consolidated pp questions 06.26.2010

8/13/2019 Consolidated PP Questions 06.26.2010

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Consolidated Interview Questions in SAP PP

1. Can MRP be carried out for one particular level of a bom ( Level code !!!1"!!!# etc$.

Yes it can be done by running for specific materials (Single Material Single Level)

# %ow Re&uiements( PIR'Sles rder' Customer Re&uirement$ are reduced after t)e* areproduced+

Reqmts are reduced automatically after Delivery is made to the Particular rder(!n case of Strategy ""# the P!Rs are consumed after the $R for Production rder)

,. Can-t one material be assi ned to more t)an one operation in a routin + ne material from a % M &' be assigned to different perations*

!t can be done by defining the material for so many times as required in the % M

/. 0)ere we )ave to specif* t)e teardown time in one operation+ eardo+n time can be defined as one of the Standard Parameters***

. %ow t)e process time is calculated in a 0C w)en bot) labour' Mac)ine cate ories e2ist+ Scheduling is done based on the &apacity &ategory +e define in the ,or-center

3. %ow to create opb4ect dependencies in a 5 M 6 R A C 76I89RA5L: MA;:RIAL+ $o to ./tras 01 b2ect Dependency 01 'ssign3or this 4 need to create &haracteristics and &lass (of &lass ype 566) earlier

<. Can an* bod* e2plain me w)* wor= sc)edulin view is re&uired for semi finis)ed andfinis)ed products+

(5ecause we-ll mention all details in MRP views$ ') ,e need to maintain +or-ing scheduling vie+ in order to ma-e that finished or semi finished goodsavailable for production as +e assign production scheduler and production scheduler profile in thisvie+# if not maintained conversion of planned order to production +ill not be possible*

1. 0)ic) is t)e )i )est or anisational level in SAP

a) Plant b) &lient c) Storage Location

'ns7 b

#. 6or Material Master record PP >ata w)ic) is t)e )i )est or anisational level


'ns7 a

,. 0)at is t)e difference between 61 %elp ? 6/ %elp.

a) 3" is for possible values and 38 is for application helpb) 3" is for 'pplication 9elp and 38 is for echnical 9elpc) 3" is for 3ield 9elp and 38 is for possible entries*d) one of the above

'ns7 c



a) Ma-e : to : stoc- .nvironmentb) Ma-e : to : rder .nvironmentc) Spare parts Saled) Repetitive Manufacturing .nvironment

'ns7 a

. Confi urable Material c)ec= for a material is set in

a) %asic Data b) MRP ;ie+c) Sales ;ie+ d) &lassification

'ns7

3. 5asic >ata screen contains eneral data suc) as

a) Material umberb) Material descriptionc) %ase unit of measured) echnical data

'ns7 a# b# c

<. 6unctions of Classification are

a) o find an appropriate ob2ectb) o find similar ob2ectsc) o establish that no appropriate ob2ect e/ists*

'ns7

<* .ntering =>o? in command field

a) .nds current transactionb) .nds the current cessionc) pens ne+ cessiond) pens ne+ transaction

'ns7

@* 3or creating Material Master the follo+ing ransaction &ode is used 7

a) md6"b) mm6"c) me6"d) mc6"

'ns7 b

1!. ;)e unit in w)ic) t)e stoc= =eepin is done in a compan* is called

a) Stoc- unit of measureb) %ase unit of measurec) 4nit of issued) Purchase unit of measure

'ns7 b



11. 5atc) is

a) Same as material codeb) Partial quantity of material managed separately from other quantity of same material in stoc-c) ' non reproducible homogeneous unit +ith unique specificationsd) one of abovee) 'll of above

'ns7 b

1#. A is a complete' formall* structured list of t)ecomponents t)at ma=e up a product or assembl*.

'ns7

1,. Component in t)e 5 M are allocated to operation in

a) % Mb) Material Masterc) Routingd) ,or- &enter

'ns7 c

1/. 5 M contains t)e followin

a) List of &omponentsb) Aty of &omponentsc) peration to +hich components is attached*d) 4nit of Measure of components

'ns7

1 . 5 Ms are alwa*s created as

a) Single Levelb) Multi Levelc) &omponentsd) 'long +ith routings

'ns7 a

Question 0)at is t)e name of t)e plannin level for t)e MRP run+

'* S P%* MP&* MRPD* & P'

Question 0)at are t)e main features of t)e MRP t*pes -P>- or -@5-+

'* BPDB can only be used +ith B et &hange PlanningB%* B;MB can only be used in total planning



$uess that planned orders have been created +ithout capacity requirement indicator in MRP (C C 0Lead ime scheduling)# if this is the case# then +hen converted to process orders they +ill haveimpact on the Resource* !f you +ant to see them as planned orders# re0run the MRP or change inevery planned order# going to the Menu7 .dit 001 Scheduling

'nother couple of possibilities are to do +ith the routing>+or- centres used and +hether it isactuallycalculates consumption of capacity of the category at the +or- centre being displayed in &M6" (itmight consume a capacity pool or it might not consume the category)*

0)at is t)e output of MPS run+

3rom MPS run you plan the materials +hich are of B'B type in the abc analysis (<6E dollar value) thathave to be planned before hand*MPS is also a type of MRP only in +hich components 2ust belo+ the materials on +hich MPS run ista-en place# are planned*

>ata dictonar* table for S P plannin data B Dou are usin Standard S P (Info structure S!<3$'in w)ic) table can *ou see t)e plannin values t)at *ou maintained in MCE, transaction+

Dou loo=ed under table FS!<3F and did not see an* values t)ere.

4se *&ode M&@F to display your entries under the version +hich maintained the the table S6GH*

Production order operation-s component allocation B %ow does SAP =now t)at an operation)as components as indicated b* t)e component allocation indicator+ ;code C !G.

&omponent allocation is done via routing maintenance or % M maintenance for the assembly* his ismaster data maintenance* 's soon as a P is created# the master data is read into the P *

1. A plant can be a p)*sical plant or a lo ical section of a plant

a) Yes b) o*

'ns7 a

Stora e locations are areas w)ere materials are stored wit)in a plant

a) Yes b) o*

'ns7 a

A purc)asin or ani ation can bu* for a number of plants

a) Yes b) o*

'ns7 a



a) Yes b) o*

'ns7 a

#. Strate * 8roup is relevant for Material Re&uirement Plannin

a) rue b) 3alse

'ns7 a

,. MRP can be caried out at

a) Plant Levelb) 'll Routingsc) Single item : single leveld) Single item : multiple level

'ns7 a# c# d

/. In Material Re&uirement Plannin

a) Material availability is ensuredb) !f shortage e/ists the corresponding elements are plannedc) Stoc- transfers are also possibled) he availability of the components is ensured via dependent requirements

'ns7 d

. 0it) Ma=e H to Stoc= strate * 1!

a) MRP run considers only Sales rdersb) MRP run considers only P!Rc) MRP run considers both Sales rder I P!Rd) Sales rder can consume P!R

'ns7 b

3. ;)e Individual " Collective indicator in t)e material Master determines

a) ,hether a component is procured for a special customer requirement in the individual segmentb) Requirement quantities of dependent materials are grouped together during MRP runc) he Material Requirement Planningd) he Special Procurement*

'ns7 c

<. A;P H Available to Promise (Availabilit* c)ec=$

a) System chec-s if all issues are covered by e/isting receiptsb) &hec-s if receiptsJ quantity still available to cover ne+ly received issues

'ns7 a

G. Availabilit* C)ec= PIRs



S*stem does not c)ec= a ainst PIRs

a) rue b) 3alse

'ns7 b

7o A;P &uantities' receipts or stoc=s are included

a) rue b) 3alse

'ns7 b

>etermines if sufficient PIRs are planned to cover a S

a) rue b) 3alse

'ns7 b

11. 6or Plannin at P)antom Assembl* Level planned orders are created for P)antomassembl*

a) rue b) 3alse

'ns7 b

1#. Stoc= Re&uirements List ives situation of stoc= re&uirement for t)ematerial

a) Static 7 of the last MRP Runb) Dynamic 7 ./isting at current situation

'ns7 b

1,. Is Sales order A Qt*. 1 PC and Sales order 5 Qt*. # PC are boo=ed on same date andstoc= is ! PC

a) Separate Planned rder for each Sales rder shall be created if individual indicator is setb) nly one planned order is created if individual indicator is setc) Separate Planned rder for each Sales rder shall be created if &ollective indicator is setd) nly one planned order is created if &ollective indicator is set

'ns7 a# d

1,. Plannin can create t)e followin after MRP run

a) Planned rdersb) Production rdersc) Purchase rdersd) Schedule Lines

'ns7 a# b

1/. 7:;C% is

a) 4sed in Demand Managementb) Key to run MRP for otal hori onc) Key to run MRP for otal Planning hori on



'ns7 c

1 . Re enerative Plannin

a) Plans all material for a specified plantb) Plans all material for a specified plant for total planning hori onc) Stands practical for the first time planning run

'ns7

A*" ,hat is ' P 9o+ can you configure itJs components in the System ./plain about itJscomponents too*

A* ,hatJs the difference bet+een Daily Requirements and &ollective requirements chec-

A*5 ,hat are the planning strategies have you used ./plain Planning +ith 3inal assembly (86) andPlanning +ithout final assembly (F6) planning strategies !n Material Master +here you definePlanning strategy (on +hich vie+ )

A*8 ,hat is %asic dates scheduling and Lead time scheduling

A*F 9ave you +or-ed on %atch Determination ./plain me +hat are the %atch LevelJs are available,hat do you configure for the %atch determination 9o+ it +or-s

A*H ell me about lot si ing procedure 9o+ it +or-s !n the Material Master +here do you define Lotsi ing procedure -ey

A*G ./plain about MRP types

A*< ,hat -ind of configuration have you done in PP ell me fe+ things about configuration*

A*@ ,here do you chec- availability chec- for Production rder 9o+ do you configure it in thesystem

A*"6 9ave you used 4S.R ./it 9o+ do you find 4S.R ./it in the system

A*"" ,hat is Routing for ell me types of Routings* ,hat are the configuration you do for Routings

A*" ./plain me about &apacity .valuation and &apacity Leveling* ,hat transaction code have youused for that

A*"5 ./plain the Production steps in the PP +ith ransactions*

A*"8 9ave you done testing ,hat type of testing ./plain the steps of each testing that you havedone Li-e any test scenario or any test process have you developed

A*"F ,hat is Production ;ersion ,hy it is useful

A*"H ,hat is ;ariant &onfiguration ,hat -ind of Settings you have maintained for the ;& inProduction Planning Process

A*"G ,hat is Super % M

A*"< ell me +hat are the %atch Levels



A*"@ ,hat is Movement types ell me the Movement types that you have used in PP also e/plainthe purpose of each*

A* 9o+ do you configured Production rder ,hat do you configured for rder type

A* 5 +hat do you configured for the confirmation (shop floor control)

"* ,hat is scheduling* ,hat is control -ey significance +rt +or- center

5* Difference bet+een cost center and +or- center8* ,hat is bac-flushF* ,hat is revision levelH* ,hat is the difference bet+een configuration and customi ationG* ,hat -ind of specifications go into +or- center<* ,hat are the terms %D&# LSM,# &'@* $roup counter usages in routing"6* &omponent 'llocation usage""* ,hat is control -ey function in routing" * Difference bet+een strategies "6 and """5* ,hat are the -ey fields in schedule margin -ey"8* ,hat are the configurations required for production order"F* ,hat are order types and +hat are the standard order types"H* ,hat is the movement type for $oods !ssue and $oods Receipt"G* ,hat is the transaction code for confirmation"<* ,hat are the tables corresponding to % M"@* Difference bet+een repetitive and discrete manufacturing

6* ,hat do you configure in planning strategies"* ,hat are the parameters involved in S GH

* ,hat is the version used in S P5* ,hat do you do in demand management8* 9o+ do you transfer from S P to demand managementF* ,hat are the required things for MPSH* ,hat is the frequency of MRP runG* Do you run MRP for R 9# components or 3.R<* ,hat is fle/ible planning@* ,hat do you do in S P# +hat does it constitute

56* ,here do you use S P discrete or repetitive5"* !f you are configuring info structures# +hat is the numbering you use ,hat are S'P info

structures

MRP roups are used +hen the plant division for planning is not enough for the division of thedifferent materials MRP requirements* You assign different groups according to the requirements torun MRP (different Settings)* hese settings +ill be ta-en in account +hen you run MRP for single itemor total planning*

MRP controller is the person in charge of the MRP run for the materials* !t is still a further division onyour MRP* his is +or- load related* You can have one MRP controller for materials +ith differentMRP groups*

n your MRP group# you +ill define the parameters for the MRP run* hese parameters are calculatedin accordance +ith the settings on your material master MRP vie+s*

'vailable stoc- NPlant stoc- 0 safety stoc- O



receipts of (purchasing orders O purchasing agreements O production orders) 0 requiredquantity*

his means that all the requirements are calculated in the bases of your material master settings andyour MRP group settings*

0)at if not)in )appens w)en *ou run MRP+

he reasons could be 70

0 You have purchase requisitions that are delayed but the delivery time has not been updated on thesystem*

0 he settings on your material MRP screens are not correct# i*e* your material have not yetentered the re0order point level*

0 Your requirements have not been ta-en in account +hen running MRP*

'ssuming that everything is +ell and the requirement has been calculated# go to transaction codeM>!/ and verify that the different requirements are reflected in the MRP list and also if there is anypurchase requisition scheduled by the system* ;erify also if there is any other delivery schedule that+ill e/ceed the actual requirements*

!f the purchasing requisition is there# the only thing that you have to troubleshoot is the message to tellyou that the purchasing requirement +as calculated*

!f the requirement is not there# re0visit your material master and chec- your settings for the MRPgroup*

0)at is t)e real meanin and usa e of t)e followin s confi ured in PP1. MRP Controller#. Sc)edule mar in =e*,. MRP roup/. MRP profile.

"* MRP &ontrollerhis +ill help you to group the material for some controlling purpose* You can run mrp by mrp

controller*you can do evaluation by mrp controller* his +ill help us if have different people in one organisationinvolved in purchasing*

* Schedule margin -ey

his +ill help you to determine the floats* !n case if you have production order you can see the impactof floats

5* MRP group

his +ill help you for the material to reac in tems of the settings made relavant to each group* o-no+ more details on the group you can che- the tcode oppr*

8* MRP profile

,e can have some prefi/ed datas in the profile and and +e can enter teh profile for diff material so thevalues +ill copied as defaulted in the profile*



") &ustomi ation of Material Master a* 9o+ does material t*pe selection affect the flo+

,hether the material is intended for a specific purpose# for e/ample# as a configurablematerial or process material

Q ,hether the material number can be assigned internally or e/ternally Q he number range from +hich the material number is ta-en Q ,hich screens appear and in +hat sequence Q ,hich departmental data you may enter Q ,hat procurement type the material has that is# +hether it is manufactured in0house or procured e/ternally# or both

0 ype of inventory management (quantity>value)0 'ssignment of account categories and reference0 3ield selection and screen se+quence0 $eneral indicators (pricing for popleline# process or configurable)0 &osting control0 !tem &ategory in SD

0 'uthori ation group

ogether +ith the plant# the material type determines the materialBs inventory managementrequirement that is7

Q ,hether changes in quantity are updated in the material master record Q ,hether changes in value are also updated in the stoc- accounts in financial accounting!n addition# the accounts affected by a material entering or leaving the +arehouse depend on thematerial type*

3inished products (3.R )3inished products are produced in0house* Since they cannot be ordered by Purchasing#

a material master record of this material type does not contain purchasing data*

Ra+ materials (R 9)Ra+ materials are al+ays procured e/ternally and then processed* ' material master record of this type contains purchasing data# but not sales data since they cannot besold*

Q Semifinished products (9'L%)Semifinished products can be procured e/ternally and manufactured in0house* hey arethen processed by the company* ' material master record of this material type cancontain both purchasing and +or- scheduling data*

Relation %et+een MRP ype and MRP $roup

!n the MRP data# you enter an MRP group or a strategy group*• he strategy group determines the planning strategy for the configurable material (for

e/ample# ma-e0to0order production)*• he MRP type determines +hether and ho+ the material is planned (for e/ample# using

planned orders)*• he lot si e determines the lot0si e procedure that the system uses to calculate the quantity of

the material to be produced*• ' configurable material needs e/act lot si es*

MPS



he system creates dependent requirements for the % M level directly belo+ the planning level* !tdoes not# ho+ever# plan levels belo+ this*

MRP7

Process 6low

"* he system calculates net re&uirements for all the requirement quantities that are to beplanned* he system thereby compares available +arehouse stoc- or the scheduled receiptsfrom Purchasing and Production +ith planned independent requirements# materialreservations and incoming sales orders* !n the case of a material s)orta e # that is# if theavailable stoc- (including firmed receipts) is smaller than the quantity required# the systemcreates procurement proposals *

* he system calculates the quantity recorded in the procurement proposal according to thelotBsi in procedure that you specified in the material master* ;arious lot0si ing procedures

are supported by the system* You can define a lot0si ing procedure for each individualmaterial*5* he procurement proposal is also scheduled +hich means that# for materials procurede/ternally# the delivery and release dates are determined# and for materials produced inhouse#the production dates are calculated*8* 3or materials produced in0house# the dependent re&uirements of the components aredetermined during the % M e/plosion* 3or each component# the dependent requirementsdate is displaced by the in0house production time of the higher0level material*F*Additional re&uirements (unplanned goods issues# e/cess consumption of components inproduction# and so on) can be covered by using the materials forecast +ithin MRP* hehistorical values of unplanned requirements form the basis of the forecast* heserequirements are then ta-en into account along +ith the e/act requirement quantities*

) % Ma* ,hat is recursive % M* ./plain +ith an e/ample and '#b# c

i* ,hat are the dis0advantages of recursive % Mii* 9o+ do u control itiii* ,hy does S'P have recursive % M then

Recursiveness C)ec=

' % M is recursive if the product contains a component +ith the same ob2ect number as thesuperior assembly* his is often due to input errors# but in individual cases it may be intentional*

' component has the same material number as a higher0level product* !n paintproduction # a residual quantity of the paint to be produced is used as a component*

he figure belo+ sho+s the repeated e/plosion of an ob2ect +ithin an e/plosion path(recursiveness)*



Recursiveness c)ec= wit)in a 5 M roup

he recursiveness chec- includes all % Ms in a % M group* 3or e/ample# the system findsrecursiveness in a variant % M# even if an individual variant is not recursive* ' variant % M has variants7

he first variant for material A has the follo+ing material components7 : !tem 66"6 +ith material % : !tem 66 6 +ith material &

he second variant for material 5 has the follo+ing material components7 : !tem 66"6 +ith material ' : !tem 66 6 +ith material &

either variant is recursive* 9o+ever# the system finds the follo+ing materialcomponents to be recursive7

!n variant for material A7 item 66"6 +ith material 5!n variant for material 5 7 item 66"6 +ith material A

5 M e2plosion for recursive 5 Ms% M e/plosions stop at the component that causes recursiveness*SAP A8 5 Ms (PPB5>B5 M$Recursiveness C)ec=,hen is a % M ./plosion erminated TPage 5@GU

'llo+ing Recursiveness TPage "HHU

Allowin Recursiveness

!f you create a recursive % M# you must decide +hether you +ant to allo+ recursiveness or delete the component that caused the recursiveness*

Recursiveness online

You enter a material item that causes recursiveness* !f you confirm your entry# the systemrecogni es the recursiveness*Processing comprises the follo+ing phases7"* he systema) Sets the Bill of material is recursive indicator b) Displays the error message Bill of material is recursivec) $oes to the $eneral data screen

* You process the item in the % M*a) !f you +ant the % M to be recursive# you set the Recursiveness allowed indicator inthe General data section in the “Basic data” screen of the item*b) !f you do not +ant the % M to be recursive# delete the item*



Indicator 5 M is recursive

!ndicator set by the system if the e/ploded 5 M for an ob2ect contains the ob2ect itself as an item*

b* ./plain various item categoriesi* L> >K etcii* ,hat is the difference bet+een L and typeVho+ does it affect the creation

of purchase order>requisition>schedule lines>prodn order iii* !f ' contains % and &# and if % is L and & is # then ho+ +ill the business flo+

be"* !f both % and & are e/ternally procured then ho+ +ill the business

flo+ be

!f you define an item category for materials +ith a material type that is -ept in stoc-#stoc- can be chec-ed automatically *

!n &ustomi ing for Production, you define the features of the item category by choosing Bill of Material WItem Data WDefine item categories. o define an item category# you ans+er thefollo+ing questions7

!s a material number a required entry!s the item to be chec-ed against stoc-!s the item a te/t0only item +ith no further functions

're different0si ed sections of the item to be entered 're negative quantities allo+ed 're sub0items supported!s the item a plant maintenance (PM) structure element

!s the item an intra material!s the item a document item or class item,hich screens are selected and +hich fields appear on the item detail screens



Item Cate ories for Material Items

he standard R>5 System supports several item categories for a material item*You can classify all material items that have a material master*You can use the follo+ing item categories for material items7

Stoc- !tems TPage " <U

on0Stoc- !tems TPage " @U;ariable0Si e !tems TPage "56UPM Structure .lements TPage "5"U!ntra Materials TPage "5 U

Stoc= Items

!f you +ant to enter a material that is -ept in stoc- as a component # select this item category*

5efore *ou start

' valid material master record +ith a material type that supports stoc- must e/ist in the plant you

select*Pipeline materials (material type P!P.) are not -ept in stoc-# so you cannot enter them as stoc- items*

Special functions

he follo+ing are e/amples of functions that are supported for stoc- items7!n an alternative item roup' you can group together all stoc- items*You can use the discontinuation functions to transfer dependent requirements that are

no longer covered by stoc- to a follo+0up item*Stoc- items are handled in the follo+ing +ays in related application areas7

3or e/ample# in MRP' activities are started that ensure that the material is available on acertain date# in sufficient quantity# and at the lo+est cost*

XDuring materials planning# the system creates dependent requirements for all thematerial components of a product that are sub2ect to material requirements planning(MRP)*X,hen you open a production order# the system generates a reservation*

Product costin functions ta-e the material valuation from the material master record( osting vie+)*

7onBStoc= Items

4se this item category if you +ant to enter a material that is not -ept in stoc- before use# andthat is only procured for a specific planned order or production order *

he material is only rarely required for a custom0made product and is used directly inthe product as a purchased part *5efore *ou start

You can enter a non0stoc- item either +ith or +ithout a material master* !f you enter a non0stoc-item +ithout a material master# you must enter a description* 3or non0stoc- items# you have tomaintain purchasing data in the bill of material *You enter the follo+ing materials as non!stoc" items because the quantities are notupdated in the material master record7

Materials +ith a material type that supports configurationPi#eline materials # +hich can be ta-en from a pipeline at any time

Special functions

he follo+ing functions are supported for non0stoc- itemsYou maintain purc)asin data for non0stoc- items in the bill of material*!n the planning run# the system generates purchase requisitions instead of dependent



System for MRP# you can define +hether direct procurement is triggered by the planningrun or by production order management*

Product costin processes ta-e valuation data from the % M item*he system determines the release strategy on the basis of the price data you enter* he

material group is required to produce a purchase requisition*

@ariableBSi e Items

!f you +ant different0si ed sections of a material (ra+ material) to be represented by one materialnumber in % M items# you use this item category*

5efore *ou start

' valid material master record +ith a material type that supports stoc- must e/ist in the plant youselect*

Special functions

n the Detail $creen% &aria'le!$i e Item Data, the system automatically calculates the quantityof the variable0si e item required from the si es and any formulas entered*Different0si ed sections of a material (for e/ample# sheet metal) can be stored under one material number*

You can group together all alternative variable0si e items into an alternative item group*You can use the discontinuation control function to transfer dependent requirements to a

follo+0up item if they are no longer covered by sufficient stoc-*

Intra Materials

his item category is relevant to process industries (master recipes)* Materials that only e/isttemporarily# bet+een subprocesses in the production process# are entered as components +ith

this item category*

Prere&uisites

!n the standard R>5 System# material type ! R is defined for intra materials* he vie+s youmaintain for this material type include7

%asic data&lassificationAuality management

!n % Ms# status management for these items is restricted*

5) ,or- &enter and Routinga* ,hat is &ontrol Key ,hat is itJs significance ,here do u define it ,hat are itJs

paramentersb* !f for a routing# ,& is 666"# for operation "6 +e say control -ey as AM6" but in +or-

center it is defined as PP6"# so +hich value +ill it ta-ei* Routing oneii* ,or- center one

c* ,hat happens if +e do not enter control -ey in routing ,ill it +or- 3rom +here +illthe value be ta-en ,hat +ill happen

8) ,hat is standard value -eya* ,here is it used Significance ,hat screenb* ,here do u enter the time required for set0up>processing>labor

i* !n routing !n +cii* ,hat screen



Standard value

Standard values are planned values for the e/ecution of an operation and are maintained intheoperation* ypical standard values are# for instance# set0up and processing* ;)e e2ecution time'costs and capacities are calculated in operations using formulas TPage " GU from the +or- centersand standard values from the operations*

,hen you assign a +or- center to an operation# up to si/ data fields and -ey +ords are assignedto the operation via the standard value =e* of t)e wor= center * he standard value -ey is defined inthe &ustomi ing for )or" centers by choosing $tandard value and is entered in the Basic data screenof the +or- center*

he rules for maintenance for standard values in the +or- center Basic data screen determine+hether you have to maintain standard values in the operation or +hether this is optional*You can enter default units of measure for t)e standard values in the +or- center screenDefault values * 3or inhouse0production operations the default value for the unit of measure of +or- is maintained in the screen $cheduling *

S P

Sales I perations Planning is made up of t+o elements7 standard S P and fle/ible planning*Standard S P comes largely preconfigured +ith the system* 3le/ible planning offers multipleoptions for customi ed configuration* Planning in standard S P is based on product grouphierarchies and is al+ays carried out level by level* 6le2ible plannin is carried out on hierarchiescontaining any chosen organi ational levels (for e/ample# sales organi ation# distribution channel#material# and plant)* Moreover# in fle/ible planning the content and layout of planning screens can bedefined by the users*

000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000

,hat -ind of servers did u do the customi ation>configuration

a* esting server b* Production server

• ,here do u define the planning strategieso ,hereo ,hat all do u customi eo Strategy $roup

,here definedRelationship betn Planning Strategies and Strategy $roup

• ,hat is control cycleo ,here do u define Supply 'reas

!s it pic-list>pull list dependent• !ntegration of PP +ith & >MM

o ,hat customi ation do u do in Purchase rder &reationo ,hat are type of purchase rders createdo ,here is it definedo ,hat are movement types

9o+ are they customi ed,here r they defined

• 9o+ do u load the data into S'P system from old systemo ransactiono ,hat is the transaction

• 9o+ is MPS run



o Difference betn MPS and MRP runo ,hat is run first MRP or MPSo 9o+ do u define part for MPS

• Shopfloor controlso ./ecutiono Prodn Support

• Prodn order not released• &ost not settled• rouble shooting

• ,hat are the master data for R.M

• &onfigurations for R.M

• 9o+ do u assign product cost collector in R.M

o Production ;ersion

• &apacity Planning

• ,hat is %PP 9o+ many did u create and for +hat sections of PP

• ./plain entire manufacturing process in the previous pro2ect

o 9o+ many products per hour o 9o+ +as the i>po 9o+ +as the o>po ,hat +ere the i>p to the prodn lineo .*g* capacitors>P&%sVho+ did they come to the lineo 9o+ are they fed into the assy lineo 9o+ do u -no+ that only "6 products have been used and not "" ,hat interface do

u use 9o+ do u bac-flush in such conditionso

• &onfigurations for Discrete Manufacturing

• &onfigurations of Planning Strategieso ,hat do u do in it

:valuations H >efinition

.valuations in repetitive manufacturing provide the follo+ing information7pull listreporting point overvie+ (goods in process)component reprocessing listdocument log& reports

Statistics and analyses can also be accessed from the Logistics !nformation System7goods receipt statisticsreporting point statisticsmaterial consumption analysisproduction costs analysis

Run Sc)edule %eader



' Run Schedule 9eader must be created before a material can be planned in repetitivemanufacturing* !t is used for planning and settling finished and semi0finished products that areproduced repetitively over a longer period*

he run schedule header contains no production quantities nor does it contain any dates* %othquantities and dates are planned using run schedule quantities assigned to the run scheduleheader*

RS headers can be created +ith or +ithout a production cost collector* &osts can be settled7via a production cost collector per run schedule header via a production cost collector that is created for several run schedule headersvia production orders

Plannin Run Sc)edule Quantities

>efinition

he Run Schedule Auantities specify the production quantities for a run schedule header that areproduced in a certain period* 'ctual data and cost settlement data are collected by the production costcollector*

Planning +ith run schedule quantities is especially useful if7

a product is produced repetitively over a long period of timethe same routings and therefore the same +or- centers are used for the production of a

product family (production organi ed by production lines)

a* ,hat phase of pro2ect did u 2oin Pro2 prep phase &ollection phase

b* ,hat +as your role in it

a* 9o+ did u collect requirement specificationsb* 9o+ did u intervie+ the clientc* Did u do more reqd collection or documentationd* ./plain the entire blue print creation process

c* ,hat strategies did u use Ma-e0to0stoc-> M

d* ./plain the entire process for Prodn Planning

a* Li-e ho+ did u get forecasting 3orecasting module 3orecasting types used 9o++as the flo+

b* Did it come from S!S ,hy S!S !t is traditional +ay of forecasting ,hy is itbeing used

c* 9o+ is the prodn planning doesd* 9o+ is the demand transferred to Demand managemente* MRP Run Planned order Prodn rder ,hat is the requirement type> order

t*pe for PIR and >ependent re&uirementf* ,hat is the entire flo+ for Prodn planning to e/ecution

e* ,hat is procedure for configuration

a* Procedure for configuration



i* 3rom +here do u get the info +hat to doii* %usiness %lue print 3rom ,here elseiii* 9o+ do u decide +hat to config and +here to doiv* 0)at does *our ;eam Leader ive *ou

b* ,hat is the step after config 9o+ are the config put in other servers

c* ,hat is ;ransportation Re&uest

d* ,hat r different types of transportation request

i* ,or-bench type"* &lient !ndependent ,hat does it contain

* &lient dependent ,hat does it containii*

e* ,here did u do the configuration !n ne+ pro2ect r in Standard>reference !M$

f* ,hat +as the type of &lient used +hile configuration

a* &lient umberb* ype of &lient (Development &lient or Sandbo/ &lient )c* ,as the client on 4ni/ or on

g* ,hat +ere the requirement types and classes used by you

a* LS3>;S3b* &lass "66

h* ,hat is the control Key used

a* PP6"V,hat does it contain 9o+ does it affect

i* 9o+ do u integrate PP +ith &

a* 9o+ is the cost being calculated at &ost &enterb* 9o+ is activity type assignedc* 9o+ is the entire & process &ost center N1 &osting .lement N1 'ctivity ype

2* Did u perform any .nterprise level customi ation

a* Li-e creation of plant ,hat is the entire process

-* ,hat is the role of a eam Leader ,hat does he do 9o+ does he guide you

"* !f there are "66 P!Rs and "6 Sales rder Aty and MRP run at mid0nite daily**So based on thefollo+ing strategy +hat +ill happen

a* Strategy "6i* P!R consideredV Sales rder ii* &onvert all the P!RS

b* Strategy 86i* %y Sales rder onlyii* ,hat is the rder ype ( ype ;% for op level item)iii* 4nless +e have sales order no prodn done 01 %ut Planned order for sub0assy

done

* ,hat is difference bet+een S P and 3le/ible Planninga* S P is based on forecasting and information from pastb* 3le/ible plnng based on certain selected levels



3. &osting 9o+ activity type accounted fora* 9o+ the cost collectedb* 9o+ do u find the Planned ;s 'ctual

i* 'ctual is done +hile confirmation"* &onfirmation N1 milestone**operationlevel

/. 0)at is 0or=6low process++

F* ,hat is A;P C)ec=in rules

a* &hec-ing group N1 &ollection of rules for given material for specific applicationb* &hec-ing rule N1 each rule specifies +hat needs to be chec-ed Stoc-# receipts#

issues# rders to be chec-edc* ' P done during 8 things

i* Sales order creation (quotation time)ii* Planned order iii* Prodn rder iv* !nventory Management N1 Missing part

H* ,hat is the difference bet+een S'P 8*6 b and S'P 8*H c

a* !n 8*6 there +as no concept of MRP 'reai* MRP area defines +here u +ant to run MRP TMRP" vie+U

"* at Plan level* at Storage locn level

5* MRP &ontroller level

G* +hat is the MM process

a* !M7 $oods movementb* ,M7 ,arehouse Management

<* ,hat is difference bet+een 3inite Scheduling and Lead ime Scheduling

"* ,hat are configurations for different strategiesa* Ma-e0to0order and Ma-e0to0Stoc-b* ,hat is the business process

* 9o+ frequently do u run MRP

5* 9o+ do u run MRP overall if u have "66 materialsa* ,e do not +ant to run MRP for individual materials**So ho+ is it done

8* 9o+ do +e transfer S P to Demand managent

F* !n S P# +hat are the planning ype

a* !f the req is there for region 01 sales area 01 plant 01 mfg plant# +here +ill the data beenteredV

b* hings to do in S Pc* 9o+ +ill u get sales pland* ,hat is S!S

H* !mportant features of S P

G* Difference bet+een et Planning ("6) and $ross0requirement ("")

<* &an you run MRP for a specific &ontroller



a* ho+ to do it in systemb* 9o+ do u define D.3'4L values for MRPc* ,hat are the options for running MRP

@* &oncept of Schedule Margin Key

a* 3%P# 3'Pb* ,hat is opening Period Say 6 dayV*then ho+ +ill MRP react

"6* ,hat is rgani ation levels for Material Master

a* ,hat r various vie+sb* ,hat if = ,or- Scheduling ? vie+ is not maintained ,hat +ill system do ,hen +ill

it give probsc* ,hat are options in basic data

""* ,hy do u have material types

a* ,hat is the significanceb* ,hat +ill happen if only " material type based on business processc* ,hat if u have both procurement type Z

" * % M

a* Different % M &ategoriesb* !tem categories

i* Different item categoriesii* Difference betn Stoc- and on0stoc-

"* 9o+ does it affect the systemiii* ,hat is intra0material item

"5* ,hat is %4LK !ndicator 9o+ does it +or- 9o+ does it affect the % M and MRP run

"8* ,hat are the various reports in PP

"* ,hat are the Special procurement Je*sa* F 7 &ollective order b* 567 Sub0contracting

* ,hat is rder Settlement ,here do +e do it

5* ,hat are the rder ypes

8* 9o+ is re+or- done 9o+ is itJs config

F* ,hat is collective accesss of production order

H* ,hat is the role of MRP &ontroller

G* ,hat is % M alterantive material

<* ,here is automatic goods receipt indicator maintained

a* Prodn Scheduling profileb* ,or- &enter c* Routing



@* ,hat are the configurations for MRP at Plant level

"6* ,hat is MRP type# Lot0si e# schedule margin -ey

""* ,hat is %ul- Material ,here is the indicator maintained

"* ,hat is the use of PR

a* ,hat -ind of PR s have u +or-ed +ithi* PR machine# PR diagram# !mages# tools

b* 9o+ do u assign it to the operationsc* 'ny idea regarding PR machine assignment

i* 9o+ do +e create PR master data

* ,hat is S P

a* 9o+ do u perform planningb* Difference bet+een fle/ible planning and Standard S P

5* ;ariant &onfiguration7

a* ypes of strategies TMa-e0to0 rder or Ma-e0to0Stoc-Ub* 9ave u +or-ed +ith Ma-e0 o0'ssemble Strategyc* !n Ma-e0to0 rder strategy# do u -no+

i* Difference bet+een static and dynamic types

8* ,hat is material staging

a* ,hat are the various types of material stagingb* ,hat is the outcome of material stagingc* 9o+ is it doned* 9o+ do u define that material is to be staged to a particular locn

F* production order

a* ,hat is meant by e/ternal processing of order i* ,hen a specific operation is outsourced to other vendor for processing#

instead of performing in0house*ii* !n this case# purchase requisitions are created

b* Difference bet+een Sub0contracting and ./ternal processingi* !n Sub0contracting# u send the product '# % to the vendor and get the

transformed item Say Z as input from the vendor

he openin period is the time required by the MRP controller to convert the planned orders intopurchase requisitions* !t is only ta-en into account +ith bac-+ard scheduling*

5ac=ward Sc)edulin for InB%ouse Production

Implementation ptions

http://help.sap.com/saphelp_47x200/helpdata/en/f4/7d294a44af11d182b40000e829fbfe/frameset.htm



3or materials that are planned according to the MRP and forecast0based planning procedures# therequirement dates in the future are -no+n* Scheduling is al+ays bac-+ard* he system automaticallys+itches to for+ard scheduling only if the start date lies in the past*

Process 6low

"* he system calculates the oods receipt processin time bac-+ards using therequirements date and thus determines the order finis) date *

* he system calculates the inB)ouse production time bac-+ards using the order finish dateand thus determines the order start date *

5* he system calculates the openin period bac-+ards using the order finish date and thusdetermines the order openin date *

R.M Profile7NNNNNNNN

Post processing7 !f standard costing done for 2uly but 2une open# +ill post processing be done bycogi ,ill cogi allo+ it

9o+ is cost difference posted in the material master MR "

9o+ do you upload % M components for same header material for LSM,9o+ many steps are there in uploading LSM,*

9o+ does re+or- process +or-NNNNNNNNNNNNNNNNNNNNN3or Process industry you use batch management (on basis of batch) quality chec- no up to themar- Process the material again no re+orat operation level create a ne+ production order+ith ne+ order type finished product put to bloc- stoc- or separate storage location consume thefinished product in some other production order associate the cost to a material or cost center

"* ,hat is MRP Key*

* ,hat are the MRP procedures in S'P

i) MRP

ii)&onsumption based planning(Reorder Point#3orecast I ime based



planning)!f anything is there apart from the above# please e/plain me*

5* 's a case# i +ant to implement Reorder point planning(automatic)for some of my materials categori ed under Regular consumables*Please tell me the necessary changes to be done in the system*(!M$#

Material Master# PR# P # $R I !R)NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

&reate Production rder 7 &o6<NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

'll $R from production order happens through the "6" movement only* So this should help # and it isal+ays advisable to have different movement types +hile you do re+or- and normal production*00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000A7 &ustomi e % M field status

'7 P3'Spro 01 Plant Maintenance and &ustomer Service 01 Maintenance Plans# +or- center 01 ,or- &enters01 $eneral Data 01 Define 3ield Selection

0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000Define =&ontrol Keys for perations? used in % M N1 P66 (e*g* PP6" N1 !n0house prodn +ithoutconfirmation)00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000"* Maintain P!R for materials at depot plants in the system* * Run MPS>MRP so S R is created at depots +hich are then converted to S by depot planners*

his +ill put requirements (demand) on production plants thru SPK* 5* MPS>MRP at production plant +ill create planned orders to cover these S # +hich the plannerscan convert to production orders and ship to depots against these S s* 8* Depots perform $R of materials from production plants against these S s and ship out ofinventory to deliveries for sales orders at depot* F* 4nder this scenario# the sales orders must be created in the system +ith depot plants as deliveryplants*

H* 3or the production plants# it is only the S Rs and S s that +ill provide demand visibility against+hich the production planning must be performed*NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

& 687 &hange &haracteristics===================================================

"* 9o+ did you configure S'P in your &lientBplace I+hat is you role preciously

* ,hat is meant by process mapping

5* +hat is meant by %usiness %lue Print

5* ./plain customi ation +ith an eg*

8* 9o+ +ill you configure I calculate &apacityPlanning

F* ,hat is Land Scape NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNM3%37 R.M %ac-flush : ransaction ;ariant& !S7 Production rder !nformation SystemSM687 4ser list online**SM6"7 ransaction &odes7 Loc->4nloc-M%F 7 Display of Stoc- in ransitNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

PP[7 R>5 N1 &hec-ing Rule> Determine &hec-> Plant> MRP $roupDefine chec-s and MRP profiles**+hile conditions +hile MRP run li-e consider Stoc- in transit**0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000



& < N1 Report sho+ing Production rders and their status# technically complete# closed0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000

P[% N1 Display System Message& "" N1 .nter time tic-et for production order A.F" N1 Result Recording ,or-list

&S"F N1 ,here0used Material usageM%F% N1 Stoc- on Posting date (,!P)0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000,hat are the configurations into MRP000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000Difference bet+een Discrete vs Repetitive Manufacturing (R.M)

if +e see the repitive manufacturing ime v>s Auanity graph is Linear i*e* Auant* proportional to ime*and time bet+een the t+o setup is same*

,hile in Discrete manufacturing this graph is not linear* if +e see the time and quantity a/is# the valueof Auantity may go up for same time for sometime and some time this value may go do+n*

!n case of discrete manufacturing the material moves the C[ob ShopC* he machines are placedaccording there categories (eg* all drilling m>c in drilling section# all lathes in turning section etc) andnot according to the manufacturing sequence* Material moves from one machine to other according tothe routing specified* bviously material movement is either manual or using vehicles etc* i*e* notautomatic* o ma-e material movement economical lot si ing is done*(material moves in lots)

in discrete manufacturing basically batch production# so# each and every stage you have to generateprod* order or pur* req* from the planned order* then here bac-flushing is not necessary I normalrouting only you should use**

!n case of repetitive mfg# machines are arranged so that manufacturing seqence is follo+ed as per the

routing of the material* Material moves thru these machines automatically e*g* conveyer* Series ofthese machines is called production line*9ence material moves thru the machines (production line) at a determined rate* his rate is importantparameter for repetitive mfg as it determines ho+ many 2obs a production line can ma-e per giventime*

in R.M basically mass prod*** assy line components# the prod starts +ith the planned order itself***bac-flushing plays a very important role here +hile $! I $R# here you should use Rate routingV



Item Repetitive >iscreteProduction Suitable for bul- qty produced over a certain period of

time*Suitable for frequent change overs > lot +isemanufacturing

Product follo+s the same sequence of operationsthrough the machines*

Suitable for comple/ operation sequences

Data Punching Minimal ./cessiveProduction rder o production order# Data punching +ill done for item

code and produced quantity*Lot +ise# item +ise individual orders +hich +ill be muchat higher side* \ 866]8F6 production orders +ill becreated for each unit per day* Production order closingto be done either by completing the order or shortclosing*

delays Possible +ith single reason Possible +ith single reasonPR s ot Possible Possible&o0product ot Possible PossibleMaterial availablity chec- ot Possible PossibleRe+or- o proper +ay available Possible

ransaction Less MoreProduct &osting &ost and variance are analy ed for a particular period

(Monthly)*&osting and variance +ill be done production lot +ise

Settlement Periodic settlement .ach and every production order has to settled# hencemore efforts reqd*

System performance ,ill be better for log time Performance +ill be detiorited in very short periodMRP result o impact ,ill be affected in case of open production order hence

+e have to close the open production order manuallybefore every MRP run

Life consumption counter ot Possible Possible

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNAueries"* Difference b>+ pic- list and pull list

* schedule lines (in MRP)5* Auota arrangement in PP (its application)8* ,hat is the significance mi/ed MRP field inmaterial master F* +hat is planning calender>planning cycleH* +hat is "st dayBs supply I nd dayBs supplyG* ,hat is overall change profile ( &M)<* a brief on data migration tools (LSM,# %D&# S&' )@* +hat is top0do+n and bottom0up approach in S P"6* Difference b>+ detailed scheduling# productionrate scheduling and rough cut scheduling""* 3i/ed and movable parameters in order confirmations" * effectivity in % M"5* +hat is the difference bet+een follo+ingconfirmations for operations i* ime tic-et ii* time event iii* collective entry iv* progress confirmation and +at is the basic difference bet+een enteringconfirmation for operation and fast entry

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN 'fter MRP Run

B RDR.SB means order reservation for process>prodn order BD.PR.AB means dependent requirement for a planned order BAML B means the order is delivered and is in A! status a+aiting usage decision*

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN!ntervie+ qns70000000000000000

"* +hat is cu tomising * +hat is mapping



6inite Plannin does 3inite Scheduling at the same time* !f there is no capacity available on thedesired date# the system loo-s for +hen capacity !S available* hen it stops to see if Materials +ill alsobe available (usually based on the lead0time for those components)* !f there is a material problem#then the system figures out +hen the materials ,!LL be available# and then chec-s to see if capacityis available on 9' day# and if so# it bloc-s off capacity# and allocates the materials for that day*

00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000%y default system +ill fetch the +or- center for the operation from theProduction rder# for the first confirmation fro the operation* You have thefle/ibility to change the same during confirmation*During the ne/t confirmation for the same operation# system +ill fetch the+or- center entered in the last confirmation*000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000)en to use P)antom Assembl*

ur Crule of thumbC is that if +e do not hold stoc-s of a material# it is created +ith special procurement-ey F6 (N Phantom assembly)*

e*g* in our business +e manufacture petfood* the actual food in the can is made up of gravy and meat*he meat is stoc-ed so is a non0phantom# but the gravy is made up of po+ders and liquids +hich +e

mi/ together then add the meat into it* !n this case the gravy is a phantom material (+ith a % M) as +edo not stoc- it* !t is an Bin0lineB product* i*e* it is produced and immediately used to produce somethingelse*

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNMMP; and MMP!7 for closing and initiali ing the posting period for materials* his is used to solve theproblem of old>prev posting period +hich does not allo+ u to create ime ic-et or $!>$R*NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

opic7 Substitute Matl instead of 'lternate % M# if u +ant system to automatically select a particular% M based on availability of matl*

he typical scenarios +ere li-e the client +ould give me a brief overvie+ of the current status of thepro2ect and +ould sometimes tell me the s-ill set they +ere loo-ing in a candiate and then +ould as-me to tell more about my professional e/pereince*

Did u +or- in a production support pro2ect +hat issue did you faceDo you have e/perience in traning end users and communicating +ith people offshoreDo you have e/perience in a 4pgrade pro2ect +hat release BBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBB "* Did you +or- on % M configuaration

* ./plain about Ma-e to order +ith configuarable material5* !s it necessary to have a production version if you have bom and routing

• MPS n MRP ( ho+ it -no+s its MPS (mrp type as MPS)• MRP is consistent planning +here as MPS is Level by level*• +hy MPS (long lead and <6E of cost)• MPS run( & D.) and MRP run• &onsumption based planning : ;%>;M• Planning time fence > Planning hori on• planning files• things imp for Prdn order ( procurement type n prdn scheduler profile in ,or- scheduling vie+• &ontrol -eys n order types• . &9> . PL> Regenerative planning• shelf life n e/piration date in P!



• asap methodology• +here is bom status indicator • costing in prd order ( +hen its done partial or at close of prdn order)• legacy system before S'P• types of %ac-flush• $lobal dependencies : tcode• ho+ u deactivate %atch management• once u release prdn order can u ma-e changes• once &LSD nothing changed• can u delete prdn order • control -ey for sub contract item that u need to maintain• R>5 vs .&&• ,hat is the role of recipe in P!• MRP list vs Stoc- requirement list• !f safety stoc-N<6# sales orderN "66# then prdn orderN

• &onfig of R.M profilebatch search procedure

costingmovement typesfirm> not firm> firm +ithin planning fence

• --fHn : prd cost collector ( for each of prdn version)• bac-flush n stagging• Planning table : assist planner in planning prd quantities by lines* it chec-s quantities in

glance n determine actual capacity load utili ation of prdn lines as +ell as chec- availability ofmaterials

• !nterfaces0 barcode using R3!D ( radio frequency !dentification)• 3le/ible planning : steps n need• e/plain ur +or- : streamline n flo+( full life> upgrade> rollout)• functional spec• different strategies ( "6 vs ""# F vs H)• Discrete vs R.M 0( order types)• batch management• Serial no and barcodes• LSM, concept• P! Sheets ( abap based n bro+ser based)• %ac-log7 capacity req tht have been scheduled# after scheduling or distribution# to periods tht

lie in the past*• bac-order processing• Special procurement types• phanton assembly• full life cycle implementation vs reali ation phase•

sop vs fle/ible planning• planning method(consistent planning# delta# consistent planning)0 pg "8@• prd group7 that are similar to sales n prdn behavior • +here do u assign dependencies : assign to the components in the super bom• planning type > planning heirarcy• +hy do u create info structure in fle/ible planning• diff discrete industry n process industry• +hy do u have discrete manufacturing sometime in pharma company• dependencies : selection # precondition n procedure• dependency net0 collection of all dependencies• ho+ variant pricing is done• can a variant material be ma-e to stoc- item• 3or variants that are required frequently# you can create material variants# +hich can be

produced +ithout a sales order and -ept in stoc-* ,hen you receive a sales order# you canchec- +hether the variant required is in stoc-# so that you can deliver immediately*



Inte ration Points in SAPLe ac* to SAP >ata Mi ration

Key !ntegration points PM +ith MM 0 Purchase rdersKey !ntegration points PP +ith MM 0 Purchase rdersKey !ntegration points PP +ith SD 0 Sales rdersKey !ntegration points MM +ith 3! 0 $L PostingsKey !ntegration points MM +ith & 0 Product &ostingKey !ntegration points ,M +ith MM 0 $oods !ssue# Receipt# Purchase rdersKey !ntegration points ,M +ith PP 0 Production rdersKey !ntegration points PM +ith PS 0 'sset agsKey !ntegration points ,M +ith SD 0 Sales rders!ntegrating MM>PP +ith Plant Shop 3loor Systems>5rd party systems



A*5 ,hat are the planning strategies have you used ./plain Planning +ith 3inal assembly (86) andPlanning +ithout final assembly (F6) planning strategies !n Material Master +here you definePlanning strategy (on +hich vie+ )


A*F 9ave you +or-ed on %atch Determination ./plain me +hat are the %atch LevelJs are available

,hat do you configure for the %atch determination 9o+ it +or-sA*H ell me about lot si ing procedure 9o+ it +or-s !n the Material Master +here do you define Lotsi ing procedure -ey





A*"" ,hat is Routing for ell me types of Routings* ,hat are the configuration you do for Routings

A*" ./plain me about &apacity .valuation and &apacity Leveling* ,hat transaction code have youused for that


A*"8 9ave you done testing ,hat type of testing ./plain the steps of each testing that you havedone Li-e any test scenario or any test process have you developed

A*"F 9o+ MM>PP>,M integrates +ith each other ell me the point of integration*

A*"H ,hat is Production ;ersion ,hy it is useful



purchase requisition scheduled by the system* ;erify also if there is any other delivery schedule that+ill e/ceed the actual requirements*

!f the purchasing requisition is there# the only thing that you have to troubleshoot is the message to tellyou that the purchasing requirement +as calculated*




controller*

you can do evaluation by mrp controller* his +ill help us if have different people in one organisationinvolved in purchasing*


his +ill help you to determine the floats* !n case if you have production order you can see the impactof floats

5* MRP group


8* MRP profile,e can have some prefi/ed datas in the profile and and +e can enter teh profile for diff material so thevalues +ill copied as defaulted in the profile*

Question ;)e followin control parameters can be set in a lon Bterm plannin scenario

' Planning period% pening stoc-

& Strategy groupD MRP type. ;ersion of available capacity

Question 0)at is t)e name of t)e plannin level for t)e MRP run+

'* S P%* MP&* MRPD* & P'

Question 0)at are t)e main features of t)e MRP t*pes -P>- or -@5-+



'* BPDB can only be used +ith B et &hange PlanningB%* B;MB can only be used in total planning&* BPDB triggers a % M e/plosionD* B;MB can use the forecast for the calculation of the safety stoc-

Question 0)at is t)e meanin of t)e plannin time fence+

'* !t determines the planning period for the planning run%* !t determines the period in +hich the planned orders are to be converted into production orders&* !t determines the period in +hich no automatic changes are to be made to the production plan

Question In forecastBbased plannin ' w)ic) forecast model does SAP support+

'* dynamic model%* seasonal trend model&* split trend model

D* &onsumption model

Question 0)at conditions must be fulfilled in Customi in if a production order is to be c)ec=ed foravailabilit*+

'* Scope of chec-%* &hec-ing group&* chec-ing ruleD* &hec-ing assignment.* !nspection period

0)at )appens to planned after it )as been converted into production order+

,hen you convert Planned order to Production order* the planned order are offset by productionorder* Reference of planned order can be seen in the production order*

%ow to attac) a drawin for a material to 5 M+ Is it possible+

Yes# you can attach a dra+ing*3irst create a document using ransaction &ode C&;6" 0 &reate DocumentC*

'ttach your dra+ing in that document*he system +ill generate a document number* 'ssign this document in the % M +ith item categoryD*

Report in Lon ;erm Plannin B Dou use lon term plannin for *our customers' w)at t)e*need are ver* simple' 4ust to calculate future re&uirements for 1 or # *ears.Are t)ere an* reports in SAP to list of material re&uirement from L;P+

Dou need a list of material re&uirement from lon term plannin result for eac) item.

4se MSG6 then use M&.&*

Sc)edulin planned order B %ow can *ou et planned orders sc)eduled so t)at *ou can docapacit* levelin +



sc)eduled automaticall* on creation+ Dou )ave tried settin up an action to sc)edule t)eorders but cannot et t)at to wor= eit)er.

,hen running MRP# try selecting C C in the scheduling bo/ this +ill bring planned orders into &M6"and &M "

Capacit* plannin CM!1 B 0)en *ou run capacit* plannin ;Bcode CM!1' *ou found t)e planorders are not included in t)e pe ed re&uirement' *ou c)ec=ed t)e profile' t)e c)ec= bo2 fororder and plan order are all actived.

$uess that planned orders have been created +ithout capacity requirement indicator in MRP (C C 0Lead ime scheduling)# if this is the case# then +hen converted to process orders they +ill haveimpact on the Resource* !f you +ant to see them as planned orders# re0run the MRP or change inevery planned order# going to the Menu7 .dit 001 Scheduling

'nother couple of possibilities are to do +ith the routing>+or- centres used and +hether it isactuallycalculates consumption of capacity of the category at the +or- centre being displayed in &M6" (itmight consume a capacity pool or it might not consume the category)*

MPS in 5ac= ound" nline B Dou want to run MPS for a plant eit)er online or in t)e bac= round'but *ou do not et an* results. If *ou run MPS for a sin le material"plant' t)en ever*t)in is1!!K J.

You need to run a planning file and a consistency chec- first# transaction MD and MDR.respectively youBll need to set up t+o 2obs to do it but it is straight for+ard# once youBve done this setup the bac-ground 2ob for MPS to run and do it in .4PL first time round and then change to . &9after that*

0)at is t)e output of MPS run+

3rom MPS run you plan the materials +hich are of B'B type in the abc analysis (<6E dollar value) thathave to be planned before hand*MPS is also a type of MRP only in +hich components 2ust belo+ the materials on +hich MPS run ista-en place# are planned*

;able for production order status B 0)at is t)e table for findin status (for :2 ;:C ed prodnorders$. 0e are not able to find from A6J and A6R9 tables t)e status of production orders orat least t)e lin= tables if =nown can be mentionned. Dou are unable to lin= t)e structure caufvdand I %:A>:R 0I;% A6J and A6R9.

[.S is the table*

>ata dictonar* table for S P plannin data B Dou are usin Standard S P (Info structure S!<3$'in w)ic) table can *ou see t)e plannin values t)at *ou maintained in MCE, transaction+


4se *&ode M&@F to display your entries under the version +hich maintained the the table S6GH*

Production order operation-s component allocation B %ow does SAP =now t)at an operation)as components as indicated b* t)e component allocation indicator+ ;code C !G.



&omponent allocation is done via routing maintenance or % M maintenance for the assembly* his ismaster data maintenance* 's soon as a P is created# the master data is read into the P *

%ow to delete roups of products+

%ow to delete a roup of products t)at was created in screen MCG/+

Delete the members in the product group and then archive the product group in transaction S'R'#ob2ectNMMQM' R*

( he product group is created as a material master record +ith material type PR D and this record isdeleted in S'R'*)

F) &ustomi ation of Material Master a* 9o+ does material t*pe selection affect the flo+

,hether the material is intended for a specific purpose# for e/ample# as a configurablematerial or process material

Q ,hether the material number can be assigned internally or e/ternally Q he number range from +hich the material number is ta-en Q ,hich screens appear and in +hat sequence Q ,hich departmental data you may enter Q ,hat procurement type the material has that is# +hether it is manufactured in0house or procured e/ternally# or both

0 ype of inventory management (quantity>value)

0 'ssignment of account categories and reference0 3ield selection and screen se+quence0 $eneral indicators (pricing for popleline# process or configurable)0 &osting control0 !tem &ategory in SD0 'uthori ation group

ogether +ith the plant# the material type determines the materialBs inventory managementrequirement that is7

Q ,hether changes in quantity are updated in the material master record Q ,hether changes in value are also updated in the stoc- accounts in financial accounting!n addition# the accounts affected by a material entering or leaving the +arehouse depend on the

material type*

3inished products (3.R )3inished products are produced in0house* Since they cannot be ordered by Purchasing#a material master record of this material type does not contain purchasing data*

Ra+ materials (R 9)Ra+ materials are al+ays procured e/ternally and then processed* ' material master record of this type contains purchasing data# but not sales data since they cannot besold*

Q Semifinished products (9'L%)Semifinished products can be procured e/ternally and manufactured in0house* hey arethen processed by the company* ' material master record of this material type can



Relation %et+een MRP ype and MRP $roup

i* $eneral flo+ (li-e screen sequence>valuation class)

ii* Li-e MRP type>groupiii* Material type>groupiv*

!n the MRP data# you enter an MRP group or a strategy group*• he strategy group determines the planning strategy for the configurable material (for

e/ample# ma-e0to0order production)*• he MRP type determines +hether and ho+ the material is planned (for e/ample# using

planned orders)*• he lot si e determines the lot0si e procedure that the system uses to calculate the quantity of

the material to be produced*• ' configurable material needs e/act lot si es*

v* Mrp type (MPS6 or ;;**so ho+ +ill system react)"* e*g if top0level is MPS and lo+er0level is ;;# then ho+ +ill process

flo+

MPShe system creates dependent requirements for the % M level directly belo+ the planning level* !t

does not# ho+ever# plan levels belo+ this*

MRP7Process 6low"* he system calculates net re&uirements for all the requirement quantities that are to beplanned* he system thereby compares available +arehouse stoc- or the scheduled receiptsfrom Purchasing and Production +ith planned independent requirements# materialreservations and incoming sales orders* !n the case of a material s)orta e # that is# if theavailable stoc- (including firmed receipts) is smaller than the quantity required# the systemcreates procurement proposals *

* he system calculates the quantity recorded in the procurement proposal according to thelotBsi in procedure that you specified in the material master* ;arious lot0si ing proceduresare supported by the system* You can define a lot0si ing procedure for each individualmaterial*5* he procurement proposal is also scheduled +hich means that# for materials procurede/ternally# the delivery and release dates are determined# and for materials produced inhouse#the production dates are calculated*8* 3or materials produced in0house# the dependent re&uirements of the components are

determined during the % M e/plosion* 3or each component# the dependent requirementsdate is displaced by the in0house production time of the higher0level material*F*Additional re&uirements (unplanned goods issues# e/cess consumption of components inproduction# and so on) can be covered by using the materials forecast +ithin MRP* hehistorical values of unplanned requirements form the basis of the forecast* heserequirements are then ta-en into account along +ith the e/act requirement quantities*

H) % Ma* ,hat is recursive % M* ./plain +ith an e/ample and '#b# c

i* ,hat are the dis0advantages of recursive % M

ii* 9o+ do u control itiii* ,hy does S'P have recursive % M then



Recursiveness C)ec= ' % M is recursive if the product contains a component +ith the same ob2ect number as thesuperior assembly* his is often due to input errors# but in individual cases it may be intentional*

' component has the same material number as a higher0level product* !n paintproduction # a residual quantity of the paint to be produced is used as a component*

he figure belo+ sho+s the repeated e/plosion of an ob2ect +ithin an e/plosion path

(recursiveness)*

Recursiveness c)ec= wit)in a 5 M rouphe recursiveness chec- includes all % Ms in a % M group* 3or e/ample# the system finds

recursiveness in a variant % M# even if an individual variant is not recursive* ' variant % M has variants7

he first variant for material A has the follo+ing material components7 : !tem 66"6 +ith material % : !tem 66 6 +ith material &

he second variant for material 5 has the follo+ing material components7

: !tem 66"6 +ith material ' : !tem 66 6 +ith material &either variant is recursive* 9o+ever# the system finds the follo+ing material

components to be recursive7!n variant for material A7 item 66"6 +ith material 5!n variant for material 5 7 item 66"6 +ith material A

5 M e2plosion for recursive 5 Ms% M e/plosions stop at the component that causes recursiveness*SAP A8 5 Ms (PPB5>B5 M$Recursiveness C)ec=,hen is a % M ./plosion erminated TPage 5@GU

'llo+ing Recursiveness TPage "HHU

Allowin Recursiveness!f you create a recursive % M# you must decide +hether you +ant to allo+ recursiveness or delete the component that caused the recursiveness*Recursiveness onlineYou enter a material item that causes recursiveness* !f you confirm your entry# the systemrecogni es the recursiveness*Processing comprises the follo+ing phases7"* he systema) Sets the Bill of material is recursive indicator b) Displays the error message Bill of material is recursivec) $oes to the $eneral data screen

* You process the item in the % M*

a) !f you +ant the % M to be recursive# you set the Recursiveness allowed indicator inthe General data section in the “Basic data” screen of the item*b) !f you do not +ant the % M to be recursive# delete the item*



Indicator 5 M is recursive

!ndicator set by the system if the e/ploded 5 M for an ob2ect contains the ob2ect itself as an item*

b* ./plain various item categoriesi* L> >K etcii* ,hat is the difference bet+een L and typeVho+ does it affect the creation

of purchase order>requisition>schedule lines>prodn order iii* !f ' contains % and &# and if % is L and & is # then ho+ +ill the business flo+

be"* !f both % and & are e/ternally procured then ho+ +ill the business

flo+ be

!f you define an item category for materials +ith a material type that is -ept in stoc-#stoc- can be chec-ed automatically *

!n &ustomi ing for Production, you define the features of the item category by choosing Bill of Material WItem Data WDefine item categories. o define an item category# you ans+er thefollo+ing questions7

!s a material number a required entry!s the item to be chec-ed against stoc-!s the item a te/t0only item +ith no further functions

're different0si ed sections of the item to be entered 're negative quantities allo+ed 're sub0items supported!s the item a plant maintenance (PM) structure element

!s the item an intra material!s the item a document item or class item,hich screens are selected and +hich fields appear on the item detail screens



number in % M items# you use this item category*5efore *ou start

' valid material master record +ith a material type that supports stoc- must e/ist in the plant youselect*Special functions

n the Detail $creen% &aria'le!$i e Item Data, the system automatically calculates the quantity

of the variable0si e item required from the si es and any formulas entered*Different0si ed sections of a material (for e/ample# sheet metal) can be stored under one material number*

You can group together all alternative variable0si e items into an alternative item group*You can use the discontinuation control function to transfer dependent requirements to a

follo+0up item if they are no longer covered by sufficient stoc-*

Intra Materialshis item category is relevant to process industries (master recipes)* Materials that only e/ist

temporarily# bet+een subprocesses in the production process# are entered as components +iththis item category*

Prere&uisites!n the standard R>5 System# material type ! R is defined for intra materials* he vie+s youmaintain for this material type include7

%asic data&lassificationAuality management

!n % Ms# status management for these items is restricted*

G) ,or- &enter and Routing

a* ,hat is &ontrol Key ,hat is itJs significance ,here do u define it ,hat are itJsparamentersb* !f for a routing# ,& is 666"# for operation "6 +e say control -ey as AM6" but in +or-

center it is defined as PP6"# so +hich value +ill it ta-ei* Routing oneii* ,or- center one

c* ,hat happens if +e do not enter control -ey in routing ,ill it +or- 3rom +here +illthe value be ta-en ,hat +ill happen

<) ,hat is standard value -eya* ,here is it used Significance ,hat screenb* ,here do u enter the time required for set0up>processing>labor

i* !n routing !n +cii* ,hat screen

Standard valueStandard values are planned values for the e/ecution of an operation and are maintained in theoperation* ypical standard values are# for instance# set0up and processing* ;)e e2ecution time'costs and capacities are calculated in operations using formulas TPage " GU from the +or-centers and standard values from the operations*

,hen you assign a +or- center to an operation# up to si/ data fields and -ey +ords are assignedto the operation via the standard value =e* of t)e wor= center * he standard value -ey is defined inthe &ustomi ing for )or" centers by choosing $tandard value and is entered in the Basic data screenof the +or- center*

he rules for maintenance for standard values in the +or- center Basic data screen determine



You can enter default units of measure for t)e standard values in the +or- center screenDefault values * 3or inhouse0production operations the default value for the unit of measure of +or- is maintained in the screen $cheduling *

S P

Sales I perations Planning is made up of t+o elements7 standard S P and fle/ible planning*Standard S P comes largely preconfigured +ith the system* 3le/ible planning offers multipleoptions for customi ed configuration* Planning in standard S P is based on product grouphierarchies and is al+ays carried out level by level* 6le2ible plannin is carried out on hierarchiescontaining any chosen organi ational levels (for e/ample# sales organi ation# distribution channel#material# and plant)* Moreover# in fle/ible planning the content and layout of planning screens can bedefined by the users*

@) ./plain the entire Standard PP0P! !ntegrated Process flo+a* Starting from planning to the endb* ,hat are the types of forecastin model used ,here is it being defined and ho+ do

u use it

c* S Pi* ./plain entire processii* ./plain Product group ,hat is it

"* !s it a material Does it e/ist in M'R' table* !f it is not a material# then ho+ does it +or-

iii* Planning types in S P"* ,here do u define it &ustomi e it ,hat r the default planning

types* 3le/ible planning

5* S 3 & P'>& PMa* S PJAPA

his planning type is used for the planning of individual

product groups *b* S PJAPAMhis planning type is used for the planning of individual

materials *c* S P>IS

his planning type is used for the dual0level planning ofproduct group hierarchies *

iv* 9o+ are S P transferred to Demand Management"* ,hat is accomplished in it

v* 9o+ MRP is run"* ,hat happens step0by0step

* +hat is the data out of MRP5* ,hat happens at top0level8* +hen is accomplishedF* ,hat do u see in MRP run and things to consider

vi* ,hat is MRP List"6) ./plain the entire PP0P! process

a* 9o+ things are customi edb* Master data for P!0Sheet# batch managementc* Master data for Process Management

000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000Client Interview # patni

,hat -ind of servers did u do the customi ation>configurationc* esting server d* Production server



• ,here do u define the planning strategieso ,hereo ,hat all do u customi eo Strategy $roup

,here definedRelationship betn Planning Strategies and Strategy $roup

• ,hat is control cycleo ,here do u define Supply 'reas

!s it pic-list>pull list dependent

• !ntegration of PP +ith & >MMo ,hat customi ation do u do in Purchase rder &reationo ,hat are type of purchase rders createdo ,here is it definedo ,hat are movement types

9o+ are they customi ed,here r they defined

• 9o+ do u load the data into S'P system from old systemo ransactiono ,hat is the transaction

• Procedure for P! sheet>process industry

• 9o+ is MPS run

o Difference betn MPS and MRP runo ,hat is run first MRP or MPSo 9o+ do u define part for MPS

• Shopfloor controlso ./ecutiono Prodn Support

• Prodn order not released• &ost not settled• rouble shooting

• ,hat are the master data for R.M• &onfigurations for R.M• 9o+ do u assign product cost collector in R.M

o Production ;ersion • ,hat are the configurations for &

o 'ctivity ypeo &ost &enterso &ost .lementso verhead &ost

• &apacity Planning• ,hat is %PP 9o+ many did u create and for +hat sections of PP• ,hat soft+are did you use for creating the trainin uide

o !nfoPa-• ,hat interfaces of S'P +ith m>c did u use for %ac-flusing

o M.So

9o+ did u bac-flush• Manual or automatic• ./plain entire manufacturing process at . &



o 9o+ +as the i>po 9o+ +as the o>po ,hat +ere the i>p to the prodn lineo .*g* capacitors>P&%sVho+ did they come to the lineo 9o+ are they fed into the assy lineo 9o+ do u -no+ that only "6 products have been used and not "" ,hat interface do

u use 9o+ do u bac-flush in such conditions• &onfigurations for Discrete Manufacturing• &onfigurations of Planning Strategies

o ,hat do u do in it•

Janban>efinitionK' %' production control is a technique for controlling production and material flo+ based ona modular bac-+ard lin-ing of operations in production* he replenishment or production of amaterial is only triggered +hen a production level actually requires the material* K' %' canalso be implemented for organi ing internal or e/ternal production according to the _supermar-etprincipleJ*Selection Criteria

he aim of K' %' is to create a self0regulating environment controlling production andprocurement# and to reduce the manual administrative effort required in production as far aspossible# paving the +ay for shorter lead times and ero inventories*

he success of K' %' depends on the follo+ing conditions7 ' relatively constant consumption level of the -anban part +ithin a period that is greater

than the replenishment lead time of the -anban*Minimum setup times and reliable production along +ith many small lots +ithin a short

period*

Control C*cle B Janban>efinition

he -anban control cycle defines the relationship bet+een the supply source and the demand

source* he control cycle defines the replenishment strategy assigned# the number and contentsof the circulating containers# the -anban (card) print# the delivery address and so on*

Janban Control>efinitionK' %' is controlled by the -anban signal +hich triggers the status change for the containers*

he most important status changes are setting the containers to _fullJ and _emptyJ*he -anban signal is usually triggered by scanning a bar code* ,hen a container is empty# the

system receives the necessary data for the control cycle and for replenishment via the bar codeand automatically carries out the postings required to trigger replenishment* ,hen a container isfull# the goods receipts for the replenishment are posted automatically depending on your settings*

Janban 5oard



he Kanban %oard displays the control cycles sorted according to the supply areas to +hich theyare allocated* 3or each control cycle# all the containers in circulation are displayed +ith their respective status*Selection Criteria!f you select this component# the supply source and the demand source receives a detailedovervie+ of the container circulation* he -anban board can also be used for triggering the

-anban signal*

:valuations>efinition.valuations in repetitive manufacturing provide the follo+ing information7

pull listreporting point overvie+ (goods in process)component reprocessing listdocument log& reports

Statistics and analyses can also be accessed from the Logistics !nformation System7goods receipt statistics

reporting point statisticsmaterial consumption analysisproduction costs analysis

Run Sc)edule %eader >efinition

' Run Schedule 9eader must be created before a material can be planned in repetitivemanufacturing* !t is used for planning and settling finished and semi0finished products that areproduced repetitively over a longer period*

he run schedule header contains no production quantities nor does it contain any dates* %othquantities and dates are planned using run schedule quantities assigned to the run scheduleheader*

RS headers can be created +ith or +ithout a production cost collector* &osts can be settled7via a production cost collector per run schedule header via a production cost collector that is created for several run schedule headersvia production orders

Plannin Run Sc)edule Quantities>efinition

he Run Schedule Auantities specify the production quantities for a run schedule header that areproduced in a certain period* 'ctual data and cost settlement data are collected by the productioncost collector*Planning +ith run schedule quantities is especially useful if7

a product is produced repetitively over a long period of timethe same routings and therefore the same +or- centers are used for the production of a

product family (production organi ed by production lines)

;)ird Client interview ;oleido' )io

l* ,hat phase of pro2ect did u 2oin Pro2 prep phase &ollection phasem* ,hat +as your role in it

a* 9o+ did u collect requirement specificationsb* 9o+ did u intervie+ the clientc* Did u do more reqd collection or documentationd* ./plain the entire blue print creation process



o* ./plain the entire process for Prodn Planninga* Li-e ho+ did u get forecasting 3orecasting module 3orecasting types used 9o+

+as the flo+b* Did it come from S!S ,hy S!S !t is traditional +ay of forecasting ,hy is it

being usedc* 9o+ is the prodn planning does

d* 9o+ is the demand transferred to Demand managemente* MRP Run Planned order Prodn rder ,hat is the requirement type> ordert*pe for PIR and >ependent re&uirement

f* ,hat is the entire flo+ for Prodn planning to e/ecutionp* ,hat is procedure for configuration

a* Procedure for configurationi* 3rom +here do u get the info +hat to doii* %usiness %lue print 3rom ,here elseiii* 9o+ do u decide +hat to config and +here to doiv* 0)at does *our ;eam Leader ive *ou

b* ,hat is the step after config 9o+ are the config put in other serversc* ,hat is ;ransportation Re&uestd* ,hat r different types of transportation request

i* ,or-bench type"* &lient !ndependent ,hat does it contain* &lient dependent ,hat does it contain

ii*e* ,here did u do the configuration !n ne+ pro2ect r in Standard>reference !M$

q* ,hat +as the type of &lient used +hile configurationa* &lient umberb* ype of &lient (Development &lient or Sandbo/ &lient )c* ,as the client on 4ni/ or on

r* ,hat +ere the requirement types and classes used by youa* LS3>;S3b* &lass "66

s* ,hat is the control Key used

a* PP6"V,hat does it contain 9o+ does it affectt* 9o+ do u integrate PP +ith &a* 9o+ is the cost being calculated at &ost &enterb* 9o+ is activity type assignedc* 9o+ is the entire & process &ost center N1 &osting .lement N1 'ctivity ype

u* Did u perform any .nterprise level customi ationa* Li-e creation of plant ,hat is the entire process

v* ,hat is the role of a eam Leader ,hat does he do 9o+ does he guide you

Interview Qns to Amit 8upta

@* !f there are "66 P!Rs and "6 Sales rder Aty and MRP run at mid0nite daily**So based on thefollo+ing strategy +hat +ill happen

a* Strategy "6i* P!R consideredV Sales rder ii* &onvert all the P!RS

b* Strategy 86i* %y Sales rder onlyii* ,hat is the rder ype ( ype ;% for op level item)iii* 4nless +e have sales order no prodn done 01 %ut Planned order for sub0assy

done"6* ,hat is difference bet+een S P and 3le/ible Planning

a* S P is based on forecasting and information from pastb* 3le/ible plnng based on certain selected levels

11. &osting 9o+ activity type accounted fora* 9o+ the cost collectedb* 9o+ do u find the Planned ;s 'ctual

i* 'ctual is done +hile confirmation"* &onfirmation N1 milestone**operationlevel



"5* ,hat is A;P C)ec=in rulesa* &hec-ing group N1 &ollection of rules for given material for specific applicationb* &hec-ing rule N1 each rule specifies +hat needs to be chec-ed Stoc-# receipts#

issues# rders to be chec-edc* ' P done during 8 things

i* Sales order creation (quotation time)

ii* Planned order iii* Prodn rder iv* !nventory Management N1 Missing part

"8* ,hat are the steps# settings and pre0requisite for 'Pa* %usiness System $roup (%S$)

"F* ,hat is the difference bet+een S'P 8*6 b and S'P 8*H ca* !n 8*6 there +as no concept of MRP 'rea

i* MRP area defines +here u +ant to run MRP TMRP" vie+U"* at Plan level

* at Storage locn level5* MRP &ontroller level

"H* +hat is the MM processa* !M7 $oods movement

b* ,M7 ,arehouse Management"G* ,hat is difference bet+een 3inite Scheduling and Lead ime Scheduling

Interview Qns from 0ipro

"F* ,hat are configurations for different strategiesa* Ma-e0to0order and Ma-e0to0Stoc-

b* ,hat is the business process"H* 9o+ frequently do u run MRP"G* 9o+ do u run MRP overall if u have "66 materials

a* ,e do not +ant to run MRP for individual materials**So ho+ is it done"<* 9o+ do +e config material if it has to be planned simulatenously for M S and M"@* !n strategy 86# ho+ do +e consume P!R

6* 9o+ do +e transfer S P to Demand managent"* Say if u have 6 Depot (Distribution center) and 5 Plants

a* 9o+ does requirement flo+ in the systemb* Key things to configure for systemc* Sales plan and prodn pland* Say# if u have confirmed sales order from customer for " month and ne/t months

tentative ordersVho+ do u plane* ,here +ill u enter the data ,hat field

* !n S P# +hat are the planning ypea* !f the req is there for region 01 sales area 01 plant 01 mfg plant# +here +ill the data be

enteredVb* hings to do in S Pc* 9o+ +ill u get sales pland* ,hat is S!S

5* !mportant features of S P8* ,hat are the configs for L PF* ,hat is difference betn 86 and "6

a* 9o+ +ill u consume P!Rb* ,hat if P!R N "66 and sales rder N @6# ho+ +ill system reactc* ,hat if P!RN"66 and sales order N " 6# ho+ +ill system react

H* Difference bet+een et Planning ("6) and $ross0requirement ("")G* &an you run MRP for a specific &ontroller

a* ho+ to do it in system



c* ,hat are the options for running MRP<* &oncept of Schedule Margin Key

a* 3%P# 3'Pb* ,hat is opening Period Say 6 dayV*then ho+ +ill MRP react

@* &apacity Resource Planninga* !f load of resource N "66E and if it goes beyond it#

i* ,hat options should system give56* Difference bet+een Descrete0PP and process industrya* ,>& and Resourceb* Routing and Master Receipe

5"* ,hat are control messages# message destination# P! sheet# instruction categories# differenttypes of instruction type# message categories

5 * ,hat are configuration steps55* 9o+ do u do processing of P! Sheet58* Real0life issues in latest pro2ect5F* ,hat is rgani ation levels for Material Master

a* ,hat r various vie+sb* ,hat if = ,or- Scheduling ? vie+ is not maintained ,hat +ill system do ,hen +ill

it give probs

c* ,hat are options in basic data5H* ,hy do u have material typesa* ,hat is the significanceb* ,hat +ill happen if only " material type based on business processc* ,hat if u have both procurement type Z

5G* % Ma* Different % M &ategoriesb* !tem categories

i* Different item categoriesii* Difference betn Stoc- and on0stoc-

"* 9o+ does it affect the systemiii* ,hat is intra0material item

5<* ,hat is %4LK !ndicator 9o+ does it +or- 9o+ does it affect the % M and MRP run

5@* ,hat are the table number fora* P header N1 '3Kb* P confirmation

86* ,hat are the various reports in PP

t)er vendor interview &uestions

" * ,hat are the Special procurement Je*sa* F 7 &ollective order b* 567 Sub0contracting

"5* ,hat is rder Settlement ,here do +e do it"8* ,hat are the rder ypes"F* 9o+ is re+or- done 9o+ is itJs config"H* ,hat is collective accesss of production order "G* ,hat is the role of MRP &ontroller"<* ,hat is % M alterantive material N1 based on lot0si e dependent consumption"@* 4 have -inds of battery (Duracell used 86E of time and .veryready used H6E of time)**9o+

+ould % M be configureda* $roup Material 01 N1usa e probabilit*

6* ,here is automatic goods receipt indicator maintaineda* Prodn Scheduling profileb* ,or- &enter c* Routing

"* ,hat are the configurations for MRP at Plant level* ,hat is MRP type# Lot0si e# schedule margin -ey

5* ,hat is %ul- Material ,here is the indicator maintaineda* !f u have "666 fert then ho+ much bul- material +ill be consumed



a* ,hat is meant by e/ternal processing of order i* ,hen a specific operation is outsourced to other vendor for processing#

instead of performing in0house*ii* !n this case# purchase requisitions are created

b* Difference bet+een Sub0contracting and ./ternal processingi* !n Sub0contracting# u send the product '# % to the vendor and get the

transformed item Say Z as input from the vendor "5* batch managementa* 9o+ do u define batch characteristics# batch values# batch determination rule

"8* Difference bet+een PP0Discrete and PP0P!a* !n PP0P!# +e have inspection at every processing step* 9ence the process control

system is simplifiedb* PP0P! can have electronic batch recordingc* PP has rder C)an e Man aementd* PP has PR Js but PP0P! does not havee* PP has Routing# PP0P! has Recipesf* PP has ,or- &enters and PP0P! has Resources

"F* !ntegration of PP +ith other modules and your e/pertiseDo ot Kno+# Kno+ledgeable (minimum e/p)# Strong (+or-ed on it fe+ times)# e/pert (done it

many times)a* PP Modulei* S P7 e/pertii* MRP7 Strongiii* S3&7 Strongiv* Master Data7 Strong (% M# Routing# ,&)v* &RP7 -no+ledgeablevi* Product &ost &ollection7 Strongvii* ,are0house mangemen7 Kno+ledgable

b* MM Modulei* !M7 Strongii* Purchasing7 Kno+ledgableiii* Logical !nvoice7 strong

c* Logistic0$enerali* ;ariant &onfig7 Strongii* %atch management7 Strongiii* &lassification7 Strongiv* Material Master7 ./pert

he openin period is the time required by the MRP controller to convert the planned orders intopurchase requisitions* !t is only ta-en into account +ith bac-+ard scheduling*

5ac=ward Sc)edulin for InB%ouse Production

Implementation ptions

3or materials that are planned according to the MRP and forecast0based planning procedures# therequirement dates in the future are -no+n* Scheduling is al+ays bac-+ard* he system automaticallys+itches to for+ard scheduling only if the start date lies in the past*

Process 6low

8* he system calculates the oods receipt processin time bac-+ards using therequirements date and thus determines the order finis) date *

F* he system calculates the inB)ouse production time bac-+ards using the order finish dateand thus determines the order start date *

H* he system calculates the openin period bac-+ards using the order finish date and thus

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R.M Profile7NNNNNNNN

Post processing7 !f standard costing done for 2uly but 2une open# +ill post processing be done bycogi ,ill cogi allo+ it

9o+ is cost difference posted in the material master MR "

9o+ do you upload % M components for same header material for LSM,9o+ many steps are there in uploading LSM,*

9o+ does re+or- process +or-NNNNNNNNNNNNNNNNNNNNN3or Process industry you use batch management (on basis of batch) quality chec- no up to themar- Process the material again no re+orat operation level create a ne+ production order+ith ne+ order type finished product put to bloc- stoc- or separate storage location consume thefinished product in some other production order associate the cost to a material or cost center

"* &an anybody tell me about MRP Key*

* &an Somebody tell me about the MRP procedure in S'P* 's per my-no+ledge there are t+o type of MRP Procedure7

i) MRPii)&onsumption based planning(Reorder Point#3orecast I ime basedplanning)!f anything is there apart from the above# please e/plain me*

5* 's a case# i +ant to implement Reorder point planning(automatic)for some of my materials categori ed under Regular consumables*Please tell me the necessary changes to be done in the system*(!M$#

Material Master# PR# P # $R I !R)NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNM%F (f i i )



00000000000000000000000000000000000000000000000000000000000000000000000000000000A7 Ma-ing the =Auota 'rrangement 4sage? field in Purchasing ;ie+ of MM6" as optional instead ofrequired7

Soln $o to transaction MSR * !n the search option# enter field name M'R&04S.A4* ote theBSelection $roup umberB for this field*

You then go to MSE and ma-e the field optional for this selection group for R 9 material type*

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNA7 L!S report updation for S@5" to S@5@

'7 spro 00 1 Logistic $eneral 001 Logistic !nformation System Logistics Data ,arehouse 0014pdating 001 4pdating &ontrol 001 'ctivate updateNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN&reate Production rder 7 &o6<NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

'll $R from production order happens through the "6" movement only* So this should help # and it is

al+ays advisable to have different movement types +hile you do re+or- and normal production*00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000A7 &ustomi e % M field status

'7 P3'Spro 01 Plant Maintenance and &ustomer Service 01 Maintenance Plans# +or- center 01 ,or- &enters01 $eneral Data 01 Define 3ield Selection0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000Define =&ontrol Keys for perations? used in % M N1 P66 (e*g* PP6" N1 !n0house prodn +ithoutconfirmation)00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000"* Maintain P!R for materials at depot plants in the system* * Run MPS>MRP so S R is created at depots +hich are then converted to S by depot planners*

his +ill put requirements (demand) on production plants thru SPK* 5* MPS>MRP at production plant +ill create planned orders to cover these S # +hich the plannerscan convert to production orders and ship to depots against these S s* 8* Depots perform $R of materials from production plants against these S s and ship out ofinventory to deliveries for sales orders at depot* F* 4nder this scenario# the sales orders must be created in the system +ith depot plants as deliveryplants* H* 3or the production plants# it is only the S Rs and S s that +ill provide demand visibility against+hich the production planning must be performed*NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

& 687 &hange &haracteristicsNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

Master Recipes (PPBPIBM>$

Purpose

You can use this component to describe an enterprise0specific process in process industries wit)outrelatin to a specific order *

Master recipes are mainly used for planning the manufacture of products* 9o+ever# you can also usethem to describe the clean0out or changeover of a production line*

Master recipes are used as a reference for process orders as +ell as the basis for product costing*

he approval procedure for master recipes and the functions for planning and documenting changesbl t t th t i t t i t f $ d M f t i g P ti ($MP)*

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!n case of repetitive mfg# machines are arranged so that manufacturing seqence is follo+ed as per therouting of the material* Material moves thru these machines automatically e*g* conveyer* Series ofthese machines is called production line*9ence material moves thru the machines (production line) at a determined rate* his rate is important

parameter for repetitive mfg as it determines ho+ many 2obs a production line can ma-e per giventime*

in R.M basically mass prod*** assy line components# the prod starts +ith the planned order itself***bac-flushing plays a very important role here +hile $! I $R# here you should use Rate routingV

Item Repetitive >iscreteProduction Suitable for bul- qty produced over a certain period of

time*Suitable for frequent change overs > lot +isemanufacturing

Product follo+s the same sequence of operationsthrough the machines*

Suitable for comple/ operation sequences

Data Punching Minimal ./cessiveProduction rder o production order# Data punching +ill done for item

code and produced quantity*

Lot +ise# item +ise individual orders +hich +ill be much

at higher side* \ 866]8F6 production orders +ill becreated for each unit per day* Production order closingto be done either by completing the order or shortclosing*

delays Possible +ith single reason Possible +ith single reasonPR s ot Possible Possible&o0product ot Possible PossibleMaterial availablity chec- ot Possible PossibleRe+or- o proper +ay available Possible

ransaction Less MoreProduct &osting &ost and variance are analy ed for a particular period

(Monthly)*&osting and variance +ill be done production lot +ise

Settlement Periodic settlement .ach and every production order has to settled# hencemore efforts reqd*

System performance ,ill be better for log time Performance +ill be detiorited in very short periodMRP result o impact ,ill be affected in case of open production order hence

+e have to close the open production order manually

before every MRP runLife consumption counter ot Possible Possible

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNA7 9istorical data maintained at organi ational level along +ith distribution channel and forforecast base planning it is required at material level in pp module* 9o+ u +ill do it

'7

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNA7 ! +ant to ma-e MRP controller as compulsory field during creation of Purchase Request*

'7 $o to spro 01 matls management# purchasing# purchase request and feild selection for Pr andpic- %% document tpe and change material planner to required entry*

M.%NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNAueries"* Difference b>+ pic- list and pull list

* schedule lines (in MRP)5* Auota arrangement in PP (its application)8* ,hat is the significance mi/ed MRP field inmaterial master F* +hat is planning calender>planning cycle

H* +hat is "st dayBs supply I nd dayBs supplyG* ,hat is overall change profile ( &M)<* a brief on data migration tools (LSM,# %D&# S&' )@* h i 0d d b 0 h i S P



"6* Difference b>+ detailed scheduling# productionrate scheduling and rough cut scheduling""* 3i/ed and movable parameters in order confirmations" * effectivity in % M"5* +hat is the difference bet+een follo+ing

confirmations for operations i* ime tic-et ii* time event iii* collective entry iv* progress confirmation and +at is the basic difference bet+een enteringconfirmation for operation and fast entry

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN 'fter MRP Run

B RDR.SB means order reservation for process>prodn order BD.PR.AB means dependent requirement for a planned order

BAML B means the order is delivered and is in A! status a+aiting usage decision*

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN!ntervie+ qns70000000000000000

* +hat is cu tomising

* +hat is mapping

5* +hat is configuring

8* +hat is meant by legacy data

F* +hat is your personal role in all the above

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN9i $o-ul ^Planned rder # as the name suggests is meant basically for Planning Purposes*!t gives the indicationthat +e need to PL' this much quantity either thru PR or Prod* rder*Planned rders are the output of MRP run* fcourse u can create manually also*Production rders are authorisation to Produce*,e are no more in PL' ! $ mode but in.Z.&4 ! mode*So u need Prod* rder to get the qty*MRP controller can ta-e his>her o+n time to convert Planned rd* into Prod* rd bBco of e*g*resourceconstraints* hatBs +hy +e need Planned rd*!n nutshell Planned rd are S 3 prod*orders*4 r slating to produce but not producing*!n prod*orderu r producing# literally*

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

%y default Set up time is constant* !t is not dependent on operation qty* !f qty is F6 for operation "6*setup time mentioned in routing is "6 min* hen "6 mins is total set up time for operation "6 and F6 qty*9ave a loo- in +or- centre formula for Setup # there is no qt parameter in it*

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNhe follo+ing control parameters can be set in a long0term planning scenario 7

Planning period # MRP type# ;ersion of available capacity

,hat are the main features of the MRP types BPDB or B;%B-P>- tri ers a 5 M e2plosion >. -@M- can use t)e forecast for t)e calculation of t)e safet* stoc=

0)at is t)e meanin of t)e plannin time fence+



In forecastBbased plannin ' w)ic) forecast model does SAP support+seasonal trend model

0)at conditions must be fulfilled in Customi in if a production order is to be c)ec=ed foravailabilit*+

%* Scope of c)ec= 5. C)ec=in roupC. c)ec=in rule >. C)ec=in assi nment

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN 'P and ! are 6inite PLA77I78 tools* ,hen MRP runs +ith 'P or ! (or Red Pepper orManugistics)# it ta-es &apacity issues into consideration* MRP in S'P R>5 &ore does not# it assumesinfinite capacity available* (MRP only loo-s at material availablity*)

! believe 'P should only be used in ver* lar e companies (billions) because of the amount ofmaster data that must be maintained# and that data better be '&4R' .# or youBve +asted a hec- of a

lot of time

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

MRP

MRP Capacit* levelin and 6inite Plannin and 6inite Sc)edulin

%ut# S'P has C &apacity Leveling C* ,hat that means is you run another program after MRP (&M G and&M <)# +hich can be run in batch mode overnight* ( here is a ton of configuration and thin-ing that+ill be required to do this^)* he capacity leveling program +ill recogni e the constraint at the +or-center level # and fill up the first day# then re0schedule the ne/t order to the ne/t available capacity#then the ne/t order searches for available capacity# and so on* his is called C 3inite Scheduling C* heproblem +ith this is the opposite of !nfinite Planning# +hich is it doesnBt ta-e Material availability intoconsideration^ he system +ill re0schedule a production order +ithout thin-ing about +hether thematerials +ill be available or not*

6inite Plannin does 3inite Scheduling at the same time* !f there is no capacity available on thedesired date# the system loo-s for +hen capacity !S available* hen it stops to see if Materials +ill alsobe available (usually based on the lead0time for those components)* !f there is a material problem#then the system figures out +hen the materials ,!LL be available# and then chec-s to see if capacityis available on 9' day# and if so# it bloc-s off capacity# and allocates the materials for that day*


>ifference between C #< and M5#3

!n & G you can vie+ the production order details +henever required butin case of M% H itBs a general pic- process*,here as in & G you can customi e your o+n Pic- Profile for the pic-ing option based on the clientrequirement* %ut this does not ta-e place in case of the transaction M% H*



00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000%y default system +ill fetch the +or- center for the operation from theProduction rder# for the first confirmation fro the operation* You have thefle/ibility to change the same during confirmation*During the ne/t confirmation for the same operation# system +ill fetch the+or- center entered in the last confirmation*000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000)en to use P)antom Assembl*

ur Crule of thumbC is that if +e do not hold stoc-s of a material# it is created +ith special procurement-ey F6 (N Phantom assembly)*

e*g* in our business +e manufacture petfood* the actual food in the can is made up of gravy and meat*he meat is stoc-ed so is a non0phantom# but the gravy is made up of po+ders and liquids +hich +e

mi/ together then add the meat into it* !n this case the gravy is a phantom material (+ith a % M) as +edo not stoc- it* !t is an Bin0lineB product* i*e* it is produced and immediately used to produce somethingelse*NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

Please refer above sub4ect and would li=e to do followin . :2ternal Processin ;ime I )ave setin usin PPQ. M* client want t)is time set differentl* for different @endor. Is t)ere an*usere2it or customi ation settin s+

3 MRP l d i b li # d h 5 i 7



") he config in PPA 0 ./ternal procurement at plant level (or PPR at MRP grp 0 Scheduling>doc*type) should have the chec- bo/ mar-ed to read Sched'greem>!nforecord leadtime ( 5@@D0$ .RM)

) You should have a contract>schedule agreement# or a purchase info record maintained for thatplant0material0vendor combination

5) You should maintain source list (M.6") for the contract>schedule agreement# or info record* hischanges the default behavior of MRP to use leadtime by supplier# rather than material masterleadtime* ,hen both contract and info record e/ist# the contract +ill ta-e precedence*

Please +atchout for the case if youBre already using contracts>info records in procurement# but notusing them for planning* !n this case your leadtime data in these documents may be incorrect# or maybe left blan- 0 this +ill be interpreted as ero if you ma-e this change implementation# as mentioned inthe steps above*

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNransaction &odes in S'P0PP and !ntervie+ qns

00000000000000000000000000000000000000000000000000000000

http7>>dsmsap*blogspot*com>NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNMMP; and MMP!7 for closing and initiali ing the posting period for materials* his is used to solve theproblem of old>prev posting period +hich does not allo+ u to create ime ic-et or $!>$R*NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN

opic7 Substitute Matl instead of 'lternate % M# if u +ant system to automatically select a particular% M based on availability of matl*

! have alternate boms to manufacture a material* %ut ! +ant the system to consume>select the bom+hich is available in stoc-*./7 3in product 7 3"# ra+ mat 7 R" I R

'lt%om" for 3" is R" I 'lt%om for 3" is R *

%oth of my boms are valid at all the time I for all lot si e# so ! can not use Prod ;ersion*o+ there is a reqmt for 3"* ! +ant the system to consider R" > R +herever there is a stoc-* Priority+ill be given to R" if that alone can fulfill# ne/t to R if that can fulfill I both R" I R if combiningly canfulfill* !f even combiningly can not fulfill then the system should generate a Planned order* 9o+ can ! do that 9as anybody idea of using 'lt%om grp

Ans! thin- your problem can be solved by using BSubstitute MaterialB rather than using 'lt % M* u can givethe probability of usuage for material R"# R *[ust try this*%asically alternate % Ms can be selected by using Prod*versions if other para are equal*

's u +ant system to select the Materials automatically 'lt % M +ill be of no help*


" Long erm Planning (L P)Provides detailed off0line e/amination of planning scenarios simulating full production# purchasing andcosting implication*L P provides a method for7

" Simulation of future demandLeveling capacity

5 Planning costs

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http://dsmsap.blogspot.com/



F Previe+ for inventory management

0 5.1 Long Term Planning Process:-

L P process has 3!;. ma2or steps# they are" "* &reate scenario

* Define forecasted Plan in the scenario5 5* Run simulated Material Requirement Planning for the scenario8 8* 'naly e the result*F F* ransfer the results to Purchasing and costing information system

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN,hen MRP is run everytime# all the planned orders (including thoseare not converted to production order) are re0+ritten* 9ence +e are notable to get trac-* ,ee-ly once MRP is being run in our scenario*

,e need to -no+ planned orders +hich are not convered to productionorders(atleast pertaining to current +eee-)*

'ns00000

ld Planned rders are deleted I recreated only if you use Planning Mode C5C in your PlanningParameters (MRP Run initial screen)*Please use C"B or C B I ur old Planned rders +ont be deleted I u have a trac-***!n any case# no trace is available for deleted Planned rders in the system# this is a standard S'Pdesign

here are t+o +ays to -eep trac- of the planned orders

"* Mention planning time fence for your material say of three +ee-s or t+o then it +ont chenge the

planned order automatically in the ne/t planning run* 3irm the planned orders created after the planning run +hich is carried out each +ee-* so that they

+ont be changed ne/t time

NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN• Production orders are al+ays scheduled using lead time scheduling for the operations• ' Production order al+ays contains both sets of fates (basic date and scheduled dates)• Scheduled dates are relevant for production• o guarantee smooth materials requirements planning# it is absolutely necessary to schedule

a routing and to update the material master +ith the scheduling results*•

000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000+ip report use transcation M%F% > M%F0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000A7 Selection of t+o active production version during MRP run

'7 after MRP# first production version +ill be select by the system* if you +ant other production version to be choose# then go to c 5 and loc- the first one*

'7 u can do it by M:Q1 quota arrangement very easilt

A7 !n my system# ! created a finished material* he structure is7



3.R (3 66<6")

9'L% (9 66<6") 9'L% (9 66<6 ) (Aty ") (Aty ")

R 9 R 66<65 (Aty )

R 9 (R 66<6") R 9 (R 66<6")

(Aty ") (Aty )

Problems"* ./ploded % M using &S""# &S" # and &S"5* &S"" and &S" +ere K# but &S"5 does not

display both 9'L%s* [ust sho+s 5 R 9s** ,hile running MRP# it does not plan for 9'L%s# 2ust plans for 3.R and R 9s* ,hat could

be the reason

! have attached all the screenshots of MD6 and MD68* 3rom these screenshots# can you interpret+hat could be the problem 'm ! doing something +rong in settings

M>!# Screens)ots



M>!/ screens)ot



Master >ata

Organizational Structures

"* ,hat are the various organi ational structures in the R>5 System

* ,hich R>5 organi ational structures are used primarily for PP

5* ,hat is the relation bet+een controlling area# company code# valuation area# plant and storagelocation

Material Master

"* ,hat is the purpose of different material master vie+s

* ,hich vie+s are available

5* ,hich vie+s are used primarily for PP

8* ,hat is the relationship bet+een material master vie+s and individual organi ational structures

F* 9o+ does the industry sector influence the material master maintenance

H* 9o+ does the material type influence the material master maintenance

G* hat is the difference bet+een e/ternal and internal number assignment and ho+ is it set up in



<* ,hich other factors can influence the selection of fields in the material master

@* 9o+ can MRP profile and forecast profile be used to optimi e material master maintenance

"6* 9o+ can a material master be reorgani ed (deleted>archived)

""* ,hich units of measure can affect processing in the material master (base unit of measure#production unit# order unit# etc*)

" * ,hat is the material status used for and on +hich levels could it be maintained

"5* Revie+ the usage of the follo+ing settings

- MRP group

- MRP type

- Reorder point

- Planning time fence

- MRP controller

- Lot si e

- Procurement type- Special procurement type

- Production storage location

- %ac-flush flag

- Stoc- determination group

- %ul- material

- Scheduling margin -ey

- Safety stoc-

- Strategy group

- &onsumption mode andconsumption period

- 'vailability chec-ing group

- 'lternative selection flag

- Dependent requirement flag forindividual and collectiverequirements

- Production scheduler - Production scheduling profile

- 4nderdelivery>overdeliverytolerance

- !n0house production time (lot si edependent>independent)

- ;aluation class

- Price control indicator

- Moving average price>standardprice

Bills of Material

"* ,hat is determined by % M usage

* ,hat technical types of % M are available

5* &an the technical type of a % M be changed

8* During +hich processes +ill % M usage and status be considered

F* ,hen +ould it be useful to ma-e use of a $roup % M

H* ,hat is meant by area of validity and effectivity of a % M

G* ,hich item categories are available and +hat are their specifications

<* ,hat is a sub0item

@* 4nder +hich circumstances could a % M be recursive and +hat the usage of the recursiveindicator

"6* ,hat is a %ul- material (planning# costing)

""* ,hat is the usage of the follo+ing % M settings

- ./plosion type

- Relevant to production

- Relevant to costing

- Material provision indicator

- %ul- material

- Production storage location



Work enters

"* ,hat is a +or- center category

* ,hat data can be maintained on the various vie+s (basic# default# capacity# scheduling# costing#etc*)

5* ,hat is the purpose of a standard value -ey

8* ,hat role does the operation control -ey play,hat does referencing mean

F* ,hy to use a +or- center hierarchy,hat is a pooled capacity

H* 'naly e the usage of the follo+ing fields

- %ac-flush indicator

- &apacity category

- 3ormulas for determining capacityrequirements

- Rate of capacity utili ation- Relevant to finite scheduling

indicator

- verload

- 3ormulas for scheduling

- Location group (move time matri/)

- Aueue times (normal andminimum)

- &ost center

- 'ctivity types- 3ormulas for costing



!outings

"* ,hat does a routing define

* 9o+ is a routing structured

5* ,hat tas- list types are available in the R>5 System8* ,hat is a routing group and group counter

F* ,hat is a routing sequence# and +hat types of sequence are available

H* ,hat could be reasons to use sequences

G* ,hat are the various options to assign materials to routings

<* 4nder +hich conditions +ould it ma-e sense to assign components to operations

@* ,hat is a reference operation set

"6* 9o+ could the lotsi e0dependend inhouse production time be calculated and updated into thematerial master

Pro"uction !esources#Tools

"* ,hat types of PR are available

* ,hat is the relationship bet+een PR s and a routing>operation

$ngineering %ange Management

"* ,hat are the ob2ectives of .ngineering &hange Management

* ,hat is the significance of changes +ith a history

5* ,hich PP ob2ects can be managed using .ngineering &hange Management

8* ,hat is the purpose of an engineering change request>orderF* 9o+ is a change master record structured

H* ,hat is a revision level compared to engineering change master

Ot%er &ssues

"* ,hich scheduling options are available# and ho+ do they differ from each other

* ,hich time components are ta-en into account during scheduling

5* 9o+ are basic order dates determined

8* 9o+ are the scheduled dates determined

F* ,hich scheduling types are available in lead time scheduling

H* ,hat role do reduction measures play in scheduling

G* ,hat types of scrap can be maintained in PP basic data and ho+ +ould they be consideredduring MRP respectively scheduling

<* ,hat is e/ternal processing# and +hat conditions must be fulfilled before e/ternal processingcan ta-e place

@* ,hat are co0products



G* ,hich types of availability chec- are available (' P and chec- against planning) and +hatare the characteristics of these chec-s

<* ./plain the lin- bet+een MRP group# strategy group# strategy and requirement class*

@* ,hat settings could be made in requirements classes (on PP as +ell as on SD side)

"6* ./plain the purpose of version management in Demand Management

Master Pro"uction Sc%e"uling

"* 4nder +hich circumstances +ould you recommend the usage of MPS

* &ompare the functionality of MPS +ith MRP

5* ,hat is meant by the _firmingJ of procurement proposals# and ho+ can this effect beachieved

8* ,hat is a planning time fence# and +here is it defined

F* ,hat is a manual firming date# and +here is it defined

H* 9o+ can a planned order be _firmedJ# and +hich firming indicators are available in a plannedorder

Material !e*uirements Planning

"* ,hat is the purpose of MRP and ho+ does it fit into the PP planning environment

* 9o+ +ould you organi e MRP runs Discuss the different options

- MRP for a plant : online

- MRP for a plant : in bac-ground

- MRP for a material (individual planning) 0 online

5* ,hich planning types are available ( .4PL# . &9# . PL)8* ,hich planning parameters are to be set in the application itself

F* ,hat is the function of the planning file

H* ,hat is meant by single0level planning# multi0level planning

G* ,hat is meant by interactive MRP

<* ,hat are the characteristics of an MRP scenario that is performed in simulation mode

@* ,hat is meant by lo+0level code and ho+ is it considered in MRP

"6* ,hat is a net requirements calculation

""* ,hich buffers can be ta-en into account for the net requirements calculation in MRP (quantity

buffer7 safety stoc-# time buffer7 safety time)" * ,hat does lot0si e calculation entail

"5* ,hich lot0si ing procedures are available in the R>5 System (static# periodic and optimi ingprocedures) ,hat are the characteristics of these lot0si ing procedures

"8* 9o+ does the procurement type defined in the material master affect MRP

"F* ,hat is bac-+ard scheduling ,hat are the characteristics of bac-+ard scheduling

"H* ,hat is the difference bet+een basic scheduling and lead time scheduling



"G* 9o+ are the order due dates determined in basic scheduling

"<* 9o+ are the order due dates determined in lead time scheduling

"@* 9o+ does the in0house production time defined in the material master affect scheduling

6* 9o+ does the scheduling margin -ey affect scheduling

"* ,hat is the purpose of an % M application* 9o+ are % Ms selected in MRP ,hich criteria are ta-en into account during % M

selection

5* ,hat is a _% M selection !DJ

8* 9o+ are alternative % Ms selected

F* ,hat is a production version

H* 9o+ are routings selected in MRP ,hich criteria are ta-en into account during routingselection

G* ./plain the usage of navigation profile# filter and selection profile*

<* ,hat is an MRP list ,hat is a stoc->requirements list 9o+ are these lists structured ,hat

are the differences bet+een these lists@* ,hat is the function of e/ception messages

56* ,hat are planned orders

5"* ,hat is meant by the individual>collective conversion of planned orders

5 * ,hat is meant by =daysJ supply? and =receipt daysJ supply?

55* 9o+ can component discontinuation be managed in MRP

58* ,hat is the purpose of MRP0'reas

5F* ,hich different MRP0'rea types are there

5H* ./plain the concept of the MRP0'rea types CPlantC and CStorage LocationC*

Product Cost Plannin

'eneral &ssues

"* ,hich organi ational structure(s) are relevant for product cost planning

* ,hat is a cost element (primary>secondary)

5* ,hat is a cost component

8* ,hat is a cost component split# itemi ation# costed multilevel % M

F* Describe a cost component structure*

H* ./plain the costing variant and the main settings in customi ing*G* ,hat is a costing type

<* ,hat settings can be done in a valuation variant

@* 9o+ is a costing sheet structured



+nit osting ,it% Base Planning O ect

"* Describe unit costing

* ,hich master data are required for unit costing +ith base planning ob2ect

5* 9o+ can results of unit costing +ith base planning ob2ect be used in further calculations

8* ,hat main item categories are available in unit costing +ith base planning ob2ectF* ,hich cost estimates could be used as an input for unit costing +ith base planning ob2ect

ost estimation ,it%out *uantit/ structure

"* ,hat is meant by quantity structure

* Describe costing +>o quantity structure

5* ,hich master data are required for that costing logic

8* ,hich cost estimates could be used as an input for cost estimation +>o quantity structure

F* ,hich material master settings are relevant to product costing

ost estimation ,it% *uantit/ structure

"* Describe cost estimation +ith quatity structure

* 9o+ can the quantity structure be determined

5* ./plain ho+ cost elements are determined for material costs# production costs# overheadcosts# abc costs*

8* Describe the concept of activity based costing

F* ./plain the function of template and business process +ithin activity based costing*

H* 9o+ could results from standard cost estimation be updated into the material master

G* ,hat happens if stoc- is on hand during that price update

Repetitive Manufacturin

'eneral &ssues

"* ,hat are the differences bet+een discrete manufacturing and repetitive manufacturing

* ,hat are the characteristics of ma-e0to0stoc- repetitive manufacturing and ma-e0to0orderrepetitive manufacturing

Master )ata for Make-To-Stock !e(etiti e Manufacturing

"* ,hat master data are necessary in repetitive manufacturing (material master# bill of material#production line# routing)

* Describe the the follo+ing material master data7

- Repetitive manufacturing indicator

- Repetitive manufacturing profile

- Production versions



5* ,hich ob2ect is used to collect the material costs and production activities

8* ,hat are the various options available for establishing a lin- bet+een the cost collector andthe production version of a material ,hat role doe the repetitive manufacturing profile playhere

Planning Make-To-Stock !e(etiti e Manufacturing

"* ,hat is the purpose of the planning table in repetitive manufacturing ,hat functions can bee/ecuted from here

* ,hich options e/ist to create run schedule quantities instead of planned orders during theMRP run

5* ,hat is meant by C verdue quantityC

Material Pro ision

"* Describe the usage of pull list and stoc- determination as one of its function*

* ,hich other logics are available to ma-e sure that sufficient components are provided to theshop floor

Backflus%

"* ,hat does bac-flush mean in a repetitive manufacturing conte/t

* ./plain the functions of final bac-flush*

5* 9o+ could planned production quantities be automatically be ad2usted during final bac-flush

8* 9o+ +ill the system react +hen a final bac-flush posting is cancelled

F* 9o+ can production activities be entered in the system

H* ,hat is meant by post processing list

G* ,hat are the advantages and disadvantages of negative stoc-

<* ,hat does the reporting point bac-flush procedure entail

$ aluations

"* ,hich evaluations are available

* ,hich information could be gained from bac-flushing documents

5* ,hat is a reporting point overvie+

Production rder Processin

'eneral &ssues

"* ,hat are the characteristics of +or-0to0order production

* ,hat is defined in a production order

5* ,hat is a document type# an order category and an order type

8* ,hat are the various elements that a production order contains



F* ,hich functions are e/ecuted +hen an order is created

H* ,hat are the various options available for creating an order

G* Describe the system logic during routing selection

<* Describe the system logic during % M selection

@* 't +hich point in time are reservations generated and +hat information does it contain"6* ,hat can be achieved by performing the =Read master data? function

""* 9o+ could routing sequences be considered during production order creation

" * Describe the conversion of planned orders into production orders +ith focus on schedulingaspects

Or"er !elease

"* ,hat happens +hen an order is released

* ,hich operations are made possible and +hich are prevented +hen an order is released

5* ,hat is meant by status management8* ,hat are business transactions

F* ,hat are the differences bet+een system status and user status

H* 't +hich points in time can availability chec-s be performed ,hich settings can be made#and +hich must be made n +hich ob2ects can the availability chec- be run

G* ,hat is meant by machine commitment

<* ,hat is meant by midpoint scheduling

Printing

"* ,hich shop floor papers can be printed

* ,hich print modes are available (online# update# bac-ground)

5* ,hat does =reprinting? mean

8* ,hich conditions must be fulfilled before order documents can be printed

F* ,hich conditions must an operation fulfill before shop floor papers (and in particularconfirmation slips and time tic-ets) can be printed

'oo"s &ssue

"* ,hich control indicators influence the behavior of the components in the production order(bul- material# bac-flush# phantom assembly# etc*)

* ,hat is meant by pic-ing

5* ,hat is meant by stoc- determination ,hich settings have to be made for stoc-determination during production order processing

8* ,hat is a goods issue posting

F* 9o+ can goods issues be entered (reference to order# reference to reservation# unplanned#etc*)



H* ,hat is the purpose of movement types

G* ,hat are the effects of a goods issue posting from an integrational point of vie+ (MM# 3!#& )

<* ,hat is meant by the bac-flushing of components and ho+ can this be achieved

onfirmation

"* ,hich conditions must be fulfilled before confirmations can be entered

* ,hat is a confirmation

5* ,hich functions are lin-ed to confirmations

8* ,hich confirmation procedures are available

F* ,hat data can be entered during confirmations

H* ,hat is a milestone confirmation

G* ,hat is an unplanned milestone

<* ,hat identifies a progress confirmation@* ,hat role does the control -ey defined in the operation play during confirmation

"6* !s it possible to lin- a confirmation +ith a goods movement posting

""* ,hat is a goods receipt

" * ,hat are the effects of a goods receipt posting

"5* ,hat is the relevancy of the =delivery completed? indicator

"8* ,hat is the function of overdelivery>underdelivery tolerance in the material master play

Or"er Settlement # rc%i ing an" )eleting

"* ,hat is meant by order settlement

* Describe the individual steps during the logistical lifecycle of an production order and

5* their integration to cost ob2ect controlling*

8* ,hat is the difference bet+een prelimenary costing and actual costing

F* ,hich are the usual steps during order settlement

H* ,hat means variance calculation

G* 9o+ is an order settled if the header material is a standard price material

<* 't +hich points in time can an order be settled

@* ,hich conditions must be fulfilled before an order can be archived"6* 9o+ are orders archived>deleted

""* ,hat is meant by =residence times?

Or"er &nformation S/stems

"* ,hich information systems can be used for order management



* ,hat are the characteristics of the order information system

5* ,hat are variable ob2ect overvie+s

8* ,hat are the special characteristics of a (multi0level) order report

F* ,hat is the difference bet+een the order information system and the Shop 3loor !nformationSystem

H* ,hich functions are available from the order progress report

utomation O(tions

"* ,hat options are available for automating the processing of orders

* ,hat role does the production scheduling profile play

5* Describe the most lean production order and the necessary settings to achieve it

8* ,hich functions could be e/ecuted in the mass processing

ollecti e Or"ers

"* ,hat are the characteristics of collective orders

* 9o+ can collective orders be created ,hich conditions must be fulfilled

5* ,hat are the advantages of +or-ing +ith collective orders

8* ,hich functions can be performed on collective orders

F* 9o+ is scheduling for a complete collective order done

H* ,hat happens if a date>quantity for an order is changed +ithin the collective order

Lo istics Information S*stem

)ata Ware%ouse"* ,hat is the concept behind the Data ,arehouse

* ,hich individual information systems does the S'P Logistics !nformation System comprise

5* ,hat data are evaluated by the information systems

8* ,hat are info structures ,hat are the characteristics of info structures

F* !s there any relationship bet+een system transaction data and the data in the info structures

H* ,hich reporting options are available in the S'P !nformation System

G* ,hat is the difference bet+een evaluations in L!S and evaluations on system transaction datain the PP component

Stan"ar" nal/ses

"* ,hat are standard analyses

* ,hich navigation options are available in standard analyses

5* ,hich options in standard analyses can be used to influence the +ay in +hich data ispresented



8* ,hich analysis functions are available in standard analyses ('%& analysis# comparisons#classification# etc*)

$arl/ Warning S/stem

"* ,hat is an =early +arning system?* ,hat are the various applications for the early +arning system

5* 9o+ can the early +arning system be used in standard analyses

8* ,hat is an e/ception analysis

F* ,hich options are available for defining that an analysis should be performed at regularintervals

H* ,hich types of analysis are available in the early +arning system (threshold value analysis#trend analysis# planned>actual comparison)

2le3i le nal/ses

"* ,hat are fle/ible analyses ,hat is the difference bet+een fle/ible analyses and standardanalyses

* ,hat are evaluation structures ,hat are evaluations



A*5 ,hat are the planning strategies have you used ./plain Planning +ith 3inal assembly (86)and Planning +ithout final assembly (F6) planning strategies !n Material Master +here youdefine Planning strategy (on +hich vie+ )


A*F 9ave you +or-ed on %atch Determination ./plain me +hat are the %atch LevelJs areavailable ,hat do you configure for the %atch determination 9o+ it +or-s

A*H ell me about lot si ing procedure 9o+ it +or-s !n the Material Master +here do youdefine Lot si ing procedure -ey





A*"" ,hat is Routing for ell me types of Routings* ,hat are the configuration you do forRoutings



A*" ./plain me about &apacity .valuation and &apacity Leveling* ,hat transaction code haveyou used for that


A*"8 9ave you done testing ,hat type of testing ./plain the steps of each testing that youhave done Li-e any test scenario or any test process have you developed

A*"F 9o+ MM>PP>,M integrates +ith each other ell me the point of integration*

A*"H ,hat is Production ;ersion ,hy it is useful

A*"G ,hat is ;ariant &onfiguration ,hat -ind of Settings you have maintained for the ;& inProduction Planning Process

A*"< ,hat is Super % M

A*"@ ./plain the %atch Management 9o+ and ,hy you have used %atch Management Letme -no+ the necessary settings for %atch Management

A* 6 ell me +hat are the %atch Levels

A* " ,hat is Movement types ell me the Movement types that you have used in !M and ,M#also e/plain the purpose of each*

A* 9o+ do you configured Production rder ,hat do you configured for rder type

A* 5 +hat do you configured for the confirmation (shop floor control)

1. If *ou )ave released Prdn order toda* and it )ad one to s)op floor. 7e2t da* it wasfound t)at t)ere is s)orta e of material. 0)at will *ou+ #. %ow *ou define Standard Cost and @ariable cost in PP+ ,. 0)ere can *ou find Read PP Master in SAP(PP$+ /. 0)at are all t)e settin s done for confi urin inte ration of PP wit) 6IC +

"* Do availability chec-* You +ill get missing parts list* Procure those missing parts* hen confirmthe production order* ne more thing you can do# change customi e setting so that user cannotrelease if parts are missing during order release*

* Standard cost is the cost +hich is fi/ed for a period# variable cost is varying +ith period* 's fore/ample cost of semi finished# finished materials are fi/ed I cost of ra+ materials are varied*

5* You +ill find in master data tab page of production header data overvie+# & 6 0 Read PPMaster Data* 'lso from 3unctions menu you +ill get Read PP Master Data*



8* 'ssigning of &ost center to +or- center* 'ssigning 'ctivity type to +or- center# Standard &ostestimate# &osting Run# rder settlement# Product costing*

1. Can MRP be carried out for one particular level of a bom ( Level code !!!1"!!!# etc$. Yes it can be done by running for specific materials (Single Material Single Level)

# %ow Re&uirements( PIR' Sales rder' Customer Re&uirement$ are reduced after t)e*are produced+

Reqmts are reduced automatically after Delivery is made to the Particular rder(!n case of Strategy ""# the P!Rs are consumed after the $R for Production rder)

,. Can-t one material be assi ned to more t)an one operation in a routin + ne material from a % M &' be assigned to different perations*

!t can be done by defining the material for so many times as required in the % M

/. %ow to insert an inspection c)ec=point at t)e end of an operation+ !f in process sample is to be defined# assign inspection type 65 in the Material Master*

hen create M!&s and assign them in the Routings*System automatically generates the !nspection Lots

. 0)ere we )ave to specif* t)e teardown time in one operation+ eardo+n time can be defined as one of the Standard Parameters***

3. %ow t)e process time is calculated in a 0C w)en bot) labour' Mac)ine cate oriese2ist+

Scheduling is done based on the &apacity &ategory +e define in the ,or-center

<. %ow to create ob4ect dependencies in a 5 M 6 R A C 76I89RA5L: MA;:RIAL+ $o to ./tras 01 b2ect Dependency 01 'ssign3or this 4 need to create &haracteristics and &lass (of &lass ype 566) earlier

G. Can an* bod* e2plain me w)* wor= sc)edulin view is re&uired for semi finis)ed andfinis)ed products+

(5ecause we-ll mention all details in MRP views$ ') ,e need to maintain +or-ing scheduling vie+ in order to ma-e that finished or semi finishedgoods available for production as +e assign production scheduler and production schedulerprofile in this vie+# if not maintained conversion of planned order to production +ill not bepossible*

E. 0)at )appens to planned after it )as been converted into production order+



,hen you convert Planned order to Production order* the planned order are offset by productionorder* Reference of planned order can be seen in the production order*

1!. %ow to attac) a drawin for a material to 5 M+ Is it possible+

Yes# you can attach a dra+ing*

3irst create a document using ransaction &ode C&;6" 0 &reate DocumentC* 'ttach your dra+ing in that document*he system +ill generate a document number* 'ssign this document in the % M +ith item

category D*

11. Report in Lon ;erm Plannin B Dou use lon term plannin for *our customers' w)att)e* need are ver* simple' 4ust to calculate future re&uirements for 1 or # *ears.Are t)ere an* reports in SAP to list of material re&uirement from L;P+

Dou need a list of material re&uirement from lon term plannin result for eac) item.

4se MSG6 then use M&.&*

" *Sc)edulin planned order B %ow can *ou et planned orders sc)eduled so t)at *oucan do capacit* levelin +M>11 and t)en Sc)edule wor=s fine but ideall* *ou would want t)e planned ordersc)eduled automaticall* on creation+ Dou )ave tried settin up an action to sc)edule t)eorders but cannot et t)at to wor= eit)er.

,hen running MRP# try selecting C C in the scheduling bo/ this +ill bring planned orders into&M6" and &M "

1,. Capacit* plannin CM!1 B 0)en *ou run capacit* plannin ;Bcode CM!1' *ou foundt)e plan orders are not included in t)e pe ed re&uirement' *ou c)ec=ed t)e profile' t)ec)ec= bo2 for order and plan order are all actived.

$uess that planned orders have been created +ithout capacity requirement indicator in MRP (C C0 Lead ime scheduling)# if this is the case# then +hen converted to process orders they +ill haveimpact on the Resource* !f you +ant to see them as planned orders# re0run the MRP or change inevery planned order# going to the Menu7 .dit 001 Scheduling

'nother couple of possibilities are to do +ith the routing>+or- centers used and +hether it isactually calculates consumption of capacity of the category at the +or- centre being displayed in&M6" (it might consume a capacity pool or it might not consume the category)*

1/. MPS in 5ac= ound" nline B Dou want to run MPS for a plant eit)er online or in t)ebac= round' but *ou do not et an* results. If *ou run MPS for a sin le material"plant' t)enever*t)in is 1!!K J.

You need to run a planning file and a consistency chec- first# transaction MD and MDR.respectively youBll need to set up t+o 2obs to do it but it is straight for+ard# once youBve done thisset up the bac-ground 2ob for MPS to run and do it in .4PL first time round and then change to

. &9 after that*

1 .0)at is t)e output of MPS run+

3rom MPS run you plan the materials +hich are of B'B type in the abc analysis (<6E dollar value)that have to be planned before hand*



MPS is also a type of MRP only in +hich components 2ust belo+ the materials on +hich MPS runis ta-en place# are planned*

13. ;able for production order status B 0)at is t)e table for findin status (for :2 ;:C edprodn orders$. 0e are not able to find from A6J and A6R9 tables t)e status ofproduction orders or at least t)e lin= tables if =nown can be mentioned. Dou are unable to

lin= t)e structure caufvd and I %:A>:R 0I;% A6J and A6R9.

[.S is the table*

1<. >ata dictionar* table for S P plannin data B Dou are usin Standard S P (Infostructure S!<3$' in w)ic) table can *ou see t)e plannin values t)at *ou maintained inMCE, transaction+


4se *&ode M&@F to display your entries under the version +hich maintained the table S6GH*

1G. Production order operation-s component allocation B %ow does SAP =now t)at anoperation )as components as indicated b* t)e component allocation indicator+ ;codeC !G.

&omponent allocation is done via routing maintenance or % M maintenance for the assembly*his is master data maintenance* 's soon as a P is created# the master data is read into the

P *

1E.%ow to delete roups of products+

%ow to delete a roup of products t)at was created in screen MCG/+

Delete the members in the product group and then archive the product group in transactionS'R'# ob2ectNMMQM' R*

( he product group is created as a material master record +ith material type PR D and thisrecord is deleted in S'R'*)

QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ

1. 0)ic) is t)e )i )est or anisational level in SAP


'ns7 b

#. 6or Material Master record PP >ata w)ic) is t)e )i )est or anisational level


'ns7 a

,. 0)at is t)e difference between 61 %elp ? 6/ %elp.



a) 3" is for possible values and 38 is for application helpb) 3" is for 'pplication 9elp and 38 is for echnical 9elpc) 3" is for 3ield 9elp and 38 is for possible entries*d) one of the above

'ns7 c

/. @ariant Confi uration is t*picall* used in

a) Ma-e : to : stoc- .nvironmentb) Ma-e : to : rder .nvironmentc) Spare parts Saled) Repetitive Manufacturing .nvironment

'ns7 a

. Confi urable Material c)ec= for a material is set in

a) %asic Data b) MRP ;ie+c) Sales ;ie+ d) &lassification

'ns7

3. 5asic >ata screen contains eneral data suc) as

a) Material umberb) Material descriptionc) %ase unit of measured) echnical data

'ns7 a# b# c

<. 6unctions of Classification are

a) o find an appropriate ob2ectb) o find similar ob2ectsc) o establish that no appropriate ob2ect e/ists*

'ns7

<* .ntering =>o? in command field

a) .nds current transaction

b) .nds the current cessionc) pens ne+ cessiond) pens ne+ transaction

'ns7

@* 3or creating Material Master the follo+ing ransaction &ode is used 7



a) md6"b) mm6"c) me6"d) mc6"

'ns7 b

1!. ;)e unit in w)ic) t)e stoc= =eepin is done in a compan* is called

a) Stoc- unit of measureb) %ase unit of measurec) 4nit of issued) Purchase unit of measure

'ns7 b

11. 5atc) is

a) Same as material codeb) Partial quantity of material managed separately from other quantity of same material in stoc-c) ' non reproducible homogeneous unit +ith unique specificationsd) one of abovee) 'll of above

'ns7 b

1#. A is a complete' formall* structured list of t)ecomponents t)at ma=e up a product or assembl*.

'ns7

1,. Component in t)e 5 M are allocated to operation in

a) % Mb) Material Masterc) Routingd) ,or- &enter

'ns7 c

1/. 5 M contains t)e followin

a) List of &omponents

b) Aty of &omponentsc) peration to +hich components is attached*d) 4nit of Measure of components

'ns7 a# b# d

1 . 5 Ms are alwa*s created as



a) Single Levelb) Multi Levelc) &omponentsd) 'long +ith routings

'ns7 a

SAP PP ;est Questions (MCQ$

1. A plant can be a p)*sical plant or a lo ical section of a plant

a) Yes b) o*

'ns7 a

Stora e locations are areas w)ere materials are stored wit)in a plant

a) Yes b) o*

'ns7 a

A purc)asin or ani ation can bu* for a number of plants

a) Yes b) o*

'ns7 a

A purc)asin roup is a subBset of a purc)asin or ani ation

a) Yes b) o*

'ns7 a

#. Strate * 8roup is relevant for Material Re&uirement Plannin

a) rue b) 3alse

'ns7 a

,. MRP can be caried out at

a) Plant Level

b) 'll Routingsc) Single item : single leveld) Single item : multiple level

'ns7 a# c# d

/. In Material Re&uirement Plannin



a) Material availability is ensuredb) !f shortage e/ists the corresponding elements are plannedc) Stoc- transfers are also possibled) he availability of the components is ensured via dependent requirements

'ns7 d

. 0it) Ma=e H to Stoc= strate * 1!

a) MRP run considers only Sales rdersb) MRP run considers only P!Rc) MRP run considers both Sales rder I P!Rd) Sales rder can consume P!R

'ns7 b

3. ;)e Individual " Collective indicator in t)e material Master determines

a) ,hether a component is procured for a special customer requirement in the individual segment

b) Requirement quantities of dependent materials are grouped together during MRP runc) he Material Requirement Planningd) he Special Procurement*

'ns7 c

<. A;P H Available to Promise (Availabilit* c)ec=$

a) System chec-s if all issues are covered by e/isting receiptsb) &hec-s if receiptsJ quantity still available to cover ne+ly received issues

'ns7 a

G. Availabilit* C)ec= PIRs

S*stem does not c)ec= a ainst PIRs

a) rue b) 3alse

'ns7 b

7o A;P &uantities' receipts or stoc=s are included

a) rue b) 3alse

'ns7 b

>etermines if sufficient PIRs are planned to cover a S

a) rue b) 3alse

'ns7 b



E. Consumption based plannin is usuall* used for followin materials

a) 'll ' I % &lass Materialsb) Materials +ith smooth consumption pattern*

'ns7 b

1!. 6or Plannin at P)antom Assembl* Level planned orders are created for P)antomassembl*

a) rue b) 3alse

'ns7 b

11. Stoc= Re&uirements List ives situation of stoc= re&uirementfor t)e material

a) Static 7 of the last MRP Run

b) Dynamic 7 ./isting at current situation

'ns7 b

1#. Is Sales order A Qt*. 1 PC and Sales order 5 Qt*. # PC are boo=ed on same date andstoc= is ! PC

a) Separate Planned rder for each Sales rder shall be created if individual indicator is setb) nly one planned order is created if individual indicator is setc) Separate Planned rder for each Sales rder shall be created if &ollective indicator is setd) nly one planned order is created if &ollective indicator is set

'ns7 a# d

1,. Plannin can create t)e followin after MRP run

a) Planned rdersb) Production rdersc) Purchase rdersd) Schedule Lines

'ns7 a# b

1/. 7:;C% is

a) 4sed in Demand Managementb) Key to run MRP for otal hori onc) Key to run MRP for otal Planning hori ond) ot related to MRP

'ns7 c

1 . Re enerative Plannin



a) Plans all material for a specified plantb) Plans all material for a specified plant for total planning hori onc) Stands practical for the first time planning run

'ns7

Commonl* 9sed ;codes in PP Module Part 1MA;:RIAL&R.' .0$. .R'L MM6" !MM.D!. .LY MM"" S&9.D4L.&9' $. MM6 !MM.D!. .LY MM" S&9.D4L. MM"5 '& !;' .3L'$ 3 R D.L. ! MM6H !MM.D!. .LY MM"H S&9.D4L.D!SPL'Y MM65 D!SPL'Y &4RR. MM"@ D!SPL'Y ' K.Y D' .D!SPL'Y &9' $.S MM68 '& !;. &9' $.S

MM"8 S&9.D4L. &9' $.S MM"G M'SS M'! . ' &. MM'M &9' $. M' .R!'L YP.

9.R MM%. S &K ;.R;!., MMP; &L S. P.R! D MMR; 'LL , P S ! $ PR.;! 4S P.R! D MMF6 ! S ' M' .R!'L ;!., MMS& . .R S R'$. L &' ! S MMH6 M' .R!'L L!S

'R&9!;! $(M' .R!'L) MMG" 'R&9!;.>D.L. . MMG D!SPL'Y 'R&9!;.5ILL 6 MA;:RIAL (MA;:RIAL 5 M$

&S6" &R.' . &S6 &9' $. &S65 D!SPL'Y.Z R'S &S < 'R&9!;! $ &S 6 M'SS &9' $.S.;'L4' ! >% M &S"" % M M4L !L.;.L.ZPL S! >M' .R!'L &S" S R4& 4R. M4L !L.;.L% M &S"5 S4MM4R!S.D % M0 RJ C:7;R:S &R6" &R.' . &R6 &9' $. &R65 D!SPL'Y &'<F R.PL'&.&'P'&! Y &R"" &R.' . &R" &9' $. &R"5 D!SPL'Y9!.R'R&9Y &R " &R.' . &R &9' $. &R 5 D!SPL'YL! . 9!.R'R&9Y LD%" &R.' . LD% &9' $. LD%5 D!SPL'YR.P R ! $ &RH6 ,>& ! 3 RM' ! SYS .M



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

K`S &R.' . & S ! $ S9.. K'6" &R.' . PR!* & S .L.M. K'6H &R.' . S.&* & S .L.M. KL6" &R.' . '& !;! Y YP. KP H '& !;! Y YP.>PR!&. PL' ! $

PP Mo"ule Part 4

SAL:S A7> P:RA;I 7S PLA77I78PR D4& $R 4P M&<8 &R.' . M&<H &9' $. M&<F D!SPL'Y$R'P9!& M&@" PR D4& $R 4P

M&@ ;.R;!.,PL' ! $ M&<" &R.' .3 R PR D4& $R 4P M&< &9' $. M&<5 D!SPL'Y M&GF R' S3.R P$ PL' ! $3 R M' .R!'L M&<G &R.' . M&<< &9' $. M&<@ D!SPL'Y M&G8 R' S3.R M' .R!'LS DM M&@K M' .R!'L ';'!L'%!L! Y



S.L.& ! L!S &KM' & .dit &K86 .D! & S ! $ R4

PP Mo"ule Part Material Re&uirement PlanninMenu 7odes ;ransaction Activit*Master Data MD F &reate planning calendar MD H &hange planning calendar MD G Display planning calendar MDS' Display % M e/plosion number MDSP .dit % M e/plosion number M.A" Maintain quota file PPP ./plode % M by date MD4S Display pro2ect assignment MD4P Process pro2ect assignment MDL" &reate production lot MDL &hange production lot MDL5 Display production lotPlanning MD 6 &reate planning file entry MD " Display planning file entry MD'% Set up planning file entry in bac-ground MDR. &hec- planning file entry MD6" otal planning online MD% otal planning in bac-ground MD65 Single0item# single0level planning MD6 Single0item# multi0level planning MD85 !nteractive single0item planning MDF6 Multi0level# ma-e0to0order planning MDF" Multi0level pro2ect planning M3F Display planning table M3F6 &hange planning table M3FG Planning table by MRP lists M3F" Planning table by production list

.valuations MD68 Stoc->requirements list MD6G &ollective access of stoc->requirements list MD6F MRP list MD6H &ollective access of MRP lists MDLD Print MRP list MD8F Planning result MD8H &ollective access of planning result MD88 Planning situation for a material MD8G Planning situation for a product group MD8< &ross0plant planning situation MD8& rder report MD6@ Pegged requirements & 8H rder progress

Planned rder MD"" &reate planned order MD" &hange planned order MD"5 !ndividual access of planned order MD"H &ollective access of planned orders MD"8 !ndividual conversion of planned order into MD"F &ollective conversion of planned orders int MD4M &onvert planned order into purchase requisi & 86 &onvert individual planned order into produ & 8" &ollective conversion of planned orders int & 8< Partial conversion of planned order into pr



& RG !ndividual conversion of planned order into & RGQP& &ollective conversion of planned orders int & R< Partial conversion of planned order into pr MD;P &ollective availability chec- MD'& ./ecute action for planned order

MPSBMAS;:R SC%:>9L: I;:MS'L PL' ! $ MD86 L! .

MD%S S' %'&K$R 4 D [ % MD8" S! $L. ! .M 0 M4L ! L.;.L MD8 S! $L. ! .M 0 S! $L. L.;.L MD85 S! $L. ! .M 0 ! .R'& !;. MDF6 S! $L. ! .M 0 S'L.S RD.R MDF" S! $L. ! .M PL' ! $# PR [.&

NNN :@AL9;I 7 IS SIMILAR ; MRPPR D4& ! & R L

RD.R 0 &R.' . & 6" ,! 9 M' .R!'L & 6G ,! 9 4 M' .R!'L & 86 3R M PL' .D RD.R & 8" & LL.& !;. & ;.R ! 3 PL' .D RD.R & 6< 3 R S'L.S RD.R & "6 3 R PR [.& & 6 &9' $. & 65 D!SPL'Y& R L MD68 S &K>R.A4!R.M. S L!S & 9; M'SS PR &.SS! $ & M'& & LL.& !;. ';'!L'%!L! Y &9.&K & 6F & LL.& !;. R.L.'S. & 68 PR! & 6@ ';'!L'%!L! Y ;.R ;!.,$ DS M ;.M. M3HF S &K R' S3.R 3 R R.S.R;' !M' .R!'L S '$! $ M3H< L $

M%"' $ DS !SS4. M%5" $ DS R.&.!P & ,%P'&K P'&K M' .R!'L& 3!RM' ! & "; !M. !&K.3 R P.R' ! & "8 D!SPL'Y & "5 &' &.L & "L R.A4.S .D & 3!RM' ! S & "P PR.D.3! .D PR &.SS.S

LS0'R&9!;! $ & G< RD.R K '' S. .LM. D &4M. S

CAPACI;D PLA77I78.;'L4 ! &M6" L 'D, RK &. .R ;!., &M6 RD.RS &M65 P L &M68 %'&KL $ &M6F ;.RL 'D &M6G ;'R!'%L..Z . D.D .;'L4 ! &MF6 , RK &. .R ;!., &MF" ! D!;!D4'L &'P'&! Y ;!.,



&MF RD.R ;!.,L.;.LL! $ &M " PL' ! $ '%L. ($R'P9!&'L), RK &. .R ;!., &M PL' ! $ '%L. ( '%4L'R)! D!;!D4'L &'P'&! Y ;&M G PL' ! $ '%L. ($R'P9!&'L) &M < PL' ! $ '%L. ( '%4L'R)

RD.R ;!., &M5" PL' ! $ '%L. ($R'P9!&'L) &M5 PL' ! $ '%L. ( '%4L'R)

';'!L'%L. &'P'&! Y &R" &9' $.&'P'&! Y &R"5 D!SPL'Y P8' S9!3 S.A4. &. P85 3'& RY &'L. D.R

S P Pro"uction Planning Ta le

Planned rders PL'3 Planned rders

>iscrete Production '3K rder 9eader '3P rder !tem Detail '3;& rder perations Detail '33L rder Sequence Details '339 rder PR 'ssignment '3%P rder %atch Print Requests '3R4 rder &ompletion &onfirmations '33, &onfirmations 00 $oods Movements +ith .rrors '3R& &onfirmations 00 !ncorrect &ost &alculations '3RD &onfirmations 00 Defaults for &ollective &onfirmation '3R9 &onfirmations 00 9eader !nfo for &onfirmation Pool '3R; &onfirmation Pool '3,! &onfirmations 00 Subsequently Posted $oods Movements

S P PP Master )ata Ta les

MAS;:R >A;A

0or= Center &R9D ,or-center 9eader Data&R&' ,or-center &apacity 'llocation&R& ,or-center &ost &enter 'ssignment&R99 9ierarchy 9eader&R9S 9ierarchy Structure&R Z ,or-center e/tK'K &apacity 9eaderK'`Y !ntervals of &apacity

Routin PLP Routing peration DetailsPLK Routing 9eader DetailsM'PL Routing Lin- to Material



PL'% Relationships 0 Standard et+or-PL'S as- List 0 Selection of perationsPLM` &omponent 'llocationPLP9 &'PP Sub0operationsPL39 PR 'llocationPL,P Maintenance Pac-age 'llocationPLMK !nspection &haracteristics

5ill of Material S P % M !tem DetailsS P4 % M Sub !tems (designators)S K % M 9eader DetailsM'S % M $roup to MaterialS `4 % M 9istory RecordsS 'S % M !tem SelectionS P3 % M ./plosion Structure

Ta le of t%e Or"er Pro"uction O(eration

0)ic) is t)e table of t)e order production operation details+ I need to et t)e activities forproduction order Setup' Labor' Mac)ine' Confirmed and to confirm. I can see loo= at t)is in C !# " peration verview (f $ " peration >etalis " Qt*BActivities

hat is probably the hardest information to piece together# ! used F tables +ith multiple 2oins toget 4ser 3ields for operations in a production order* Maybe you can use something simular*

'3K 0 this is for your basic production header info 0 order number# basic finish date etc

S6 0 this is for your operation header details 0 operation number# ,or- centre etc if you areonly after the header details such as setup time and e/ecution time# you can probably stop here+ithout going to '3;& or '43; (you definitely need '43K if you +ant order status)

'43K 0 this is for your order master data 0 rder released flag# order complete flag# technicallycomplete date# youBll need this to filter out closed orders

'3;& 0 this is to lin- to the detail table 0 ho+ever ! used the control -ey field in it so ! +ould -no++hether it +as a M!L. stone or $PP" for confirmationBs sa-e

'43; 0 this is the user field table 0 you may +ant to replace this +ith +hatever detail you are after

Delete all the automatic 2oins7

'3K 01 '43K on7 '43 R 01 '43 R

'3K 01 S6 on7 '43 R 01 '43 RPL %.` 01 M' R

'3K 01 '3;& on7 '43PL 01 '43PL



S6 01 '3;& on7,.RKS 01 ,.RKSPL 3L 01 PL 3L; R R 01 ; R R

he 2oin belo+ is for user fields in operation detail# you +ill have to find your o+n relevant table#

but ! assume the t+o -ey fields +ill be the same

'3;& 01 '3;4 on7 '43PL 01 '43PL 0 Routing number of operations in the order 'PL`L 01 'PL`L 0 $eneral&ounter for order

)ifferences et,een (lanning an" sc%e"uling6 finite an" infinite

R>5 does planning +ithout consideration for capacity situations* So if MRP says you need F66parts on 5>">68# it schedules them all to be built at the same time# even though you can only do"66 at a time* 'ssume you have a fi/ed lot si e of "66# youBll get F planned orders for "66 to starton the same day* his is C!nfinite PlanningC* 'P +ould recogni e that constraint# and insteadschedule out the F orders over time* he important part of that is that it also +ill schedule out thedeliveries of the components for F different days* his is C3inite PlanningC*

o+# assume old fashion MRP* !t schedules all F orders for the same day# and the buyers go outan get all of the components for the same day* hen the planner reali es he canBt do all F# andmanually changes the schedule# and manually spreads out the F orders* he buyers +ill receiverescheduling notifications# but not until the scheduler does the manual rescheduling* You couldcall this C!nfinite SchedulingC# but that only means the same thing as !nfinite Planning*

%ut# S'P has C&apacity LevelingC* ,hat that means is you run another program after MRP(&M G and &M <)# +hich can be run in batch mode overnight* ( here is a ton of configurationand thin-ing that +ill be required to do this^)* he capacity leveling program +ill recogni e theconstraint at the +or- center level# and fill up the first day# then re0schedule the ne/t order to thene/t available capacity# then the ne/t order searches for available capacity# and so on* his iscalled C3inite SchedulingC* he problem +ith this is the opposite of !nfinite Planning# +hich is itdoesnBt ta-e Material availability into consideration^ he system +ill re0schedule a productionorder +ithout thin-ing about +hether the materials +ill be available or not*

3inite Planning does 3inite Scheduling at the same time* !f there is no capacity available on thedesired date# the system loo-s for +hen capacity !S available* hen it stops to see if Materials +illalso be available (usually based on the lead0time for those components)* !f there is a materialproblem# then the system figures out +hen the materials ,!LL be available# and thenchec-s to see if capacity is available on 9' day# and if so# it bloc-s off capacity# and allocatesthe materials for that day*

)ifference et,een M!P s MPS

:2plain t)e difference between MRP ? MPS. ;)ou ) bot) components ives *ou t)ere&uirement list' w)at we ain out of MPS run rat)er t)an runnin MRP. 0)at is t)e mainidea be)ind t)is+

he follo+ing might help in e/plaining the difference bet+een MPS and its counter part MRP*



Master Production Sc)edule (MPS$ MPS operates +ithin only one level of the % M# ,hile MRP can be utili ed throughout all levelsof a materialJs % M* !f a MPS is run on a material# the necessary orders are planned at thatlevel* Dependent requirements (if any) are placed on the ne/t % M level do+n# and then theprocess stops*

Main !dea 7 Master production scheduling (MPS) is a form of MRP that concentrates planning onthe parts or products that have the great influence on company profits or +hich dominate theentire production process by ta-ing critical resources* hese items are mar-ed as _'J parts (MPSitems) and are planned +ith e/tra attention* hese items are selected for a separate MPS run thatta-es place before the MRP run* he MPS run is conducted +ithout a % M e/plosion so that theMRP controller can ensure that the Master schedule items (MS!) are correctly planned before thedetailed MRP run ta-es place*

he master production schedule is a line on the master schedule grid that reflects the anticipatedbuild schedule for those items assigned to the master scheduler* he master scheduler maintainsthis schedule# and in turn# it becomes a set of planning numbers that drives material requirementsplanning* !t represents +hat the company plans to produce e/pressed in specific configurations#quantities# and dates* he master production schedule is not a sales item forecast that represents

a statement of demand* he master production schedule must ta-e into account the forecast# theproduction plan# and other important considerations such as bac-log# availability of material#availability of capacity# and management policies and goals* Syn7 master schedule*

Material !e*uirements Planning 7M!P8 : ' set of techniques that uses bill of material data# inventory data# and the master productionschedule to calculate requirements for materials* !t ma-es recommendations to releasereplenishment orders for material* 3urther# because it is time0phased# it ma-es recommendationsto reschedule open orders +hen due dates and need dates are not in phase* ime0phased MRPbegins +ith the items listed on the MPS and determines

(") the quantity of all components and materials required to fabricate those items and

( ) the date that the components and material are required* ime0phased MRP is accomplishedby e/ploding the bill of material# ad2usting for inventory quantities on hand or on order# andoffsetting the net requirements by the appropriate lead times*

S P 2actor/ alen"ar

3actory calendar contain company specific dates such as alternate +or-ing Saturdays# Plantshutdo+n etc*

You can create your company factory calendar via transaction code B SCAL B*

'ssignment of the factory calendar by plant is done in transaction code B SM,! 0 ;Q 66",B*

'n e/ample of a S'P application that uses the factory calendar is the S'P MRP modules*

'ssuming that you have a specified an alternate +or-ing Saturday# MRP +ill postponed theplanned orders to the ne/t +or-ing day if it happened to falls on a non0+or-ing Saturday*



e/t +e thin- of the situation +here the item requested is produced by us* !n this case (asmentioned before)# the $R is S !LL legitimate 0 perhaps not needed if it ta-es less than a day foryour company to receive material from production# inspect it# certify it# and load it up*

9o+ever# a C6C is a legitimate entry to this field*

,hat is also needed is a place to locate the time for CproducingC this item* hat is +here there areoptions* ne option in MRP is the field Cin0house productionC (M'R&0D`.! )* his issometimes useful# but dangerous* !t assumes that no matter ho+ large an order is or ho+ muchof a material is needed# it can al+ays be produced in the same period (in BdaysB# of course)* henumber of days fits in this field*

!f that doesnBt Bdo itB for you# you can go to the C,or- SchedulingC vie+ of the Material Master andinclude the details for the fields under the Cin house production time in daysC grouping (Setuptime !nteroperation Processing time and base quantity)* 't L.'S this gives the system a BshotBat planning longer times for greater quantities* !f you fill both data points in (in house productiontime and C in days# the Bin daysB +ill supercede the other)*

o+ youBve put in all the data that you 9';. to input to have the system plan the length of timeneeded for telling your customer +hen you +ill have their product ready for them*

!n the case of your conflict +here you produce R source the item# then you M'Y have aproblem +ith $R 0 loo- at both scenarios and see +hat your entry should be* You &' use the

otal Replenishment Lead0time (M'R&0,`.! ) field to be the 'L !M. +hen producing thematerial in0house# because the e/ternal replenishment does not loo- at this field* So MRP +ill runand depending on ho+ you have it set# it +ill consider purchasing the material# or ma-ing thematerial# and the fields +eBve mentioned +ill impact the result as mentioned*

alculation to "etermine t%e "eli er/ "ate an" release "ate

here have been three parameters that S'P +ill ta-e it into calculation to determine the deliverydate and release date during material requirement planning* hey are 0

") Planned Delivery ime +hich is the vendor0dependent lead time being measured from the timeP is outputted (for sending to the vendor) till the time the shipment is delivered at the+arehouse*

) $R processing time represents the necessary period of time being required for receipting theshipment into the +arehouse* his period is# usually# for quality and quantity inspection*

5) Purchasing Processing ime* his is the internal required time for processing the purchasingdocument (Purchase Requisition) till Purchase rder* You can set it up plant0+ise via ransaction

M!<*

,ith these three parameters# it is possible that you can set it up correctly in your system toenable the appropriate planning of your material requirement*

Purc%asing (rocessing Time - OPP9

Please refer above sub4ect and would li=e to do followin . :2ternal Processin ;ime I )aveset in usin PPQ. M* client want t)is time set differentl* for different @endor. Is t)ere an*usere2it or customi ation settin s+



3or MRP to ta-e lead time by supplier# you need to have 5 settings7

") he config in PPA 0 ./ternal procurement at plant level (or PPR at MRP grp 0Scheduling>doc* type) should have the chec- bo/ mar-ed to read Sched'greem>!nforecordleadtime ( 5@@D0$ .RM)

) You should have a contract>schedule agreement# or a purchase info record maintained for thatplant0material0vendor combination

5) You should maintain source list (M.6") for the contract>schedule agreement# or info record*his changes the default behavior of MRP to use leadtime by supplier# rather than material

master leadtime* ,hen both contract and info record e/ist# the contract +ill ta-e precedence*

Please +atchout for the case if youBre already using contracts>info records in procurement# but notusing them for planning* !n this case your leadtime data in these documents may be incorrect# ormay be left blan- 0 this +ill be interpreted as ero if you ma-e this change implementation# asmentioned in the steps above*

)efine Safet/ Stock aila ilit/

he !M$ can be set in SM,! 0 @ /,GM S

You define per plant and per MRP group the percentage of the safety stoc- that is to be availablefor planning* his helps to avoid a situation +here order proposals are created unnecessarily bythe system to cover small shortage quantities*

3or e/ample7

Mat* " Mat* Mat* 5

Safety stoc-7 "66 pc "66 pc "66 pc

available for planning7 6E F6E F6E

Shortage quantity " pc " pc F" pc

rder proposal quantityfor lot0for0lot order qty " pc 6 pc F" pc

9uestions on M!P 'rou( an" M!P ontroller

MRP groups are used +hen the plant division for planning is not enough for the division of thedifferent materials MRP requirements* You assign different groups according to the requirementsto run MRP (different Settings)* hese settings +ill be ta-en in account +hen you run MRP forsingle item or total planning*

MRP controller is the person in charge of the MRP run for the materials* !t is still a further divisionon your MRP* his is +or- load related* You can have one MRP controller for materials +ithdifferent MRP groups*



n your MRP group# you +ill define the parameters for the MRP run* hese parameters arecalculated in accordance +ith the settings on your material master MRP vie+s*

'vailable stoc- N Plant stoc- 0 safety stoc- Oreceipts of (purchasing orders O purchasing agreements O production orders) 0 required

quantity*

his means that all the requirements are calculated in the bases of your material master settingsand your MRP group settings*

0)at if not)in )appens w)en *ou run MRP+

he reasons could be 70

0 You have purchase requisitions that are delayed but the delivery time has not been updated onthe system*

0 he settings on your material MRP screens are not correct# i*e* your material have not yetentered the re0order point level*

0 Your requirements have not been ta-en in account +hen running MRP*

'ssuming that everything is +ell and the requirement has been calculated# go to transaction codeM>!/ and verify that the different requirements are reflected in the MRP list and also if there isany purchase requisition scheduled by the system* ;erify also if there is any other deliveryschedule that +ill e/ceed the actual requirements*

!f the purchasing requisition is there# the only thing that you have to troubleshoot is the messageto tell you that the purchasing requirement +as calculated*




controller*you can do evaluation by mrp controller* his +ill help us if have different people in oneorganisation involved in purchasing*


his +ill help you to determine the floats* !n case if you have production order you can see theimpact of floats

5* MRP group




8* MRP profile,e can have some prefi/ed datas in the profile and and +e can enter teh profile for diff materialso the values +ill copied as defaulted in the profile*

Planning se(aratel/ ia Storage Location or en"or ,it% M!P rea

Steps " 70

You must convert the e/isting planning file (table MD;M) to the ne+ planning file (table D%;M)in order to be able to use MRP areas in materials requirements planning* ransaction M!6 *

"* During the conversion# the system creates a plant MRP area for every plant** he e/isting planning file entries are copied from the planning file used up to no+ into

the ne+ planning file*5* he system deletes the planning file that had been used up to no+ after the conversion has

ta-en place*

8* 't client level# the indicator Planning file entries for MRP area converted is set in asystem table* his indicator causes material requirements planning to be carried out usingplanning file entries at MRP area level from this point on+ards*

F* he report also converts the individual customer planning file entries at plant level toindividual customer planning file entries at MRP area level*

Steps 70

'ctivate MRP 'rea in SM,! B ;!!!M> *(Material requirements planning +ith MRP areas cannot be reversed once activated)*

Steps 5 70

During conversion in Steps "# S'P +ill automatically create a MRP area for all your e/istingPlants*

o+# you can start creating the MRP area for storage location or vendor to be plannedseparately* hatBs is the +hole purpose for using MRP area*

Define MRP 'rea in SM,! B @ M>L@ *9ere you define +hether the MRP area type 706" 0 Plant6 0 Storage Location65 0 ;endor

Steps 8 70

!n Material Master MRP "# t)e MPR area section will appear once you successfully completethe above Steps*

'ssign MRP 'reas to Materials

You assign the MRP areas to the materials by creating an MRP area segment for each MRPareain the material master* You can assign several MRP areas to one material*



'n MRP area of the subcontractor type may also only contain one subcontractor*

MRP areas of the storage location or subcontractor type are only suitable for7

"* components t)at are planned and produced for stoc=

*finis)ed products t)at are planned and produced for stoc= *

%y assigning a storage location in a sales order or by entering an MRP area +hen creatingthe planned independent requirements# you can define +hether a material is planned in theplant MRP area or in the MRP area of the storage location*

Material requirements planning for each MRP area allo+s you to have specific control overthe staging and procurement of parts produced in0house and purchased parts for each shopfloor and assembly area* !f# for e/ample# you define an MRP area for the productionstorage location of an assembly line# the system plans the material requirements for theassembly line separately from all other requirements*

./ample7 Subcontractor

You can also carry out planning for components to be provided in subcontracting using an MRParea by defining an MRP area for every subcontractor and assigning the components to beprovided to the MRP area of the subcontractor* You therefore plan the requirements tobe provided for these components for one subcontractor separately from all other requirements*

Depending on the requirements situation# the system creates either stoc- transfer reservationsfrom the plant to the stoc- of material provided of the subcontractor or it createspurchase requisitions +ithin subcontracting>third0party order processing# according to thespecial procurement -ey settings*

he planning run ta-es into account the planning +ith MRP areas as follo+s7!f you do not enter a separate scope of planning# the system plans the +hole plant# that is# allMRP areas in the plant# during the total planning run* !f you +ant to carry out a total planning runfor a particular MRP area only# you must specify the required MRP area in the scope of planning*During single0item# multi0level planning# the system plans the selected material in the MRP areaentered* !n addition# the system ta-es into account planning file entries from other MRP areas# fore/ample# if the material is to be procured using stoc- transfer*During single0item# single0level planning# the system plans the selected material in the MRP areaentered only*

You define the MRP areas in &ustomi ing for MRP* You can thereby assign the follo+ing to anMRP area7 one or more storage locations (e/ample7 you +ant to carry out planning for aparticular assembly line and therefore assign a production storage location to the MRP area)a subcontractor*

You assign the various MRP areas to the materials in the material master* 3or this# you create anMRP area segment for a material for every MRP area# in +hich it is used* !n this MRP areasegment# you can define MRP parameters such as# for e/ample# the lot si e or MRP



type* his allo+s you to plan the material differently in the MRP area from ho+ you plan it in theplant MRP area*

MRP +ith MRP areas for t)e material is not activated until t)e material )as beenassi ned to an MRP area. !f you have not assigned a material to an MRP area# that is# youhave not created an MRP area segment in the material master# the material +ill continue to beplanned in the plant MRP area only* !f you have assigned an MRP area to it# the system can planit in the plant MRP area and in the assigned MRP area*

PP - T%e ommon Planning Strateg/ use"

he planning strategies are maintained in &ustomi ing for Demand Management in SM,! B@ ;/31S *

Define the Planned Requirement ype and assign the requirement class in MP1 *

Define the requirement class in MP *

&hec- the independent requirement and consumption of requirement class in MPC *

Maintain the message for invalid requirement type in MP *

You define the strategy group in SM,! B @ ;/31P *

You define the Plant to MRP group in SM,! B @ ;/,GM S *

Maintain the consumption mode and period of ad2ustment in SM,! B @ ;/,GM @ *

Listed here are some common used planning strategies 70

Strategy "6 in summary 70

"* Sales rder creation 0 no impact*

* $oods Receipt 0 reduce the planned independent requirement during MRP run 3or e*g* if P!R is "66# quantity remained as "66 in P!R# ho+ever during MRP run# "66 +ill notbe included in the MRP planned as stoc- is available*

5* Delivery 0 minus the quantity for the oldest planned independent in demand management*

3or e*g* if P!R is "66 and delivery @6# P!R becomes "6 (+ithdra+al @6)*

"6 LS3 Ma-e0to0stoc- production KSL Sale from stoc- +ithoutindependent requirement reduction

&hoose this strategy if you +ant production to be determined by a production plan (Demand

Management) and if you do not +ant sales orders to influence production directly*



You must maintain the follo+ing master data for the finished product7

Strate * roup 1! on t)e MRP screen.

Item cate or* roup (for e2ample' 7 RM$ on t)e Sales r ani ation screen.

Availabilit* c)ec= field in Customi in so t)at *ou perform an availabilit* c)ec= wit)out

replenis)ment lead times (in t)e standard s*stem' *ou must enter !# )ere$.

!n net requirements planning according to strategy "6# the order does not create a requirement

the sales order is displayed# but does not generate planned orders*

he planned independent requirement is reduced during processing of the goods issue* ld

quantities can still be retrieved by using either

$oto 01 Schedule line history in Demand Management# or by using thetotal requirements list (.valuations 01 Display total requirements from the Demand Management

menu)* he quantities issued are displayed in the ,ithdra+al quantity field*

he system al+ays reduces the oldest planned independent requirements unless

the consumption fields (&onsumption mode# 3+d consumption per*# %+d consumption per*) are

maintained in the material master or in the MRP group*

"" %S3 $ross planned independent requirements KSL Sale from stoc- +ithoutindependent requirement reduction

Strategy "" in summary 70

"* Sales rder creation 0 no impact*

* $oods Receipt 0 minus the quantity for the oldest planned independent in demandmanagement* 3or e*g* if P!R is "66 and delivery @6# P!R becomes "6 (+ithdra+al @6)*

5* Delivery 0 no impact as delivery is issue from sales order*

his strategy is particularly useful if you need to produce# regardless of +hether you have stoc-

or not* 3or instance# steel or cement producers might +ant to use this strategy because they

cannot shut do+n production a blast furnace or a cement factory must continue to produce# even

if this means having to produce to stoc-*

You need to maintain the follo+ing master data for the finished product7

Maintain strate * roup 11 on t)e MRP screen.

Set t)e Mi2ed MRP indicator to # on t)e MRP screen.



Maintain t)e item cate or* roup (for e2ample' 7 RM$ on t)e Sales r ani ation screen.

Maintain t)e Availabilit* c)ec= field so t)at *ou perform an availabilit* c)ec= wit)out t)e

replenis)ment lead time (c)ec=in roup !# in t)e standard s*stem$.

Strategy "6 "" Stoc- is ta-en into account Yes o Reduction of planned independent requirements ta-es place during V V goods issue for ***goods receipt for a production the delivery order (discrete production)# for a planned order(repetitive manufacturing)# or for a purchase order (trading goods)*

6 K. !ndividual sales order +ithout consumption

Strategy 6 in summary 70

"* Sales rder creation is the only impact*

* Demand management not in used*

!n ma-e0to0order production# a product is produced specifically for an individual sales order*

his planning strategy is used +hen planning of the (parent) product is not required or

not possible* either Demand Management is involved in this process# nor is there an

allocation mechanism* rders are ta-en as they come* his strategy represents a production

procedure in +hich each product is only produced once# although over time the same or similar

production processes are repeated* .ach product is specifically produced for an individual

customer so that the finished product is rarely placed in stoc-*

You also must maintain the follo+ing master data settings for the finished product7

Strate * roup #! on t)e MRP screen

Item cate or* roup (suc) as 7 RM$ on t)e Sales r ani ation screen

Sales rder 01 MRP 01 &ustomer Stoc- 3inished Product 01 Delivery 0000O

O000000000000000000000000000000000000000000000000000000000000000000O Reduction

86 ;S3 Planning +ith final assembly KS; Sales order +ith consumption

Strategy 86 in summary 70

"* Stoc-s on hand reduces the P!R during MRP run*



e*g* if stoc- is "66 and P!R is "66# MRP run +ill not prompt "66 for procurement* if stoc- is 6and P!R is "66# MRP run +ill prompt "66 for procurement*

* Sales order creation reduces the P!R* e*g* if P!R is "66# sales order @6# P!R becomes "6 (+ithdra+al @6)*

5* Delivery reduces the Sales rder*

his strategy is probably the most +idely used ma-e0to0stoc- strategy* !t ma-es sense to use this

planning strategy if you can forecast production quantities for the final product*

Planned independent requirements are consumed by incoming sales orders so that the master

plan is al+ays ad2usted to suit the current requirements situation* his means that the

important feature of this planning strategy is that you can react quic-ly to customersJ

requirements* he smoothing of the master plan is less important*

You must maintain the follo+ing master data for the finished product in the material master7

Strate * roup /! on t)e MRP screen.

Consumption parameters (Consumption mode' 5wd consumption' 6wd consumption$ to

allow consumption of independent re&uirements. If no consumption parameters are

maintained in t)e material master' t)e s*stem uses default values are ta=en from t)e MRP

roup.

;o control consumption' *ou maintain a consumption mode as well as a consumptionperiod.

!tem category group (for e/ample# RM) on the Sales rgani ation Data screen*

3our important points 70

"* Planned independent requirements are used to trigger the procurement and production of the

necessary assemblies and components before receipt of the sales orders*

* 's soon as the sales order is received# it consumes the planned independent requirements*

5* 'n ' P (available to promise) logic during sales order processing +ill chec-s

+hether sufficient planned independent requirements have been planned to cover the sales

order*



8* Requirements from the sales orders are passed on to production and can lead to

changes made to procurement if the requirements from the sales orders e/ceed the

planned independent requirement quantities* !f there is insufficient coverage of components (the

sales order quantities e/ceed the planned independent requirement quantities)# the sales orders

cannot be confirmed* he system therefore automatically ad2usts the master plan* Planned

independent requirement quantities that are left unconsumed increase the +arehouse stoc- of

the finished product*

W%/ Planning file entr/ still $3ists;

>oes an*one =now w)* a plannin file entr* would e2ist for 7:;C% or 7:;PL w)en t)ere)as been 7 activit* on t)e material since t)e last plannin run+ 7o movements' no P -screated' no rders ta=en' no activit* w)atsoever . . . and MRP ran' created a plannedorder' w)ic) was converted to a re&uisition and t)en a P . ;)is P was converted for adate earlier t)an w)at MRP recommended.

7ow eac) time MRP runs' we et e2ception 1 B dela* t)e order until later ( ives date$.0e don-t c)an e it and t)e plannin file entr* doesn-t o awa*' even after t)e run.

6ound a note t)at seemed to appl*' but . . . I uess it doesn-t reall*.

FIf t)e plannin run terminates for a material wit) plannin file entr* on account of an errormessa e' t)e plannin file entr* is not deleted if t)is is not e2plicitl* set in customi in . Intransaction M>D' *ou can set for w)ic) errors (messa e number$ *ou want t)e planninfile entr* bein deleted.F

I t)ou )t t)is was m* answer. %owever' after loo=in in M>D B t)e messa e !1 >atesincorrect (start date finis) date$. And messa e 1 :nter value for version numberincrement (@ers7umIncr.$.

7eit)er of t)ese defines m* MRP List e2ception messa e 1 FPostpone process(#G.!3.#!!/"#3.!3.#!!/$F B on a current date of !,"!3"#!!/. It-s CL S:' but not t)e firstmessa e.

So if I set t)e field for t)e deletion of t)e plannin file entr*' it still wouldn-t affect m* realproblem B tr*in to et t)is entr* to - o awa*- after doin w)at it was supposed to do.

Please &hec- &S"F 0 +here used list* May be this material has been added to a % M of aproduct>'ssy# +hich has caused an entry in planning file*

&hec- MD68 for the source of reqt*

'lso chec- MDH5# if a P!R e/ists*

!f not# delete from planning file* ry report RMMD;M"6 0 consistency chec-*

Planning Strateg/ Selection

Selection priority for planning strategy is7



3irst material# second MRP group and last plant parameters* .*g* System first chec-s formaterial# if strategy is defined there# that is used# if itBs not maintained there# then it chec-s if itBsdefined in MRP group*

hat is the same for all MRP parameters# not only strategy*

!f you +ant to test ho+ it +or-s# try this7

"* create an mrp group# say 666"# and assign strategy group C86 0 planning +ith final assemblyCin the MRP group parameters*

* create a material# say product" and define planning strategy as C 6 0 ma-e to orderC* 'nd alsoenter the MRP group 666" in material master*

5* &reate a sales order and create an order item for product"*

8* !n the sales order header# go to the Procurement tab* here# you +ill see the requirement typefor product"# +hich is automatically selected by system according to the planning strategy it uses*

hat requirement type should be CK.C if strategy 6 is selected# or it should be CKSLC if strategy86 is selected by system*

F* !n my test# system selected K. requirement type# +hich indicates that system used strategy6# and +hich ! have entered in the material master* !t didnBt select KSL# +hich indicates that

system uses strategy 86# +hich is entered in the mrp group* 3inally# this test sho+s that systemta-es the planning strategy in material master (if itBs entered)# not the strategy in MRP group*

! thin- you can no+ ma-e another test ho+ system uses MRP groupBs planning strategy* (hint7Delete planing strategy from the material master and repeat the previous test steps* hat +ouldend up using strategy 86# +hich is selected using the MRP group parameters*)

W%en "o ,e use (lanning ,it%out final assem l/ strateg/;

0e )ave mainl* M;S' M; ' plannin wit) final assembl* and plannin wit)out final

assembl*. 7ow w)en we are dealin wit) plannin wit) final assembl*' we would usuall*

produce subassemblies (%AL5s I uess$ usin ma=e to stoc=' so do we use a plannin

strate * <! for subassemblies and do a MRP run. ;o m* =nowled e I t)ou )t we run MRP

onl* for final products (wit) final assembl*$ so in t)at case )ow would we plan for

subassembl* products.

! get to understand you are using strategy planning +ith final assembly* So you are using strategy86 for the finished product*

[ust to clarify certain things# MRP can be run for any material***be it finished or semi finished or

ra+ material* 'ctually +hen you run a MRP for the finished product using MD6 # you are doing a

multilevel run*



Secondly# +hen you are using 86 for the finished product you may or may not use any strategy

for the semi finished goods* !t depends on your business* !f you are going to produce semi

finished goods independent of the finished goods# you may have a ma-e to stoc- strategy "6

(one of the many options) and produce them independent of the finished good requirement* o+

+hen a requirement +ill be generated for the finished good and a MRP run +ill be ta-en# it +ill

sho+ that the Semi 3inished is either in stoc- or a planned>production order e/ists and thus only

the remaining quantity +ill be planned for (there is a better strategy e/isting for this type of a

scenario*****

9o+ever if you do not put any strategy for the Semi 3inished# then planned orders +ill be created

for the Semi 3inished for the same quantity as the orders created for the 3inished goods*

M!P Mont%l/ lot size

Appreciated if some uide can be provided.MRP lot si e )as been set to M5 (Mont)l* lot si e$

It is =nown t)at wit) t)is settin ' material are alwa*s brin in on t)e first wor=in da* oft)e mont).:2 >ep re&uirement #3B1!B!/ 1!! pcs>ep re&uirement ,!B1!B!/ 1E! pcs

0)en MRP completion' t)e PR item s)own 1B1!B#!!/ #E! pcs' is t)at an* possible to brinin material 4ust ri )t before dependant re&uirement #3B1!B!/ sa* about #/ or # of t)emont).5ecause. we dont tend to =eep more stoc=s until actual re&uirement.

!n that case you might li-e to consider lot si e -ey ,% (+ee-ly)* !t +ill bring in material at the first+or-ing day of the +ee-* !n your case it is ct F# 668

5ut in t)is case' I will )ave increase administrative cost on monitorin t)e material lotwee=l*.I want to )ave mont)l* lot si e t)at roup all t)e re&uirement' but brin in material asclose as possible on t)e first re&uirement.

An* comment are welcome..

9o+ about manually change delivery date in P item

C)ec= *our confi . in MI/ B sc)edulin ma* b* --1-F for Lot si e of M5.C)an e to 5lan=.

3riend PPS is correct# Schedule the CR.A4!R.M. S D' . N D.L!;.RY D' .C option in&ustomi ing for Lot Si e M% (use %lan- instead of ") I your reqt Bll be met***



0e )ave similar problem and w)en I applied *our solution' t)e proposed re&uirement dateis perfect.

!eser ation <ot reate" )uring M!P !un

I )ave created a planned order t)ro MRP run' but reservation for raw material is not

created' even t)ou ) stoc= is available. After conversion to Production order reservationis created. After confirmation and oods reciept M5,1 final product is updated in stora elocation' but raw material &uantit* is not reducin .

Can an* one ive solution for t)is.

P'R !

'fter MRP run# based on the demand Planned order +ill be created and for the % M componentssystem +ill create dependent requirement if stoc- is available* !f stoc- is not available systemcreates a planned order or a purchase requisition* nce the planned order of the 9eader materialis converted into a production order # then system converts the dependent requirement intoreservations*

P'R !!

'fter confirmation and goods receipt if the item components are not consumed# it means youhave not defined bac- flush process* !f you +ant to issue manually to the order u can use 0& D. M%"'# for the same*

"* &hec- bac- flush indicator either in routing >+or- center or in material master** !n customi ation production control 0operations0confirmation ( general individual entry screen )

chec-00 post open reservation * !t +ill post open reservation +hile confirmation*5* 'fter doing this cross chec- failed goods movements*

=o, to onfigure !ange Of o erage Profile

I am tr*in to confi ure t)e ran e of covera e profile to provide a 3 mont)s safet* stoc='in w)ic) t)e -tar et cov- field s)ould be populated wit) 1G! da*s' but t)e t)at field onl*accepts # c)aracters ma2. Is t)ere anot)er wa* of accomplis)in t)is or am I doinsomet)in wron . Please let me =now. ;)e current setup is B Period Indicator M (Mont)$ B ;*pe of Period 1 (0or=da*s$ B Ran e of covera e in t)e first period B Min blan= ;ar et E! Ma2 blan= In t)is ;ar et value accepts onl* di it numbers.

Yes the system accepts only t+o digits* %ut since you +ant stoc- coverage for "<6 days* 4setarget as say H6 and the number of periods as 5 * ry it and -eep us posted* %ut the one otherissue is the system calculates the dynamic safety stoc-*!t easy to calculate the stoc- for the first period but for the later periods its difficult* So if laterthere is a problem +ith the quantity then its difficult to calculate or cross chec- +hat system hasproposed*

4sing target as H6 and number of periods as 5# only results in system maintaining safety stoc- forH6 days for first 5 periods* ! found out that there is no +ay out of this* Strange that S'P +ouldnBt



Lose of link et,een sales or"er an" (ro"uction or"er

!ssue +ith production order confirmation

Due to lose of lin- bet+een sales order and production order due to credit chec- problem heproduction order for higher level component lost lin- and +as hanging out in limbo status*

o+ the production order at lo+er level component also loose trac- and they +ere alreadyreleased +here as production orders at higher level +ere not released

So no+ lo+er level production orders +ere tecoed +ith %D& program as there +ere " 66production orders to be tecoed at lo+er level*

So once ! deleted lo+er level# ! sa+ that there +ere planned orders for same component andsame sales order and item# this +as because MRP +as running at same time*

So this MRP generated planned orders as the production orders at highest level +ere stillhanging there and to full fill those production orders lo+er level component planned orders +eregenerated

So no+ cleared the production orders in top level and ran MRP in display mode and found thatthere +ere no planned orders for lo+er level component*

%ut still there +ere t+o more planned order created at higher level has ! previously tecoed themand did ero confirmation due to some other reason# So ! had to unteco them to delete theseplanned orders and also cancel confirmation to get the production order element on to MD68screen* nce !am done +ith that it sho+ a message H

So !t should be clear that if the e/ception message is 6 ie cancel process then that productionorder must be deleted as there is no requirement to consume this order* 's all this conte/t +asmade in M stoc- product*

Batc% %aracteristics ,%ile !unning M!P

Can batc) c)aracteristics be considered w)ile runnin a MRP+ I )ave a finis)ed ood t)at)as acid value as its batc) c)aracteristics. 5ased on t)is acid value I am tr*in to pic= upa certain batc) of raw material t)at is also batc) mana ed and )as its c)aracteristics asacid value.

0)ile runnin MRP &t* re&uirements are transferred and stoc= is reserved but t)ere&uired batc) &t* ()avin t)e acid value re&uired$ of raw material is not pic=ed.

MRP does use batch data*

%ecause# +hile entering P!R# thereBs no field to enter batch number* ,hen system createsplanned order# also thereBs no field to enter batch number# both for the header material andplanned order components*

hereBs one e/ception in PP0P!# +here you can use batch specific unit of measure* hat is# youcan define batch level alternative unit of measure* 3or e/ample# you may have a liquid# and itmay have Liters as base unit of measure# and it may also have the percent based activeingredient# that is Liters of the 'ctive !ngredient can be an alternative unit of measure*



So# every movement of material in the system +ill be done using unit of measures at the sametime* e*g* goods receipt of "66 Lt liquid (+hich is also <6 Liters of 'lcohol# because of <6Ealcohol potency)# for the first batch* also goods receipt of another "66 Lt liquid (+hich is H6 Litersof 'lcohol this time# because of H6E alcohol potency) ,hen you loo- at your stoc-# you +ill see

66 L liquid# +hich is equivalent to "86 L 'lcohol ingredient*

,hatBs the use of this active ingredient data during MRP

,hen you define the batch unit of measure# you define limits for it* Say# our liquid in previouse/ample can only be bet+een F6E and @6E# therefore +e define it li-e that* .very time +ereceive this material from vendor# +e ma-e the quality inspection and determine the 'lcoholpercentage* ho+ever# +hile running MRP# system +ill create purchase requisitions# but it doesnBt-no+ the percentage of the liquid our vendor +ill send*

9o+ +ill it determine the correct quantity

!n this case# +e define a percentage for MRP# and MRP +ill use that percentage for calculation*e*g* if thereBs an industry standard that all vendors of that liquid produce it at GFE# or if +e areal+ays +or-ing +ith a vendor +ho produces H<E# then +e can enter this data (per material) andMRP +ill calculate +ith that percentage*

W%at is 2irming T/(e in t%e M!P T/(es

he firming type dictates the behavior of planning +ith P R (Planning ime 3ence)# i*e +hetherthe system should automatically firm the unfirmed planned orders and purchase requisitions#+hich are outside the P 3 as they move to fall +ithin P 3 as days progress and also if ne+planning proposals are needed to be created to cover the shortage +ithin P 3*

here are five firming types# vi * 6# "# # 5# and 8*

Listed belo+ are the characteristics of these four firming types7

6 0 P 3 has not effect on planning*

" 0 'll unfirmed planning proposals (planned orders>purch reqs) moving into P 3 +illautomatically be firmed by the system# thus protecting them from anymore automatica changesdue to subsequent planning runs)* 't the same time# if the MRP engine identifies any shortage+ithin P 3# the system +ill create ne+ planned orders# but schedule them to lie [4S outsidethe end of P 3# thus leaving them as unfirmed elements*

0 'll unfirmed planning proposals (planned orders>purch reqs) moving into P 3 +illautomatically be firmed by the system# thus protecting them from anymore automatica changesdue to subsequent planning runs)* %4 # the system +ill create any ne+ planning proposalsto cover the shortages identified +ithin P 3* he shortage is left as a 0ve qty for the planner todeal +ith manually*

5 0 o automatic firming of any unfirmed planned orders# even if they move into P 3* hey +ill bemoved out to lie [4S outside the P 3* he system +ill create ne+ proposals to cover theshortage but schedule them outside the P 3 and -eep them as unfirmed*

8 0 o automatic firming > o automatic creation of planning proposals to cover shortage*

2unctions of Pro"uction ersion



Can somebod* enli )ten me on t)e functions of production version and some tips on itsconfi uration+

Production ;ersions are used to describe the production process to be used for planned >production order*

,hy is it required

Suppose you have >5 production lines and >5 alternative % Ms to produce one 3$*

9o+ system +ill come to -no+ +hich % M and Routing to be used* his is done thruProd*;ersion*

!n production version +e maintain the combination of % M and routing* 'lso it can be designed +ith lot si e or validity period*$o to MM6 0001MRP8 > ,or- scheduling vie+ 00001 Prod*;ersion*.nter the validity period and lot si e*

'fter entering the reqd* routing no* and % M alternative # carry a chec-* 'fter getting the $reen signals #&ontinue*

hus you have saved the prod* version*Mass processing &ode0 & 5*

>oes t)is mean t)at I )ave to activate all t)e 5 MTs if in case I )ave , alternative 5 MTs+ if*es' t)en' will it t)ese , 5 MTs be e2ploded in MRP+ ITm 4ust worried Uco I mi )t bloat ourinventor* if t)ere are t)ree active 5 MTs.

o*3irst of all need not +orry about the % M e/plosion*

's ! told you earlier +hich % M and +hich Routing is decided by Prod*;ersion*

So in MRP the active prod*version only +ill be considered* hus active % M and active Routing

+ill be used for MRP*

he question comes7 9o+ to deactivate the alternative % Ms and Routing

+o ,ays7"* You loc- all other non0relevant Prod*;ersions in MM6 of the 3$>S3$ material*(.veryalternative % M and routing forms a Prod*;ersion) hus even if there are >5 prod*versionsSystem +ill go and chec- for 4nloc-ed prod* version and use it*

* !f you donBt +ant to do this business of CLoc- I 4nloc-C 2ust place the required version at thefirst place in list of prod*versions in MRP8 vie+ of the material*

nce system finds the first prod*version it +ill not spend energy in searching other alternatives*

'lso please*donBt forget to maintain the selection value of C C in MRP 8 vie+ for % M selection*

his +ill enable you to start the use of prod* version functionality in S'P0PP*(very good tool forpractical purposes# costing and MRP)*

W%at is )iscrete Manufacturing6 !$M an" )eman" Management;



1. 0)at is >iscrete Manufacturin + #. 0)at is R:M+ ,. 0)at is >emand Mana ement+

9ere are difference bet+een Discrete and R.M and small e/planation about discrete andrepetative manf*7

0 ' typical characteristic of discrete manufacturing is the frequent s+itching from onemanufactured product to another* he products are typically manufactured in individually definedlots# the sequence of +or- centers through production varying for each one of these* &osts arecalculated on the basis of orders and individual lots*

0 !n Repetitive Manufacturing# products remain unchanged over a longer period and are notmanufactured in individually defined lots* !nstead# a total quantity is produced over a certainperiod at a certain rate*

0 Discrete manufacturing typically involves varying the sequence of +or- centers through +hichthe products can pass during production* he order of +or- centers is determined in routings#+hich can often be very comple/* here can be +aiting times bet+een the individual +or-centers* 'lso# semi0finished products are frequently placed in interim storage prior to furtherprocessing*

0 Repetitive Manufacturing# on the other hand# normally involves a relatively constant flo+ onproduction lines* Semi0finished products are usually processed further immediately +ithout beingput in interim storage* Routings tend to be relatively simple*

0 !n discrete manufacturing# component materials are staged +ith specific reference to theindividual production lots* &ompletion confirmations for the various steps and processesdocument the +or- progress and enable fine0tune controlling*

0 !n Repetitive Manufacturing# components are often staged at the production line +ithoutreference to a particular order* &ompletion confirmations are less detailed# and the recording ofactual data is simplified*

0 he function of Demand Management is to determine requirement quantities and delivery datesfor finished products assemblies* &ustomer requirements are created in sales ordermanagement* o create a demand program# Demand Management uses planned independentrequirements and customer requirements*

o create the demand program# you must define the planning strategy for a product* Planningstrategies represent the methods of production for planning and manufacturing or procuring aproduct*

4sing these strategies# you can decide if production is triggered by sales orders (ma-e0to0order

production)# or if it is not triggered by sales orders (ma-e0to0stoc- production)*You can have salesorders and stoc- orders in the demand program* !f the production time is long in relation to thestandard mar-et delivery time# you can produce the product or certain assemblies before thereare sales orders* !n this case# sales quantities are planned# for e/ample# +ith the aid of a salesforecast*



$cheduling

!esc%e"uling "ate "oes not take into account t%e '! Processing Time

!f you loo- at M>!/ # the rescheduling date is based on the Stoc-s Requirement date*

!t does not ta-e into account the parameters in Procurement and Scheduling in the MaterialMaster*

!n the net requirements calculation# the system chec-s +hether +arehouse stoc- or firmedreceipts are available to cover requirements* !f a material shortage e/ists# the system usuallycreates a ne+ procurement proposal*

he rescheduling chec- is used to c)an e t)e dates of alread* e2istin firmed receipts notplanned on t)e same da* as the requirement to suit t)e re&uirement date *

3or this purpose# the system displays the appropriate e/ception messages +ith reschedulingproposals for these firmed receipts to be processed by the MRP controller*

Dou defined t)e resc)edulin parameters in Customi in for MRP. 'n important parameters is the resc)edulin )ori on period to be included*

"* PPQ per plant to &arry out overall maintenance of plant parameters*

* PPR per MRP group to &arry out overall maintenance of MRP groups*

You can also define tolerance values for the creation of e2ception messa es *

hese values define a time period in +hich no e/ception message is to be created# despite thefact that a rescheduling proposal may e/ist*

he MRP controller can thus avoid a situation w)ere too man* e2ception messa es arecreated if a certain buffer has already been planned for scheduling basis dates*

Resc)edulin :2ception Proposal

5rin process forward (resc)edule in$

,ithin this rescheduling hori on# the net requirements calculation chec-s +hether# after arequirement# a firmed receipt e/ists# +hich can be used to cover this requirement* hen thesystem displays a rescheduling date as +ell as the e/ception message %ring process for+ard forthis receipt* he net requirements calculation then uses this receipt and thesystem +ill only create another procurement proposal if the receipt quantity is not sufficient tocover the complete requirement* Several firmed receipts can be used to cover one requirement*

he rescheduling hori on is al+ays calculated from t)e MRP date *

Postpone process (resc)edule out$' or cancel process

he net requirements calculation chec-s over the complete time a/is +hether availability couldstill be guaranteed +ithout the receipt in question* !f this is the case# the system chec-s +hetherthe receipt planned here could be used to cover a future requirement* !f the system can find sucha requirement# it then displays a rescheduling date as +ell as the e/ception message Postponeprocess for this receipt*



!f the system finds no future requirement# for +hich the receipt is required# the system displaysthe e/ception message Cancel process *

Sc%e"ule Margin >e/ in Pro"uction Sc%e"uling

I want to =now impact of sc)edule mar in =e* in production sc)edulin in followinc)an es in material master1$ if I )ave sc)edule =e* w)ere all floats are ero but I enter inB)ouse production time ase. . < da*s .#$ if I )ave =e* w)ere floats before production is da*s and same values in ne2t floats andin )ouse production time as 1 da*.All above wit) M; w)at is impact of above cases in sc)edulin .

,hile C%asic SchedulingC in MRP*** Scheduling margin -ey is not considered* !t ta-es the C!nhouse productionC days for fi/ing up the start date* his is only e/act to CdaysC*

Lead ime scheduling is carried out on request from the scope of MRP* arget dates arecalculated from routing and &apacity requirement calculations are also done* he calculations aree/act to the seconds (time)*

S&9.D4L! $ M'R$! K.Y ta-es effect only for Lead ime Scheduling* 3or this you have toconfigure for Cscheduling hori onC to limit the period for +hich lead time scheduling and capacityplanning should be carried out* scheduling hori on is the period in +or-ing days* !f a plannedorder has its basic start date +ithin this period in future# lead time scheduling is carried out usingthe selected routing* he production times are calculated from the float times of the schedulingmargin -ey in the material master record and the time from the individual operations* !f theplanned order has its basic start date further in the future than this scheduling hori on# the basicdates are calculated from the in0house production times in the material master and aretransferred to the production times*

Could *ou e2plain w)at-s function of openin period in Sc)ed Mar in =e*.

pening period is li-e a Crelease +indo+C* he length of the opening period is the +indo+ ofopportunity a planner has to convert the planned order to a purchase req*

3or e/ample 0 &omponent ' has a lead time of "8 days and opening period of F days*Requirement on " 0 065

pening Date 0 " 06"065Start Date 0 " 06<0653inish Date 0 " 0 065

o+ the planner can convert the order starting Dec* "st# instead of Dec* <* !t basically is a bufferin the lead time to get things on order a little sooner than needed*

0)at-s t)e function for Plan order convert to production order+

As *our e2ample'Re&uirement on 1#B##B!,



penin >ate B 1#B!1B!,Start >ate B 1#B!GB!,6inis) >ate B 1#B##B!,

5ut I can convert plan order to production before 1#B!1B!, at random' so I wonder w)at ist)e openin period real function+ it loo=s useless to restrict w)en to convert plan order to

production order.

& 8" and MD"F are used for the conversion process* 9ere you enter the opening dates you+ish to convert* f course the opening period +ill not stop you from converting planned orders 0hopefully your planner is not randomly converting orders or you have much bigger issues^^^^

he opening period is basically 2ust to get the planned order to sho+ up on the & 8" or MD"Flists in case you +ish to convert it sooner than the lead time suggests*

Dour answer ma=e me clear to understand t)e openin period.5;0'could *ou e2plain t)e release =e* 'float after production and float before productionparameter in Sc)edMar in =e*+I =now t)e parameter affection in production' but I am not sure w)* to define )ow man*da*s in eac) parameter.for e2ample' release =e* defined for 1! wor=da*s' but *ou can release production orderout of t)e release period randoml*.an* wa* to stop release out of t)e release period+

6or e2ample B Component A )as a lead time of 1/ da*s and openin period of da*s.Re&uirement on 1#B##B!,

penin >ate B 1#B!1B!, +++Start >ate B 1#B!GB!, (from re&uirement date B lead time +$6inis) >ate B 1#B##B!, (from re&uirement date +$0)* penin date 1#"!1"#!!, )ow s*stem calculate ' Could *ou please e2plain to me..

I =now t)at w)en we run MRP s*stem will c)ec= if t)e openin date is out of open periods*stem will enerate Plan order instead of PR .

he times in the sch* margin -ey are in +or-days* hatBs ho+ it gets the dates* he component !+as describing originally +ould have been a purchased part# +here lead time is in calendar days*

he order start date and the order finish date form the frame+or- +ithin +hich a production orderis to be e/ecuted* Since malfunctions and disturbances in the production process can never befully prevented# the system uses particular floats in a production order* he system ta-es intoaccount so0called Cbefore and after production floatsC +hen scheduling an order*

he float before production is a start float* !t has t+o functions7

!t can compensate for delays in the staging of the material components*!f there is a capacity bottlenec- at the +or- centers involved# the production dates can be movedfor+ard in the future* !n this +ay it serves as a float for capacity leveling*

he float after production is a finish float* !t is used to compensate for une/pected disturbances inthe production process# so that they do not delay the scheduled finish date*



he floats before and after production are defined for each material using a scheduling margin-ey* his scheduling margin -ey is automatically transferred from the material master +hen anorder is created* 9o+ever# you can change the times in the order*

he system calculates the scheduled start of the order by adding the float before production tothe order start date* !t calculates the scheduled finish of the order by subtracting the float after

production from the order finish date*

he system deducts the number of days defined in the release period from the scheduled start ofthe order and thus determines the scheduled release date of the order* his date can be used forcollective release*

Work Sc%e"uling ie, in Material Master

0)at is t)e importance of wor= sc)edulin view in material master and t)e standardvalues in Routin +

If I am maintainin Lot si e dependent information suc) as set time' Interoperation time'Processin time in wor= sc)edulin view in material master and also ;otal inB)ouseproduction time in MRP view under sc)edulin tab' w)at will effect on t)e s*stem+

Means )ow will t)e s*stem be)ave in t)is scenario+

!n house production time in MRP vie+# specifies the time in +or-days needed to produce thematerial in0house* !n0house production time is independent of the order quantity* he systemrequires the in0house production time to determine the planned dates for planned orders inmaterials planning*

You can define +or- scheduling times in the material master record in one of t+o +ays70.ither you enter the in0house production time* !f required# you can get the system to update thisvalue from the routing*

0 r you enter the setup# teardo+n# processing# and interoperation times* !f you maintain thesevalues# the system determines the in0house production time on the basis of lot si e*

0)at is t)e basic fundamental of FIndependent lot si eF and F>ependent lot si eF in wor=sc)edulin view of a material master. I am 4umblin a lot between t)is two to understandt)e basic re&uirement of m* client.

Second t)in is t)at *ou are sa*in t)at B Dou can define wor= sc)edulin times in t)ematerial master record in one of two wa*s B:it)er *ou enter t)e inB)ouse production time. If re&uired' *ou can et t)e s*stem toupdate t)is value from t)e routin . B r *ou enter t)e setup' teardown' processin ' and interoperation times. 5ut )ow t)e s*stem update t)is first option.

I mean to sa* ' is t)ere an* settin in confi uration so t)at t)e s*stem will update wor=sc)edulin time values from t)e routin s+

You need scheduling data for types of orders# planned orders and production orders*

'nd you can have the scheduling data in 5 +ays7"* Lot si e independent in0house production time# in material master# MRP vie+* e/7 if in houseproduction time is days# it +ill schedule the order for days# and it doesnBt matter if the ordersi e is " or "666# they are both produced in days* (! never met any case that fits this situation)



* Lot si e dependent in0house production time# in material master# ,or- scheduling vie+* e/7 ifyou have F day setup time# and " day production time for lot si e of "6# then your order +ill bescheduled according to the order si e* if your order is for "6# then your total production time +illbe F day O " day / "6 > "6# +hich is H days* !f your order is for "66# then your total production time+ill be F day O " day / "66 > "6# +hich is "F days* F day setup time +ill not change +hen theorder quantity changes# because you ma-e the setup once at the beginning of the production#and use the same setup during +hole production*

5* Lot si e dependent in0house production time# in routing* he same calculation of above +ill beused for this*

So# +hich of these data is used for the order types3or the planned orders# for default# system uses the times in number above* !f that data is notentered# system +ill use the time in number " above* !f you +ant the system to use the routingdata# then you should use lead0time scheduling parameter in MRP run# then system +ill use datain number 5 above*

( he idea behind this is# MRP run al+ays ta-es long time# and if you +ant it to use routing data#that +ill also increase this run time* herefore# you can use routing but ta-e results after long

MRP run time# or you can use appro/imate times but ta-e the results after short MRP run* his+as very crucial before# because at those times hard+are technology +as not enough to processtoo much data in short time# +hen MRP run +as ta-ing days and days* %ut no+ is not that crucial#thatBs my personal opinion* 's ! said before# you can use routing data but ta-e results after longMRP run time# or you can use appro/imate times but ta-e the results after short MRP run#ho+ever# thereBs one other +ay +hich is a combination of these t+o7 You can use the system toupdate the data in number using the data in number 5# +hich is called the update of materialmaster from routing* !n that case# the appro/imate production times in material master +ill be asclose as possible to the actual production times* !n that case# not only MRP run +ill not ta-e longtime# but also +e +ill get much better results*)

3or the production orders# al+ays the routing data is used for scheduling*

7ow' I am cleared t)at w)at is independent and dependent lot si e. but still t)ere is oneconfusion in m* mind t)at w)ere did we mentioned t)is lot si e i.e 1!'1!! as per *oure2ample in case #. Secondl*' I didnt understand *our second last sentence (i.e.t)e appro2imate productiontimes in material master will be as close as possible to t)e actual production times$. Can*ou please clear me t)is sentence wit) suitable e2ample.

You enter the lot si e on the ,or- scheduling vie+ of material master# for the lot si e dependenttimes# for my e/ample you enter "6 as lot si e*

'nd the appro/imation is li-e this7 !n the material master# you enter the production times asD'YS# but in the routing you can use M! 4 .S# even seconds* herefore the most detailed andaccurate production times can be entered in routing# in material master you can enter only days#+hich +ill be the appro/imate value*

!f your routing is# for lot si e of "6# setup time is 5 hours and production time is F6 minutes# +henyou update the material master from routing# system +ill +rite 5> 8 days for the setup time# andF6>"886 minutes for the production time# because it has to convert it to days*

5ut still I donTt understand t)at w)ere I )ave to mentioned t)at lot si e 1! or 1!!+ And second t)in is t)at' If I )ave to use routin data for planned order w)at s)ould I )aveto do+ S)all I )ave to mentioned lead time sc)edulin in M>!#+



You enter lot si e in material master# on +or- scheduling vie+*

and yes# you have to mention on md6 screen that you +ant lead0time scheduling*

Dou mean to sa* I )ave to enter t)at 1! or 1!! in base &uantit* of wor= sc)edulin view ofmaterial master+

Yes*

Sc%e"uling Backgroun" ?o s for M!P

ransaction code 7 M>5;

clic- &reate ;ariant button (specified a variant name and clic- continue)*

hen fill in the follo+ing fields 70

Scope of Planning 7 ptional (refer to ote if you +ant to specify a plant grouping)

Plant 7 Your company PlantProcessing Key 7 . &9&reate P4rchase Req* 7 "Schedule lines 7 "&reate MRP lists 7 "Planning mode 7 "Scheduling 7 "Planning date 7 default date

&lic- the %ac- button and you +ill be prompt Save ;alues*

ype in a Description and clic- the Save button*

'fter creating the variant# par- your cursor at the variant and clic- the Schedule 2ob button*

3ill in the Date and ime value*

&lic- Schedule periodically and you are prompt to choose the period*

&lic- the &reate button and you are done*

o chec-# you can clic- the Sho+ Scheduling button*

ote 7

Define Scope of Planning for otal Planning in B M!: B*

"* &hoose e+ entries** .nter a -ey and a description for the scope of planning that you +ould li-e to define* Save your

entries*5* Select the scope of planning and choose Sequence of plants>MRP areas*8* &hoose ne+ entries and enter the plants or the MRP areas in the sequence in +hich they areto be planned*



M* client )as a production setup w)ere t)ere is a particular activit* w)ic) )as a setup timeof G )rs w)en it is e2ecuted for t)e first time' but if anot)er production order is ta=en upfor t)e same material t)en t)e set up rime is ero. ;)at is if I produce a material 2 at aparticular wor= center t)e for t)e first time t)e set up time is G )rs' but if anot)erproduction order of same material 2 is e2ecuted ri )t after t)is order t)en t)e setup time is

ero. 7ow' if we ive t)e setup time as G )rs in routin t)en t)e s*stem will calculate totaltime ta=in G )rs as setup time eac) time. Is t)ere an* wa* in w)ic) t)e s*stem ta=es t)esetup time as ero w)en a production order for a particular material as repeated.

a-e a loo- at the functionality associated +ith the set up group and transition matri/# if !remember rightly though the setup times are only ad2usted after production orders have beendispatched in the planning table as this is the first time S'P is a+are of the sequence ofmanufacture

If I am not wron ' setup matri2 and transition matri2 can be made use of w)en *ou o fromone operation to t)e ot)er in a particular routin . 5ut' )ere t)ere is onl* 1 operation in t)eroutin and t)at operation is bein repeated for different production orders of t)e same

material. Can t)is different setup times be iven for t)is same operation.

!f ! remember if setup group -ey is defined in the operation in the routing and then the transitiontimes bet+een setup -eys is maintained in configuration*

So itBs possible to create something li-e the follo+ing7

3rom Key " o Key " 56 mins3rom Key " o Key < hours

So different the operations in orders for the same material should both have the same -ey andshould have a setup time on 56 mins bet+een them*

hen +hen a different material +ith a different setup -ey comes along in the manufacturingsequence it +ill pic- up an < hour setup time

I am facin a muc) similar problem. 0e )ave 1 wor= stations and dail* ! B 3! productionorders are printed. I am maintainin production time as well as set up time in t)e routin s (;)ere e2ists a separate routin for all t)e part no-s $. 0)en a production order is printed itcopies t)e setup time from routin s. Suppose in one wor= station t)ere )appens )as to be# production orders processed one b* one t)en t)e setup is onl* once. but due to t)e factt)at setup is present in t)e routin s t)e production order s)ows a nonBconformit* of setuptime for t)e #nd production order. %ow to solve t)is problem.

,e have a similar situation in the company ! +or- for# +e donBt actually maintain routings atmaterial level but use reference operation sets at an aggregate level to represent the differentproduction footprints (the lin- to each material is then made through the production version in thematerial master)*

,e measure the actual setup time confirmed in each order belonging to each footprint > familyover a rolling three month period and maintain an average setup time in the reference operationset* his gets copied to each production order# but is only to ma-e sure that a time allo+ance isleft in each production +ee- for set up to create meaningful capacity planning data*

,hen the planners develop the manufacturing schedule using the graphical planning table they



then update the setup time in each order automatically +ith the setup times maintained in thetransition matri/ so itBs more accurate# as it ta-es account of the order being made on the +or-centre previously* So in our case t+o orders sharing the same footprint +ill have different setuptimes

Material Stock in Pro"uction Or"er

I )ave t)e problem in stoc= a ainst production order

ur scenario is we donTt want to create a sales order. I create a production order t)at )as operations. ;)e first operation is sub contractin . ;)rou ) control =e* (:2ternal

operation$ I create t)e purc)ase re&uisition and convert purc)ase order in t)at operation.;)rou ) t)e P I can issue t)e R % and received %AL5. 0)en I received t)e %AL5 t)estoc= of R % is automaticall* reduced. 5ut %AL5 stoc= doesnTt increase. In t)is casew)ere is m* %AL5 material for second operation+

In t)is case )ow to proceed+

Do you have a material code for 9'L% if you have material code than you can have stoc-increased* ! thin- thereBs some mista-e +ith the process* the subcontracting in operation is onlyfor the operation# not the material*

!n your configuration# you subcontract the first operation of the 3.R production* and thereBs nostoc- increase of 3.R or 9'L% +hen the first operation is completed (confirmation by purchaseorder***)

'nd +hat you +ant could be possible li-e this7

You create the 9'L% material code# and you ma-e it e/ternal procurement (3 in standard) and

+ith special procurement -ey subcontracting (56 in standard) (enter these fields in materialmaster mrp vie+)* hen you can create purchase order for the 9'L% material +hen needed#and send R 9 material to the subcontractor for the purchase order and post goods receipt for9'L% material and stoc- increases* 'nd accordingly# since the production of 9'L% is a differentprocess# not a sub process of 3.R material# you should change the routing of 3.R material to8 operations# omitting the first operation# +hich is subcontracted production of 9'L%* 'nd youshould also change the % M of the 3.R material# and remove the R 9 (+hich is used forproducing 9'L%) and put the 9'L% material itself*

utomatic on ersion to Pro"uction Or"ers

Is t)ere an*one out t)ere w)o =nows if it is possible to ma=e an automatic c)an e ofplanned orders to production orders ri )t awa* B or per)aps even to s=ip t)e planned

orders and create pp B orders instead+I )ave a customer w)o want to do t)is (s=ip t)e manual conversion$. Per)aps it is impossible+

o create production orders in MRP run +ithout chec-ing first the order proposals (plannedorders) is not a recommended process at all* !t is against the accepted norms inproduction>inventory management and its MRP0 logic on +hich S'P soft+are is also based on*



!f you have comple/ production 0 youBd have a nightmare closing all the production orders +ith theerrors not resolved at the prior to conversion stage* n the other hand# if it is too simpleproduction +ith only a handful of operations and no strict requirement of production control (+hichseems to be your case# for me)# then please do a+ay +ith production orders# and use therepetitive manufacturing +here planned orders are the final*

! am confident that a consultant +ho can see the need and benefit for the +isdom of plannedorder conversion as a separate manual process# should 'L,'YS be able to convince customer*

's al+ays# the question is# +hether you +ant the right shoe to fit the foot# or cut the foot to fit theshoe*

Pro"uction or"er confirmation ,it% future "ate is not allo,e"

3uture dates can be configured in the confirmation configuration*

!n configuration PJ/ # define confirmation parameters*

,hen this configuration comes up# in the C C)ec=s C Sections# the last parameter says

C>ate in t)e future *C

&hec- this bo/ if you +ant your dates in the future*

!t determines +hether dates in the future can be used in a confirmation*

!f the indicator is not set# you cannot ma-e any confirmations using dates in the future*

!f you try to do so# the system +ill issues an error message*

W%at is Backflus%ing;

Can an*one tell me w)at is bac= flus)in for+ 0)en is it use+

%ac- flushing is nothing but automatic goods issue* System +ill automatically posts the goodsissue +hen you confirm the operations* You have no need to ma-e manual issue* !t +ill reducethe effort*

%ac-flushing is automatic accounting ($oods issues 0 H" mvt) of material consumed forproduction# at the time of confirmation* .g* ,hen a 8 +heeler automobile is rolled out from assyline# 8 +heels I yres are deemed to be consumed and issued to production order automaticallyby +ay of bac-flushing by the system*

'ssy line pic-s the material from stores> 'ssy line and use*

o Physical issue I Manual posting ( $oods !ssue) by Stores*

%ac-flush is used for material +hich are a must and having fi/ed relationship*

his can be configured in MRP Screen# ,or- centre# Routing and production order*

.ach has some special function*



!f you configure this in routing or production order you have no need to activate this in MRP or,or- center screen*

MRP Screen defines +hether material components are bac-flushed are to be made at the +or-center*

0)en we do t)e bac= flus) t)e bac=lo s are bein created for t)e 5 M components andwe are ettin t)e messa e F5ac=lo s from bac=flus) were created or c)an edF B its 4ustan informative messa e. >o *ou t)in= t)is )as ot somet)in to do wit) t)e ne ativepostin s +

%ac-logs are created due to different reasons*

his message tells that Cthere is no sufficient stoc-s for the bom component>not able to bac-flushall the material due to plant data loc-ed etcC at the time of bac-flushing the % M Material andhence the Post0processing list is created that you have to Re0process for stoc- updation of eachmaterial*

o avoid this you can confirm the follo+ing things*"*.nsure that sufficient stoc- is available in the bac- flushing locations of each material*

* o prevent the generation of Cpost0processing listC you can bloc- the % M from gettingbac-flushed if sufficient stoc- is not available in specified location for the % M & MP . S*

o do this change the CR.M profileC to C66 Cin MRP8 vie+ for the % M M' .R!'L*(if the profileis not available you can crate it through SPR )*5* o clear the e/isting %ac-log use transaction M38G and re0process(be ensure that requiredstoc-s is available for each bom component)

=o, osting takes (lace in Pro"uction Or"ers

Can an*one please e2plain me t)e )ow t)e Costin ta=es place for t)e Production rders.

Actuall*' I am new to t)is pac=a e ' In t)er Pac=a e (RAMC :RP$(;)e Process is li=e followsa. Production 0or=B rder Resource Cost Posts to 6inance directl*b. Material Consumption postin s )appens from S@( rder Settlement @ariance$ of MACModule(Mana ement Accountin $.

Please somebod* e2plain me as above in SAP.

he follo+ing are considered in costing#

") cost of materials that you have issued for order

) activity you have performed in terms of labour hours that you entered +hile confirming theorder (the rates for the labour are defined in the activity planning tables of controllingmodule)**+hich is generally associated +ith a formula -ey and attached to a +or-center that islin-ed to a cost center also

5) overhead as applicable +ith respect to that cost center based on a predetermined cost centerplanning and its rate***



Costin updation in production order

%ow is costin updated for production order+After oods issue' conformation ? 8R' we do ;:C .5efore closin t)e order' costin details s)ould be updated. Is it not+Could *ou please uide me as to )ow t)is is done+

Also' w)at is t)e transaction code to be used+

Planned cost is calculated if you clic- Bcost calculationB in production order* $! go production order+ill update actual material cost* &onfirmation of production order +ill update actual activity cost*You can settle cost once production order has status .& or DL;* 3rom PP side# thetransaction is & 6

!n !M$ +e can define that +hen +e calcu* the planned cost*

here are 5 +ays*0 Determine planned costs +hen saving#0 Do not determine planned costs +hen saving#0 Determine planned costs +hen saving if released*

%ut the actual cost is posted +hen +e dra+ the material# +hen +e confirm the order******,e canuse co6 and clic- the calcu* cost to update the cost in the prd order*

:rror in Cost Calculation

I am usin /.<. 0)en I was savin m* production order' t)ere was t)is error messa e t)attold me t)at t)ere was an error in cost calculation. >o *ou )ave an* su estions w)at Icouldn-t )ave done+ 0)at can I do to fi2 t)is+

&hec- the log file in the Production rder 01 $oto 01 Logs 01 3or costing

hen ta-e it from here****

&hec- +hether the material for +hich you have created a production order has a price define inmaterial master li-e Moving average price or Std price*

S P flo, for !$WO!> acti it/

Question

0)at is t)e SAP flow for R:0 RJ activit* in PPBPI.

Sample Scenario 1. Initial Process rder &t* 1!pc #. Confirmed Q;D. E PCS. ,. Re4ection &t* . 1 pc. /. 7ow t)at one pc. is to be rewor=ed in operation no.!!#!.



%ow is it possible to understand later t)at' it is in t)is particular process order' so muc) ofrewor= is carried out' and t)ats t)e reason t)e process cost )as increased.

Re+or- during production depends on the clientBs decision* Li-e some companies +ant aseparate process order to process this re2ected quantity and some clients +ant to use the sameprocess order# some even +ant to identify this re2ected by assigning a ne+ batch number*

%ut in some company# they do re+or- rarely but not as frequently as you do*

,hat they do is by inserting the ne+ operation>phase after the actual operation>phase# and theoperation quantity>basequantity# queue times# etc +ill be according to the users decision* in u r e/ample do+n " pc +illbe the operation>phase quantity*

and one more thing is that remember to P& 3 the @ pc if you +ant to identify the " pc +ith thene+ batch*

'dditional comments77

You also need to remember the product costing aspect*

he primary costs of material should not be repeated +hile doing the re+or-* so# the generallyaccepted trend is that you create a separate order type for it and a common recipe +ith a re+or-operation and the materials you can assign +hile creating the process order*

Doing it in the same process order +ill have a problem of traceability of cost*

Serial <um er 2or om(onent

I )ave a 68 (A"C$ w)ic) )as a serial number. ;)is A"c )as a compressor in its 5 M.

;)e client re&uirement is to lin= t)e compressor to A"c usin serial number. So' I maintainserial number profile for t)e compressor also. 5ut w)en I do mfbf (bac=flus)$ for t)e A"c't)e s*stem as=s onl* for t)e serial no. profile onl* for t)e A"c ? not for t)e compressor.%ow do I lin= t)e two+

You can assign components (+ith serial nos*) to assembly ( also +ith serial nos*) +ith & !% aftergoods receipt*( Menu path 00Logistics 01 Plant maintenance 01 Management of technical ob2ects01 !nstalled base 01 &reate (special) 01 ,ith reference to production data*)

./ample7 Say assembly sr* no* is " 'nd components serial no* are0 "#F#"6# 6 and so on*

'fter assignment of components it can be vie+ed on right part of screen# You can have theassignment history000 ie for +hich assembly no* +hich components are assigned or vice versa* !nproduction order i*e in descrete mfg* it can be directly done at the time of operation confirmation*

he follo+ing is the detail steps7"* code00& !%

* .nter material code ( 'ssembly)* You can select specific serial no* of assembly 000 by puttingsr* no* in serial no* field*

5* &lic- on list tree0 you +ill find all assembly +ith serial numbers*8* &lic- on e/plode00 it +ill sho+ the % M ( in bottom left corner of screen)



Q ,e have a % M 0 B'B +ith t+o pac-ing materials BZB and BYB* 3or "666 units of B'B# " pac-ingmaterial of BZB is required and for F6 units of B'B# " pac-ing material of BYB is required* %asequantity of B'B is defined as "666* 9o+ can ! define BZB I BYB or in fact B'B

A Ma-e the base quantity of B'B as F666* he resulting component quantities +ould be F of BZBand "66 of BYB*

0or= Centers

Q &an +e have more than H standard values in standard value -ey

A ne +ay to achieve this is to create another operation step using the same +or- center*9o+ever this shall be +ith a control -ey that is not a milestone* ,hen the milestone operation isconfirmed# the previous operations up to the ne/t milestone are automatically confirmed* o getthe desired number of standard values # all the Bnon milestoneB steps can be built depending onthe need*

Routin

Q &an +e use same routing for materials undergoing the same process>operations &an +eavoid separate routing for each and every material produced

A1 Presume that there are F6 products and the fabrication shop uses a set of "6 machines* !f allthese products use the same settings of the machines# Reference peration Sets (tas- list typeS) can be setup for common processes that use the same +or- centers* 9o+ever costing#scheduling and capacity +ill be affected if each product has different setup time and Reference

peration sets can not be used* ' routing for each material number ( type or R) has to be set up and +ithin that routing# theReference peration Set can be used*9o+ever you can by try utili ing the KM' material and product variants invariant configuration toavoid separate routing for each material*A# You may create a routing group* $o into routing creation and enter the plant and the groupname* !f you +ant you may name the group # else name is assigned by internal counter)* &reatethe routing +ith the +or- centers# operation times# etc* $o to the C9eader overvie+C screen andclic- on the CMat 'llocC screen* 3ill in the blan-s +ith all the material masters that use thisrouting*

Q Scheduling times can be defined in the material master record by entering the in0house production time* his value can be updated from the routing by the

system* entering the setup# tear do+n# processing# and interoperation times* !f these values are

maintained# the system determines the in0house production time on the basis of lot si e*9o+ do you get the system to update this value from the routingA !n routing# carry out scheduling* $o into the routing operation overvie+ and follo+ ./tras 01Scheduling 01 Results* he pop0up +indo+ displays the scheduling data* 't the bottom there is apushbutton to copy the scheduling data to the material master &hec- this push button to updatemaster data*

Q ,e have deleted a group -ey in an operation in routing and the same does not appear for thisrouting (&'6 )* %ut +e noticed that entries are maintained in table PLP and the deletion



indicator is not set* 9o+ does the system remember this deletion of group -ey A You may loo- at the tables PLK # M'PL and PL'S*

Sales @ O(erations Planning

Q 0e defined S P in months* 9o+ever during S P transfer to demand management # ourindependent requirements are appearing in +ee-s* 9o+ can +e correct this from +ee-s intomonths

A C)ec= transaction MPA for eneral split. MPS B based on t)e MRP roup. :nsuret)at MRP roup assi ned to t)e material. >elete an* allocations in t)ese tables. ;)enperiods will be transferred to >emand Mana ement wit) t)e same splits as in S P. Alsoc hec- +hether the value of period is set as CmonthC at your plant level in ransaction B MPGB

>emand Mana ement

Q Sales quantities in S P for certain days are transferred into Demand Management and aresho+n as planned independent requirements* ,e need to -eep the settings in S P and changethe periods in Demand Management ,e +ould li-e to have a rolling hori on # for e/7 thefollo+ing 8 +ee-s on a daily basis# after that on a monthly basis* ,hat is the best +ay to do this

A 4se the automatic period split function*

M ! P

Q 0e )ave a lot si e procedure )ere w)ic) is creatin more order proposals. %ow do *ouset t)e limit value for ma/imum number of MRP order proposals per date in !M$

A 4nder customi ation# try materials management01consumption based planning01maintain allplants

Q ,hat is the difference bet+een Cplanned consumptionC and C4nplanned consumptionC &ansafety stoc- calculation be done on either of theseA ,hile customi ing movement types ( M[[) it is defined as to +hich set of consumption valuesgets posted during the material movement* 3or some it may al+ays be the total consumption andfor some it is al+ays the unplanned one and for some it is dependent on +hether the issues +eredone +ith reference to a reservation ie*# a planned consumption* he +ay these consumptionvalues are ta-en into account in MRP is defined in the customi ing of MRP types*3or Reorder point planning (;M) the total consumption is used to calculate the safety stoc- andthe reorder point*3or 3orecast based planning (;;) the total consumption is used to build the forecast +hich +ill be

used to compile the order proposals*3or Deterministic MRP (PD) the unplanned consumption is used to calculate the forecast +hich inturn is added to the actual demand*

Q ,e +ant the system to run a single level MRP automatically on receipt of sales order* 9o+ toconfigure triggering event based MRPA his can only be run if material master has planning strategy 8" (made0to0order) in the MRPvie+* ,e need to run for other MRP types* ,e have to create a user e/it in the sales orderprocessing (;'6") to start MRP based on data from our sales transaction*



Q ,e have an assembly B'B using a subassembly B%B* B%B in turn uses ra+ material B&B* !tem B'B isan MPS and is duly mar-ed in Material Master* !tem B%B and B&B are mar-ed as BPDB* ,hendemand for B'B is entered and MPS is run # upto +hich level the requirements are ta-en care ofA MRP can be run depending on your requirement* 3or e/ample7

"* Single !tem > Single Level from MPS 0 ransaction &ode MD8 0 nly the top MPS item

( B'B in this case) is planned and dependent requirements +ill be passed to MRP item ( B%B) * Run MRP# ransaction MD6 on B%B to plan it and all MRP items belo+ ** Single !tem > Multi Level from MPS 0 ransaction &ode MD8" 0 'll levels are planned 0 ' #

% I &5* otal Planning from MPS online or bac-ground 0 ransaction &ode MD86 or MD%S

,ithout mar-ing the chec-bo/ C Process MRP materialsC is li-e case ( ") aboveand +ith the chec-bo/ mar-ed is li-e case ( )*

Pro"uction Or"ers

Q ,e get an error message C&ontrol parameters for scheduling not definedC +hile creating testproduction rders* ,hyA 5efore *ou attempt creatin Production orders' c onfigure your

rder types0 ransaction &ode P9[rder type Dependent parameters 0 ransaction &ode PL<

%ac-order Scheduling 0 ransaction &ode M!9Scheduling Levels 0 ransaction &ode M!3

Q ,e are trying to create Purchase Requisition from MRP run* ,e have material # info Record#Source list # Demand in place* MRP is al+ays creating plan order * ,hyA &hec- the procurement type in MRP vie+ of material master* &hec- B&reate PurchaserequisitionB indicator +hile running MRP* !f you +ant purchase requisitions to be created in theopening period# select the for MRP control parameter Bcreate purchase requisitionsB as B"B*

Q +hat is the option C Documented goods movements C on Selection of !ndividual b2ect Lists(transaction code & <)A 9se ransaction code PL< to customi e by choosing the order type# select all the chec-bo/under CDocumentation of goods movementsC at the bottom of the page* &reate a ne+ Productionorder# ma-e $! to it# and run the report*

Q 0e would li=e to )ave a report>inquiry that +ould indicate variances (materials# materialquantities) bet+een material recipe and actual process orders* ,e tried M. M but this gives us alist of purchasing documents and not the consumption deviation* ,here can ! get suchconsumption deviation (master recipe ;s* Process1 rders) A Do a data collection first*Menu Path 0 'ccounting01&ontrolling01Product cost acctg01Process mfg01!nformation system01&ost ob2ect hierarchy01data collection(!f you are using order hierarchy you +ould select order hierarchy in place of cost ob2ect hierarchyin the menu path*)

hen# 'ccounting01&ontrolling01Product &ost 'ccounting01 rder Related Production01!nformationSystem&hoose Report Period &osting 0 arget>'ctual production variance

Q ,e have t+o components ( BZB I BYB ) in a production order in a process oriented productionprocess* ,hen F6 numbers of component BZB are issued# +e need the system to automatically



issue "66 numbers of component BYB based on ratio of " to * ,here do ! specify these ratiosA You can define the ratio in % M and material may be issued +ith reference to % M*

Q ,e have t+o storage locations are B666"B and B6H66B* Default storage location in Process orderis al+ays B666"B ,hat determines this default locationA Loo- into SS notes7 "66GFG# H58@5# @H H # <G<85# < 655# H8@8H*

he Storage location as configured in the Supply area has the highest priority*

Q 0 e need to do $! of components to production order using %ac-0flush* he component stoc-is managed in %atches* he %atch to be bac-0flushed is selected by 3!3 from the issue storagelocation* 9o+ can +e set this upA ,ith the follo+ing settings# the batches are selected the moment the production order isreleased*"7 Set up batch determination the +ay that the batches in batch selection are sorted the right +ay*e*g* sorted by e/piry date

7 4se automatic batch selection in disp vie+*57 .nsure that the components are allo+ed to be bac-0flushed (material master > +or- center)

Q ,e +ant to report on several status combinations li-e each order that has status B ot deletedB

and B ot technically completedB* ,hat set up is requiredA &hec- transaction & <* !n the selection screen note the possible selection BSystem StatusB *You can select .& for technically complete an DL for deleted from the list* Select the ./cl*indicator also*You may also try transaction & H (Logistics 01 Production 01 Production control 01 &ontrol 01!nformation systems 01 rder !nfo System 01 b2ect overvie+)* %efore e/ecuting the transactionreport# combinations of statuses can be selected or e/clude them*

Q %ow can we shut off the Cautomatic costing indicatorC and the Cautomatic schedulingindicatorC +hich go on +hen the production order is releasedA 6or Cno automatic costingC follo+ the !M$ pathProduction 01 Production orders 01Master data 01 rder 0 1Define order type dependentparameters

Select the order type for +hich u automatic costing is not required* !n the controlling settings#select Cno automatic costingC3or Cno automatic schedulingC # follo+ the !M$ path 7Production 01 perations 0 1Scheduling 01 Define control parametersSelect the order type and go to details* Deselect C automatic dates C

'lternatively# you can find indicators in the control -ey# +hich is in the routing* ransaction PL<gives you costing indicators ( rder type dependent parameters)# and P[4 (control table forscheduling) gives some scheduling options*

@ariable Si e

Q 9o+ can ! use variable si e items

A 3or e/ample# consider an item ' +ith B-gB as base 4nit f Measurement(4 M) and Bm5B asstoc- -eeping>issue unit* &onversion factor is "-g N *8 m5*!n the % M of B%B #number of ' required are specified (say F)*Specify the 5 variable dimensions i*e* length# +idth I thic-ness0 say 666mm Z 5666mm Z 8mmN 6*6 8 m5

's per % M 0 B%B # the quantity of ' required is 6*6 8 Z F N 6*" 6 m5!f a production rder is released for "F numbers of B%B # the quantity of variable si e unit +ill be"* 6 m5*



You can change the length# +idth or thic-ness in the production order I chec- the resultingvariable si e item quantity* 't the same time this requirement can be seen in B-gB instoc->requirement list*

t)ers

Q 9o+ to configure the planning calendar for the ' P calculation +here goods are shippedevery other +or-ing dayA 4se ransaction MD F and define calculation rule for every other +or-ing day* &hec- the lotsi e settings in M!8 and maintain relevant data in MMR*

Q ,e have t+o different production lines +ith different operations* ne production line +or-s Fdays a +ee- and the other G days a +ee-* he factory calendar is assigned to the plant for Fdays a +ee-* his calendar is chec-ed +hen MRP is run* 9o+ can +e assign F day a +ee- and Gdays a +ee- against a factory calendar to the related resources !s it possible to have t+o typesof calendars

A 'ssign factory calendars to the +or- centers*

Q ,hat is the difference bet+een by0product and co0product and ho+ do you differentiate themin a % M A !n case of &o0product costs are settled +ith a apportionment structure* !n case of %y0productthe price of this by0product is credited to the order or the material stoc- account of the leadmaterial being manufactured* &o0Product as +ell as by0product are defined as % M&omponents>!tems* %oth of them have negative quantities* ( ot all negative quantity items fallunder these categories^)* ,hen % M is created for 3.R # you can see one indicator in& MP . D. '!LS screen for co0product* You need to define the co0products +ith thisspecial indicator *

Q ,hat are some important tables used in PP

A 3or orders7&4'3;D dialog structure for order headers and items

'3P 0 rder item '33LD rder7 Dialog table for order sequences ('33L)

M P.R peration for production orderK%.D &apacity requirements

'3R4 rder completion confirmationsR.S% Reservation>Dependent Requirements

'339D Structure of PR Bs in ordersS P.R Sub0operations

S'3R4 Sub0operation

confirmationsSK%.D &apacity requirementsfor sub0operation

MRP table is MD %*3or P!7&'43; 0 '3;& peration +ithin an order

'33 rder Process !nstructions '33; rder process instruction values



Some other tables of interest7PLK # M'PL # PL'S*

List of PP Trans(ort !e*uest an" t%eir &M' Pat%

") Define Distribution Keys!M$ 1 Production Planning for Process !ndustries 1 Master Data 1 Material List 1 !tem Data 1!tem Data from related areas 1 Define Distribution Keys

) Determine Person responsible for Resource :!M$ 1 Production Planning for Process !ndustries 1 Master Data 1 Resource 1 $eneral Data 1Determine Person responsible

5Define Planner $roup0!M$ 1 Production Planning for Process !ndustries 1 Master Data 1 Master Recipe 1 Define&apacity Planner

8) Define &apacity Planner :!M$ 1 Production Planning for Process !ndustries 1 Master Data 1 Resource 1 &apacityRequirement Planning 1 Determine &apacity Planner

F) Determine Standard ;alue Parameter :!M$ 1 Production Planning for Process !ndustries 1 Master Data 1 Resource 1 $eneral Data 1Standard ;alue 1 Define Parameter

H) Define Setup $roups and Setup $roup &ategoriesDefine set up groups and set up categories :!M$ 1 Production Planning for Process !ndustries 1 Master Data 1 Master Recipe 1 Data foroperations and phases 1 Define set up groups and set up group categories

G) Define copy setting bet+een plants0Process!M$ 1 Production Planning for Process !ndustries 1 Process Management 1 ools 1 Define copysetting bet+een plants

<) Define Set 4p &ontrol Recipe destination :!M$ 1 Production Planning for Process !ndustries 1 Process Management 1 &ontrol Recipe>P!sheet 1 Set up control recipe destination

@Define MRP controller :!M$ 1 Material Management 1 &onsumption based Planning 1 Master Data 1 Define MRPcontroller"6) Special Procurement :!M$ 1 Material Management 1 &onsumption based Planning 1 Master Data 1 Define Specialprocurement types

"") Define 3loats (Scheduled Margin Key)0!M$ 1 Material Management 1 &onsumption based Planning 1 Planning 1 Define 3loats(Scheduled Margin Key)



" Define Splitting of 3orecast requirements for MRP0!M$ 1 Material Management 1 &onsumption based Planning 1 .valuation 1 3orecast 1 DefineSplittng of forecast requirements of MRP

"5) Maintain &orrection 3actors for 3orecast!M$ 1 Material Management 1 &onsumption based Planning 1 Planning 1 Procurement 1

Maintain &orrection factors for forecast

"8 &arry ut verall Maintenance of Plant ParametersMaintaining plant parameters in MRP :!M$ 1 Material Management 1 &onsumption based Planning 1 Plant Parameters 1 &arry outoverall maintenance of plant parameters

"F) Define Planning 9ori onDefine Planning 9ori on :!M$ 1 Material Management 1 &onsumption based Planning 1 Planning 1 MRP calculation 1Define Planning 9ori on

"H) 'ctivate Requirement Planning :!M$ 1 Material Management 1 &onsumption based Planning 1 Planning 1 'ctivate RequirementPlanning

"G) Define Range of &overage Profiles (Dynamic Safety Stoc-)Range of coverage profile :!M$ 1 Material Management 1 &onsumption based Planning 1 Planning 1 MRP calculation 1Define range of coverage profile (Dynamic Safety Stoc-)

"<) Define Stoc- in ransfer and %loc-ed Stoc- 'vailability!M$ 1 Material Management 1 &onsumption based Planning 1 Planning 1 MRP calculation 1Stoc-s 1 Define Stoc- in transfer and bloc-ed stoc-

"@) Define MRP 'reas!M$ 1 Material Management 1 &onsumption based Planning 1 Master Data 1 MRP areas 1Define MRP areas

6) &arry out maintenance of MRP groups!M$ 1 Material Management 1 &onsumption based Planning 1 MRP groups1 &arry outmaintenance of MRP groups

") Define Scope of total Planning 0 MRP!M$ 1 Material Management 1 &onsumption based Planning 1 Planning 1 Define Scope of totalPlanning

Define rder ypes

Define rder ype0!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 Master Data 1 rder 1Define rder ype

5Define rder ype Dependent parameters :!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 Master Data 1 rder 1Define rder ype Dependent parameters



8) Define Production Scheduler :!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 Master Data 1 %ill ofMaterial 1 Define Production Scheduler

F Define &hec-ing &ontrol 0 Process rderDefine 'vailability &hec- : Define &hec-ing &ontrol :

!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 perations 1 'vailabilty&hec- 1 Define &hec-ing &ontrol

H) Define &hec-ing Rule for bac-order processing :!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 perations 1 'vailabilty&hec- 1 Define &hec-ing rule for bac- order processing

GDefine Stoc- and batch determination for good movement :!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 perations 1 Define Stoc-and batch determination for good movement

<) Specify Scheduling ParametersSpecify Scheduling Parameters :!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 perations 1 Scheduling 1Specify Scheduling Parameters

@) Define Reduction StrategiesDefine Reduction Strategy :!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 perations 1 Scheduling 1Resource data 1 Define Reduction Strategy

56) Define &onfirmation ParametersDefine rder &onfirmation :!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 perations 1&onfirmation 1 Define &onfirmation Parameters

5") Define ;aluation of $oods ReceivedDefine valuation of goods receive :!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 !ntegration 1 Define;aluation of goods received

5 ) MRP creation indicator :!M$ 1 Material Management 1 &onsumption based Planning 1 Planning 1 Define creationindicator

55) Define safety stoc- :!M$ 1 Material Management 1 &onsumption based Planning 1 Planning 1 MRP calculation 1Stoc-s 1 Define Safety Stoc-s

58) Define alternative determination of Production :!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 perations 1 % M selection1 Define alternate determination of production

5F) Define no* ranges :!M$ 1 Production Planning for Process !ndustries 1 Process rder 1 Master data 1 rder 1

umber Ranges 1 Define number ranges for orders



BOM

=o, to link BOM com(onent to storage location;

If *ou )ave to issue a component for production order of main item alwa*s from a specificstora e location (component is stored in multiple stora e locations but for production of a

top item reservations s)ould be created onl* on a specific stora e loc$' w)ere can *ouprovide t)e lin= between 5 M component and stora e Loc++

Is it possible to provide t)at lin= in 5 M+ or w)ile allocatin 5 M components to routinoperations or else w)ere+

You can use the issue storage location field on the MRP screen in the material master

or

You have 5 +ays of doing it 0 not including the material master since the components are storedin multiple locations*

"* % M item 0 very fle/ible but very time consuming to maintain if you have lots of % MBs* !n&S6 you can set st* loc* on each component# and S'P +ill ta-e this st* loc* first*

* from level above 0 you can set it up so that +hatever st* loc* is the default prod* st* loc on thematerial master for the level above +ill be the issue st* loc for the components you choose# if thecomponent e/ists in that st* loc* 0 -ind of a champagne +aterfall effect* !f the st* loc* is notmaintained on the component# it +ill ta-e the material master default of the component*

5* using supply area and +or- center* create supply areas and lin- them to st* locBs* 0 then lin- thesupply area to the +or- center on &R6 * hen allocate components to operations going throughthose +or- centers*

ote7Supply 'reas are meant to be used in con2unction +ith Kanban* 9o+ever you can 2ust use themto lin- the +or- center to a storage location* You +ill never see an inventory balance in MM%. ina supply area* ,ith Kanban you can set up automatic triggers to replenish stoc- to the supplyareas from a main stoc- location*

W%en is a Material BOM <ot $3(lo"e";

' % M is not e/ploded in the follo+ing situations7

0 o % M is effective700 n the e/plosion date and in the given area of validity

3or the given effectivity parameters

0 he % M has a deletion indicator*

0 he % M is a multiple % M# and has no alternative that matches the lot si e for your requiredquantity*

0 o % M matches the selection criteria of the % M application you selected*



0 his is possible in the follo+ing situations# for e/ample7

00 he application does not ta-e all % M usages into account*3or e/ample# the application only ta-es % Ms that are relevant to production into account# so a% M that is relevant to sales and distribution is not e/ploded*

00 he application selects a specific alternative on the e/plosion date you require* he materialmaster record supports alternative determination by ./plosion date*!f the specified alternative is not valid on the e/plosion date# the % M is not e/ploded*

00 he application ta-es production versions in the material master record into account# but noproduction version has a % M that is valid on the e/plosion date you require* he materialmaster record supports alternative determination by Production version*

he system only e/plodes the % M defined for the production version that matches thealternative and>or usage entered on the e/plosion date required*

00 he application only ta-es % Ms +ith certain status indicators into account*3or e/ample# the application for MRP only e/plodes % Ms that have at least the status ./plosionfor MRP*

reating a sim(le BOM

ransaction code 7 CS!1

Material 7 Your Material code

Plant 7 Your Plant

5 M 9sa e 7 "

Item Cate or* Componment Quantit*

66"6 L Your Material code Your required quantity

Save your entries

You can used CS!# to changed the % M and CS!, to display the % M

$3(lo"e BOM

ransaction code 7

CS11 to e/plode % M level by level

CS1# to e/plode % M Multi level

Material 7 Your Material code

Plant 7 Your Plant

Alternative 5 M 7 if you have multiple % Ms



5 M application 7 PP6" if you follo+s S'P default for Production $eneral

@alid from 7 date of % M you +ant to change

Re&uired &t* 7 enter required quantity (optional)

W%ere use" list for BOM

ransaction code 7 CS1

6irst screen 7

Material 7 your material code

;*pe of w)ere used list 7 ic- Direct

@alid from date 7 default system date (change if you +ant other dates)

7e2t screen 7

Re&uired &t* 7 required qty of material

Resultin &t* 7 resulting qty of the header material

Plant 7 restrict selection to a single plant

PP B Controllin data for *our 5ill of Materials

You define the default values for % M in S#G *

0 %ased quantity0 % M Status0 Si e 4nit0 ;ar0si e item unit

You control the Material type allo+ed for the % M header in transaction S#/ *

!n transaction S#< # you define the central settings for your % M management system* hisare one0time settings for % M management# +hich should not be change after production*

Low date,hen you create or process % Ms# the default date is the date defined in your system as theearliest processing date (6">6">"@66 in the standard system)*

5 M validit* maintenanceic- if +ant the user to specify a valid0from date +hen maintaining % Ms* !f not tic- the % M

created as of the current date or the system lo+ date (">">"@@6)*

:C mana ement activeic- if you +ant to ma-e historical changes to % Ms +ith reference to a change number*

( his means that the status of the % M both before and after the change is stored in



the system*) !n this step# you only specify +hether engineering change management can beused for maintaining bills of material* !n transaction S F# &onfigure history requirementfor % Ms# you define +hether you +ant to ma-e the use of engineering change management arequirement in certain cases*

%ist. re&mt variant4se this indicator to control +hen history requirement applies to ne+ variants oralternatives in a % M group*

SubBitem documentnYou use the Sub0item documentation indicator to define +hether changes to sub0items aredocumented*

%eader &reate % M header +ith parameter validity;:C%I7CAL ;DP:Mult. 5 M inactive

ic- if no multiple % Ms can be maintained in this R>5 system*@ariant 5 M inactive

ic- if no variant % Ms can be maintained in this R>5 system

5ILL 6 MA;:RIAL I;:M5 M item e2plosion t*pe!f you create a % M item +ith reference to a change number and change the valid0from date(in the change header or alternative date)# then this can change the sequence of validityperiods of a % M item* he indicator % M item e/plosion type specifies +hether and accordingto +hat rules#the system determines a unique change status# +hen you display# evaluate or change a % M toa date in the overlap period*>escription variableBsi ed item

his indicator controls +hich te/t is displayed in % M processing for a variable0si ed item*

Repeated effectivit* via e2ternal item I>

his indicator ensures that an item that already e/ists under an e/ternal item !D can be used*

8eneral settin s4nit BpieceB!n the standard system# this field contains a unit of measure for CpieceC* You can changethis unit* his unit is the base unit of measure (% M header) or the component unit ofmeasure*

5ase unit of measure for.quipment % M3unctional location % MDocument structureStandard % M

&omponent unit of measure for7e/t itemDocument item

on0stoc- item +ithout material master record

CA> active!f you +ant to maintain % Ms from a &'D system# set this indicator* his activates anadditional field in the % M header and % M item# +hich tells you +hether the % M header or% M item +as maintained from a &'D system*



!f you deactivate engineering change management# changes to bills of material are notrecorded*

he modification parameters defined here apply to all % M categories*

he follo+ing settings are made in the standard R>5 System7

"* ;alidity date maintenance and engineering change management are active** he current system date is the default valid0from date*

5* &'D is active*8* ./plosion type for % M item7 blan-*

llocating BOM to Ot%er Plant

4se ransaction CS!< to lin- this % M to the other plants*

his shall ma-e the % M available in the other plants*

Mass %ange Bill of Materials

4se ransaction CS#! to mass change your % M*

!n this transaction code# you can 70

"* mass change item data* mass delete items

5* mass add materials etc*

Multi-le el configuration ,it% ariants

00000 riginal Message00000Sub2ect7 Multi level configuration +ith variants

9i all#

Does anybody -no+ a tric- to use preconfiguredvariants in multilevel configuration

'ccording to SS note# it is not possible because ofMRP and possible differences bet+een sales orderconfiguration and material master data configuration*

than-s in advance*

00000Reply Message00000Sub2ect7 Multi level configuration +ith variants

!f you got a some material variants that you +ould li-e to -eep in stoc-#the remaining variants are configurable materials*



!f you only sell material variants and not configurable materialBs you can trythis solution*

Kmat structure*

Level ' 0 0 0 0 0 00 Design level 0 4sed to ma-e

simulation>pricelist>decide +hich system the customer should use*Level % 0 0 0 0 Different systems depending on the selectionsmade in level '*

Level & 0 0 0 0 0 't this level ! have got the materialvariants and configurable materialJs all together*

Step "7o be able to select a material variant in level &# ! use the

classification system* ( class type 66 )*his class has got one char* ( ref to table marc and field matnr )* !t is

not necessary to ma-e the reference to a table* ! have done this because !hope to find a better solution at a later stage*

'll my material variants are allocated to this class* .nter the material

number in the class using cl 8 *Remember to ma-e the classification of the material numbers*

Step 7&reate a ;ariant table* ( ; ).nter the chars that you have got in the class ( 566 )* ,e have got manyconfigurable materials* ! have created one class for each configurablematerial*!n this class you should allocate the char marcQmatnr* 'll chars e/ceptfrom marcQmatnr should be mar-ed as -ey fields*!n the field marcQmatnr you must enter the material variant according tothe classification of the material variant* ( if the combination that youhave entered havenBt got a material variant# you must > could enter the

configurable material number*.nter all combinations thatBs necessary to cover the material variants thatyou have got in your system* he largest variant tables that ! have got#has apro/* F666 positions*

Step 57

'llocate the class(es) to the sales order bom* !f you sell configurablematerialBs you must enter positions* ne +ith the class# and one +ith theconfigurable material* his is because you canBt allocate a configurablematerial to a class* ( ! couldBnt ma-e this +or- )

hen allocate a selection condition to the class* Level % component N 666hen allocate a procedure to the class*

table ; ( a N parent*a #b N parent*b #c N parent*c #d N parent*d #

marcQmatnr N self*marcQmatnr )

his should do it you donBt sell configurable materials*

'llocate this selection condition to the configurable material*



table ; ( a N a #b N b #c N c #d N d #marcQmatnr N B 666B )

his ma-es sure that you get a configurable material if there isenBt amateral variant*

he sales person donBt have to +orry about doing things right* !n our caseit +or- very +ell* ,e have got a very good performances*!t is possible to configure 0 6 items at the same time as it ta-es forour single level configurable materials*

! thin- S'P needs to implement a solution(this) so that +e donBt have tofind>develop our o+n solutions*

ther solutions out there

%est regards

00000.nd of Message00000

W%at e3actl/ is a P%antom item or ssem l/ means;

Can an*one plese tell me w)at e2actl* is a p)antom item or assembl* means+%ow does it affect t)e MRP process+

' phantom assembly is used +hen you +ant to be able to structure a % M so it is easy tounderstand# but donBt +ant to create too many production orders*

'ssume an auto .ngine* here are hundreds of components* You might structure them as7.ngine bloc- and parts# camshaft and parts# and H piston assemblies* %ut you donBt +ant tocreate 5 production orders# too much hassle* So you +ant to issue the components for the pistonassembly in the same production order as the .ngine bloc-* So you create a ne+ materialnumber for the Piston assembly# but you mar- it as a phantom assembly* hat means that +henyou create the bom for the .ngine assembly# you only have t+o assemblies# the .ngine bloc-and the &amshaft* You add the phantom assembly for the Piston 'ssembly to the .ngine bloc-% M# saying it requires < of the phantom assembly* ,hen the production order is created for the.ngine bloc-# the pic-list +ill also include all of the components of the < piston assemblies*

1$ 0)en to use' or not use a p)antom assembl*+!f you need to do cost accounting on ho+ many hours it ta-es to assemble a piston assembly# itcannot be a phantom assembly# because as a part of the .ngine bloc- assembly# the labor costsare included in the .ngine bloc- production order# and therefore in the standard cost*

#$ Can t)e assembl* people pic= out t)e parts for t)e p)antom assembl* from t)e all of t)ecomponents in t)e Jit+!f the guy assembling the .ngine %loc- gets confused because of all of the components for thePiston assemblies are there# then it cannot be a phantom assembly* %ut if they can seperatethem easily# go for it* ' printed circuit board assembly should never be a phantom assembly#because all of those little parts for each type of P& board must be -ept separate*



,$ >o *ou usuall* build 1!! piston assemblies' put t)em into stoc=' t)en issue G at a timeto build an :n ine Assembl*+ !f so# it is not a phantom assembly* !f the Piston assembly is a phantom# you only build the < youneed +hile you are building the .ngine %loc- assembly* You normally do store a pistonassembly (phantom assembly) in stoc-*

/$ %owever' sometimes a customer calls and wants *ou to send t)em all of t)ecomponents for ne Piston Assembl*.%y having it set as a phantom assembly# even though you donBt usually create seperateproduction orders# in this case you &' create a production order for one# pull the components#close the P # and send the parts off to your customer*

$ Dou complete a :n ine Assembl*. 's you are +al-ing it bac- to the stoc-room# you drop it on the floor# and it brea-s^ Damn# but youcan still save the piston assemblies* Since they do have a S'P material number# you &' putthose bac- into stoc-* Most MRP systems ,!LL recogni e that you happen to have < pistonassemblies in stoc-# and +ill issue those +hole assemblies to the ne/t order for a .ngine %loc-*

ttac%ment Of )ra,ings in BOMs

%ow to attac) a document to a 5 M +

o+ one can attach a document to a % M in one of the follo+ing three +aysV") 'ttach document as an item in the item overvie+#

) 'ttach document to an item and5) 'ttach document to the header material*

") 'ttaching document as an item in the item overvie+7Vgo to the $eneral !tem vervie+B screenVselect the tab page DocumentBVenter item category DBVdropdo+n and select the document you +ant to attachVthe system automatically selects the respective document type# document part# documentversion and document descriptionVthe system also enters component quantity "B and component unit of measure as P&B bydefault*

) 'ttaching document to an item7Vgo to the $eneral !tem vervie+B screenVselect the particular item by 3Vthe item all data screen appearsVgo to tab page document assignmentBVdropdo+n and select the document typeB you +ant to attach Vdropdo+n and select thedocument you +ant to attachVthe system automatically selects the respective document part# document version anddocument description

5) 'ttach document to the header material7Vgo to header overvie+ screenVgo to tab page document assignmentBVdropdo+n and select the document typeB you +ant to attachVthe system automatically selects the respective# document part# document version anddocument description



Pre0requisitesVVcreate document by transaction &;6"V&ustomi ing settingsVin document management customi ing determines +hich ob2ects can beassigned to documents per ob2ect type*Vgo to !M$ 01 cross0application components 01 document management 01 control data 01 definedocuments typeVselect the document type for e/ample DR,BVselect the sub dialog define ob2ect lin-sBVselect ne+ entries and enter follo+ing ob2ectsVVBS P QD &B and screen FGB(lin-ing document to % M header) VBS K QD &B and screen

F<B(lin-ing document to % M item) Vno+ documents can be lin-ed to % M header as +ell as% M item*

'oo"s Mo ement

PP - )efine t%e "efault com(onents reser ation mo ement t/(e

During order creation# S'P +ill automatically creates reservations for the components that are-ept in stoc-*

he reservations are assigned a movement type for the material issue +ith transaction PJA.

You can control the material issue using the movement type*

&hanges are only necessary if you do not +ish to use the S'P default setting*

Movement types are predefined in the standard S'P R>5 System*

he default movement types used are70

>ev. cl. 8R 8RBcanc. 8I 8I canc. 8IBb*Bprod 8IBcancBb*Bprod

& "6" "6 H" H F5" F5

!, " H" H

'oo"s !ecei(t 71018 for Process Or"er

0e are currentl* wor=in on SAP /.<. Currentl* e2periencin a problem w)ere t)e 8oods Receipt (1!1$ for Process order ista=in place before a confirmation is done. ;)is causes a recon variance durin mont)Bend' meanin t)e 1!1movement ta=es place e. . last mont) and t)e confirmation done in t)e current mont). Is t)ere a wa* t)at I can customi e"set t)e s*stem 7 ; to process a 1!1 movement 97;ILa Process order is confirmed+ So' w)atever &uantit* was confirmed' t)e 1!1 movement s)ould ta=e placefor t)at &uantit* and not more.

7ote I )ave set t)e control =e* to 7 ; process an automatic 1!1 movement.

;)an=s in advance for *our su estions.



You have options*

"* You can use 4ser Statuses for this* You define the &onfirmed user status and this user statuslets goods receipt to be done* !f not active# you donBt let goods receipt* 'nd you set this userstatus during confirmation# manually or you may use user e/it to do this automatically* Settingsfor this option can be done in &ustomi ing*

* You should be careful for this option^ You can edit the Standard statuses for this* he systemhas P& 3 and & 3 statuses for partially confirmed and fully confirmed* 's far as you havee/plained# it seems that these statuses# +hen active# is configured that the system lets goodsreceipt done* You can edit these statuses# to not to allo+ goods receipt done# if inactive* Settingsfor this option is done thought Status .diting transactions# %S 5 for display# and %S for edit* !repeat# you should be careful# and e/tra careful if this is the first time you are using thesetransactions*

9ope it helps#

hat is one good YP!&'L problem of Production Planning* ! +ould suggest not to go for bigdevelopments +hich +ill ta-e long time to validate (may ta-e even 5 or 8 months) because allother process related to settlement is also involved for your R.& &!L!' ! *

Development for sa-e of ad2usting the quantities that you have calculated in .Z&.L>Lotus 0 &anbe considered* hat is 7 you +ill be actually trying to upload the .Z&.SS Production Auantities orR.D4&. Production Auantities in the e/isting Production rders* %ecause 0 You +ill definitelybe doing a reconciliation outside S'P once* his data need to be punched in to S'P* ypically by5rd or 8th day of the Month you +ill be doing this 0 ! believe*

'fter your ad2ustment>reconciliation for the last month 0 you have to give clearance for running theS. L.M. process*

'oo"s recei(t an" goo"s issue t%roug% a P& s%eet

Can an*one e2plain to me )ow t)e oods issue and oods receipt are done t)rou ) a PIs)eet. 0)at-s t)e lo ic be)ind callin t)e functional module.

Process instructions contain information on7

"* he individual processing steps to be carried out* he process data needed for further processing in process management such as process

parameter# process data calculation formula# inspection results request etc* During maintenanceof P! sheet# the material quantity consumed in each phases and the actual quantity produced are

entered (confirmed)* %ased on the confirmed quantity the system generates $Rfor the process order for the finished product and a goods issue for the material +ithdra+al assoon as the process messages are sent*

han-s 'rulselvan# if the materials are +arehouse managed# ho+ does the goods receipt +or-#does it +or- as a normal transaction in the bac-ground***



!n general scenerio of +arehouse management# $R and $! ta-es in different stages* ,hen youpost the $R (both for purchased material and finshed goods) the material stored in entry storagetype* %ased on the transport order materials are pic-ed and moved to the permanent storage

type* his +ill be ta-en care by +arehouse controller* 'fter entering the material quantity in P!sheet and posting the process messages# transfer request +ill be generated and the +arehousecontroller then convert the transfer request into transfer order* %ased on the transfer ordermaterial +ill be pic-ed from the permanent storage type and moves to e/it storage type and fromthere material moves to shop floor* ! have no e/perience in this but this is the general procedure*

!f this is not +or-ing# please reply*

Ste(s for Su contracting

Li-e to share +ith you my Subcontracting Steps7

"* Define all the materials in your plant (subcontracting and pac-aging etc)*

* !n the material master MRP 8 vie+ there is one field in +hich you can mention that thismaterial is not relevant to MRP planning# use this field for subcontracting material so that it +illnot be planned in MRP runs ( generally use this field for re0order point planning)*

5* !n the % M for the subcontracting material put the special procurement -ey as Subcontractingand do not -eep relevance for costing*

8* !f youBre using pac-aging material of your company and +ant to capture the cost of thesematerials in the subcontracting production order then put relevance for cost*

F* Define alternate % Ms for each customer*

H* $enerally the routing +ill be the same but materials +ill change# define different prodcutionversions for each alternate % M and assign to the routing*

G* Define the activite types for pac-ing and mi/ing in the +or- center and assign them to thecost center# use these for your routing*

<* ,henever you recive a sub0contracting order# use the relevant production version dependingon the customer*

!n my place all the palnts belong to the same client in sap and they +ant to use the same materialcode in both plants# so ! thin- my subcontracting scenario might be different from yours but it giveyou some ideas to go about it*

Stock in Transit - li*ui"ation or remo e t%e stock ,%ic% is in transit

I am transferin a product from one plant (sa* 1!!!$ to anot)er plant (sa* #!!!$. 5* usinM5 ;' I could find t)e stoc= in transit. 9nfortunatel*' t)e lorr* met wit) a fire accident andall m* oods destro*ed. 7ow I )ave a scenario w)ere I need to remove t)e stoc= w)ic) isin transit.



S)ow )ere is an e2ample on )ow to customi e t)e Capacit* Levelin Profile.

>efine time profile in P>#.

'ssuming you +ant to create a time profile for months*

.ntry ype Start Date .nd DateDatabase Read Period [ 05 5

he database read period specifies the period in +hich capacity requirements are readfrom the database* 'll requirements are accessed +hich are partially or completely+ithin the database read period*

.valuation Period $ 0" H6

he evaluation period specifies the period over +hich data is formatted and displayed*he evaluation period must lie +ithin the database read period*

Planning Period $ 0" H6

he planning period defines the period in +hich the S'P system can carry out planning*he planning period is smaller than or equal to the evaluation period* You cannot move

operations outside the planning period* .qually# +hen automatic finite scheduling iscarried out for an operation the system only searches for a ne+ date +ithin the planningperiod*

Dispatch of bac-log $ %ac-log dispatch Date N 6

he date for dispatching the bac-log is of importance in period0related planning*You use the date for dispatching the bac-log to determine the date bac-logs are to beallocated*

he follo+ing types of entry are available7

'ctual date specifications

hese date specifications (for e/ample# calendar day# calendar year) are only useful inthe profiles in e/ceptional cases*

Relative date specifications

hese date specifications (for e/ample# number of calendar days# number of calendar years)are al+ays calculated from the current day*

3or every period# you can specify in +hat form you +ant to enter the date by using therespective field C ype of entryC*

>efine t)e strate * profile in P>5.

!n this menu option you define strategy profiles to control capacity leveling +ith theplanning tables*



You can copy the standard strategy profile li-e S'PS3&;.R" or S'PQ 66"*

'ssuming you copy the strategy profile to `'PS3&;.R" tic-ing the follo+ings70

"* Dispatch at earliest point in time** &hange production version on error*

5* &ancel dispatching due to error*8* 4se operations floats*F* 4se float before production*H* 4se float after production*

and copy the strategy to ̀ 'PQ 66" tic-ing the &hange Planning direction*

>efine t)e verall profiles in P>!.

he overall profiles are used as follo+s to control capacity planning7

!f you select the menu options7&apacity planning 01 Leveling 01 ,or- center vie+ 01 Planning table# then the profileS'PS3&$66" is processed in the standard version*

You can change the profile# but the S'P sub0profiles should remain unchanged as far aspossible*

You can define your o+n profiles and allocate them to particular users by means of userparameters* (See user parameters &Y' 01 &YZ)

3or e/ample# +hen you access the planning table enter using the application menuC&apacity planningC 01 Leveling 01 ,or- center vie+ 01 Planning tablethe user parameter C&Y'C is operative*

You can select any overall profile you li-e by entering via the application menuC&apacity planningC 01 Leveling 01 ;ariable*

Your details of the profile can be as follo+s70

Profile ` L! . `%'&K$RDSelection profile S'PS3&S66F S'PS3&S66"&ontrol profile S'PQQ&66" S'PQQ&66

ime profile ` !M. S'PQQ`66.valuation profile S'PQQ'66" S'PQQ'66"Strategy profile S'PQQ 66" `S R' .$YPeriod profile S'PQQP66Planning table profile S'PS3&L6"6Prof* Plan tab (tab) S'PS3&R6""List profile S'PS3&!66" S'PS3&!66"

Work enter

'ui"e To Mass !e(lace Work enter



n t)e wor= center I )ave defined an activit* t*pe for preparation' mac)ine wor=' personalwor=. 0)en I modif* an activit* t*pe on a wor= center' t)e routin s w)ere t)ese wor=center are emplo*ed are not automaticall* updated.

4se code &'<F +ith same +or-center in e+ +or- center field* &hange the ne+ activity type indefault values screen*

%ut if your activtity types donBt change in the routings +here ever the +or-center is used# thenchec- the reference indicator in the +or-center itself* So +henever you change the activity type inthe +or-center# routing data +ill also get changed automatically*

he step by step guide belo+ gave you a blo+ by blo+ account of the steps for &'<F* [ustensure you only select a fe+ materials initially# and change the mode of transfer so that it +or-sli-e a %D& and you are sure that the data is correctly changed*



Set Parameter an" Work enter 2ormula

%ow to set parameter and formula for e. . Power' 6uel' Repair and Maintenance+

Some inputs for setting parameters and formula77

$o0to 7 PG% CParameters vervie+C

Define your requirements .g* 3or Po+er : say `.L.& li-e that

(Short Key +or->Key+ord : .lectricity# Dimension C .nergyC# Std* ;alue 4nit : K,9)

hen $o0to 7 P"@ C Standard ;alue Key 3ormula 7 vervie+ C

Select S'P" : ormal Production and &opy as (3H) and &reate ne+ 'ctivity ype Say eg* `.L.

hen 'ssign this ne+ Parameter ̀ .L.& and save (handle the transport request)

3or 3ormula Definition 7

$o0to 7 PF8 C3ormula DefinitionC

Select S'P66 : Prod*7 Machine ime and &opy as (3H) and &reate ur ne+ 3ormula Say .g*`.L.&

'nd replace S'PQ6 +ith your Parameter : `.L.&

hen itJll loo- some thing li-e C`.L.& S'PQ6@ > S'PQ6< > S'PQ""C

'ssign he Standard ;alue Key C .̀L.C to your ,or- &enter0%asic Data Screen

o+ $o0to &osting ab Page assign your formula to your Predefined 'ctivity ype for Po+er*

( ther+ise : 3irst &reate Secondary &ost .lement ( *&ode K'6H)# 'ssign this Sec* &ost.lement to your ne+ 'ctivity ype# then KP H C &hange 'ctivity > Price PlanningC



'ssign 'ctivity ype in ,or- &enter &osting ab I 'ssign Your 3ormula)

You can assign ma/* H Standard ;alues to your ,&# !*e !f you +ant to capture Po+er I 3uel&onsumption for an peration you can have both parameters set as per above procedure*

3or costing part# please refer to your & 0person for help*

Planne" Or"er

=o, to A(ermanentl/ "elete ne, (lanne" or"ers;

Dour compan* insists on fi2in planned orders' to tr* to =eep a stable' si2Bmont) plan. 5ut*ou still et new planned orders enerated inBbetween t)e fi2ed ones. Dou t)ou )t t)at*ou would et e2ception messa es to pull in all t)e fi2 planned orders before new onesare enerated. Dou need to Vpermanentl*W delete t)e new planned orders and leave onl*t)e fi2ed ones.

+o ideas +hich you can they apply to the scenario7

") !n PPA# e/clude firm planned orders from rescheduling* his +ill add a reschedulinge/ception to the planned orders# and you could filter>report that +ay*

3or e/ample# if you discovered that the rescheduling hori on +as only "66 days# you can made it@@@* o+ the fi/ed planned orders are all being rescheduled and no ne+ planned orders arecreated =in bet+een? the fi/ed ones*

) &onvert planned orders into production orders* hen you can loo- at production orders as yourfi/ed plan# and ignore planned orders*

Deleting planned orders +ill be a short 2oy# as soon as you run MRP (assuming you do***) they+ill be recreated*

PP B Assi n Multiple Planned rder to a Purc)ase Re&uisition

!n order to assign multiple planned order to a single purchase requisition number#you need to ma-e used of the e/ternal purchase requisition number range*

Define your e/ternal purchase requisition number range in M>7.

'ssign the e/ternal purchase requisition group number range to used in MI,.

nce the !M$ settings are completed# you can used M>1 to assign the multiple plannedorder into a single purchase requisition number*

!n M>1 # select the planned order you +ant to convert to a purchase requisition*

e/t# clic- the Convert nline button*

S'P +ill display the planned order in change mode*



o+# loo- for the Purc)ase Re&uisition fields and supply the Purc)ase re&uisition number*

3or e/ample# assuming that you assign the e/ternal number range 66666"*

!n the planned order# you type the first number range 66666" and item number "6subsequently# copy and paste the number range but input the item number manually*

!t +ould be li-e 66666" "6 and save 66666" 6 and save*****

he disadvantages is that the user have to trac- and enter the e/ternal number rangemanually*

herefore# there is a trade off# bet+een

"* having a single planned order for a single purchase requisition number or

* having multiple planned order to a single purchase requisition number*

$ngineering %ange Management

A basic SAP :n ineerin C)an e Mana ement Setup

his are the basic !M$ settings in order to used the engineering change managementfeatures*

2 refers to a tic-*

3irst setup the control data in S / *

Revision sections

3ields 70

Revision level active /./t* revision level /9igher revision level /

b4ect Mana ement Record sections

3ields 70

b2ect maintenance / 'ssign alternative date /

veride value"assi nment date sections

3ields 70

nly +ith leading change mst* /



Setting the Revision level active is to activate the engineering change management for material master* !f you do not +ant the engineering change management for materials#remove the tic-*

,ith a tic- in C9igher revision levelC# the ne+ revision level has to be al+ays higher than the old revision*

Secondly# setup the e/ternal number range in S , *!f you use the internal number range# then remove the e/ternal number range*

hird# define the status for the change master records in transaction SM,! B @ ;/1ES *&hange o* &hg Date &hg Dist* Loc- DescriptionStatus Poss

" / / B B 'ctive B B B B B B !nactive 5 B B B B / Loc-ed

3ourth# define modification parameters for the % M in S#< *

3ields 70

% M ;alidty Maint* /.& Management 'ctive /9istory Requirement B B4nit Piece P&

he rest of the fields are blan-*

!f the 9istory Requirement is tic-# every time during creation of the % M# S'P +illprompt your for an .& number as is compulsory*

Lastly# define fields selection for routing in P A *

PP tas= lists initial screen B C)an e number B ;ransaction code B ;ic= Re&.

Setting the ransaction code fields Required indicate that you have ma-e the .& numbercompulsory +hen changing the routing*

3inally# do a test by ma-ing changes to the Material Master# % M and Routing*

!outing

Splittin In Routin

he term CSplittingC in S'P means having more than one person or maching +or-ing on anoperation in a production order*

S'P assumes that only one person>machine +ill be +or-ing on a 2ob at a time* !f it ta-es one hourto ma-e one# and the order is for "6# the system +ill schedule the 2ob at that +or- center to ta-e"6 hours* 9o+ever# if in the operation in the routing# you select CRequired SplittingC# then you put



in Cnumber of splitsC as # then the system +ill assume you are having t+o people>machines +or-on the 2ob at the same time# hence it +ill only schedule the 2ob to ta-e F hours# not "6* !f you putin splits as 8# then the system +ill assume *F hours to get the 2ob done*

'lso# sometimes it might be ridiculous to split the 2ob* 3or instance# if that previous e/ample order+as only for pieces* 9aving t+o machines +or-ing on it +ould be dumb# because you +ould

have to do t+o setups* So the system gives you a Minimum processing time# so if itBs less than#say# F hours# do not split it*

consolidated pp questions 06.26.2010

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