independent requirements for Make-to-Stock productTransaction code ( SAP GUI) MD61

Reversal: Change Independent Requirements

Transaction code (SAP GUI) MD62

Business role Production Planner (SAP_NBPR_PRODPLANNER-S)

Business role menu Production Production Planning Demand Management Change Planned Indep. Requirements

Comment Delete line items in planning table. MRP has to be rerun in order to correct dependent requirements

SAP ERP Reports

UseThe table below lists the reports that you can use to obtain additional information on this business process.

You can find detailed descriptions of the individual reports in the following BPD documents, which provide a comprehensive compilation of all important reports:

Logistics Processes: SAP ERP Reports for Logistics (222)

The descriptions of reports that are an indispensable part of the process flow may be located directly in the section where they belong.

ReportsReport title Transaction

codeComment

Capacity Planning CM01 The capacity evaluation is displayed.

Missing Parts Info System CO24 A list of missing parts.

Production Order Information System COOIS A list of all production orders.

MRP List MD05 The stock/requirements situation at the time of the last planning run.

Stock Overview MMBE A list of stock is displayed.

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CopyrightIconsTypographic ConventionsContentsPurposePrerequisitesMaster Data and Organizational DataStorage locationsBill of Material StructureSales Data

Business ConditionsPreliminary Steps1.1.1 Optional: Remove Batch Management Requirement for Finished Product, Semifinished Product and Raw MaterialsUseProcedureResult

1.1.2 Create User Settings for Requirement PlanningUseProcedureResult

1.1.3 Assign User Parameter CORUPROF to User Master RecordUseProcedureResult

RolesUsePrerequisitesResult

Process Overview TableProcess StepsProduct Costing (Semi-finished Products and Finished Products)UsePrerequisitesProcedureResult

1.2 Optional: SOPUseProcedureResult

1.3 Create Planned Independent Requirements and Evaluation (Make-to-Stock Product)UseProcedureResult

1.4 MRP Run (Multi-Level) and EvaluationUsePrerequisitesProcedureResult

1.5 Evaluation of Total Requirements for Make-to-Stock ProductUsePrerequisitesProcedureResult

2 Follow-Up ProcessesMake To Stock production (multilevel) with Configured MaterialsMTS production (multilevel) with Configured Materials (360)UseProcedure

AppendixReversal of Process StepsSAP ERP ReportsUse

361 bpp en us forecasting of make to stock products with configured materials

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