PP (PRODUCTION PLANNING)

TABLES

2008-03-20T11:54:00.000+05:30

Production Planning tables

PLKO Routing Group Header

PLSO Routing Group Sequence

PLPO Routing Group Operations

AFKO Production Order Header

STKO BOM Header

STPO BOM Positions (detail)

MAPL Assignment fo Task Lists to Materials

AFPO Production Order Position (details)

2007-12-01T14:27:00.000+05:30

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SAP PP FAQ

SAP PP Frequently Asked Question

Production Orders

Q: We get an error message "Control parameters for scheduling not defined" while creating test production Orders. Why?

A: Before you attempt creating Production orders, configure your

Order types- Transaction Code OPHJ

Order type Dependent parameters - Transaction Code OPL8

Backorder Scheduling - Transaction Code OMIH

Scheduling Levels - Transaction Code OMIF

Q: We are trying to create Purchase Requisition from MRP run. We have material , info Record, Source list , Demand in place. MRP is always creating plan order. Why?

A: Check the procurement type in MRP view of material master. Check 'Create Purchase requisition' indicator while running MRP. If you want purchase requisitions to be created in the opening period, select the for MRP control parameter
'create purchase requisitions' as '1'.

Q: What is the option "Documented goods movements" on Selection of Individual Object Lists (transaction code CO28)?

A: Use Transaction code OPL8 to customize by choosing the order type, select all the checkbox under "Documentation of goods movements" at the bottom of the page. Create a new Production order, make GI to it, and run the report.

Q: We would like to have a report/inquiry that would indicate variances (materials, material quantities) between material recipe and actual process orders. We tried ME2M but this gives us a list of purchasing documents and not the consumption
deviation. Where can I get such consumption deviation (master recipe Vs. Process> Orders)?

A: Do a data collection first.
Menu Path - Accounting->Controlling->Product cost acctg->Process mfg->Information system->Cost object hierarchy->data collection

(If you are using order hierarchy you would select order hierarchy in place of cost object hierarchy in the menu path.)

Then,
Accounting->Controlling->Product Cost Accounting->Order Related Production->Information System

Choose Report Period Costing - Target/Actual production variance

Q: We have two components ( 'X' & 'Y' ) in a production order in a process oriented production process. When 50 numbers of component 'X' are issued, we need the system to automatically issue 100 numbers of component 'Y' based on ratio
of 1 to 2. Where do I specify these ratios?

A: You can define the ratio in BOM and material may be issued with reference to BOM.

Q: We have two storage locations are '0001' and '0600'. Default storage location in Process order is always '0001' What determines this default location?

A: Look into OSS notes: 100757, 63493, 96262, 87843, 82033, 64946.
The Storage location as configured in the Supply area has the highest priority.

Q: We need to do GI of components to production order using Back-flush. The component stock is managed in Batches. The Batch to be back-flushed is selected by FIFO from the issue storage location. How can we set this up?

A: With the following settings, the batches are selected the moment the production order is released.

1: Set up batch determination the way that the batches in batch selection are sorted the right way. e.g. sorted by expiry date

2: Use automatic batch selection in disp view.

3: Ensure that the components are allowed to be back-flushed (material master / work center)

Q: We want to report on several status combinations like each order that has status 'Not deleted' and 'Not technically completed'. What set up is required?

A: Check transaction CO28. In the selection screen note the possible selection 'System Status' . You can select TECO for technically complete an DLT for deleted from the list. Select the Excl. indicator also.

You may also try transaction CO26 (Logistics -> Production -> Production control -> Control -> Information systems ->Order Info System -> Object overview). Before executing the transaction report, combinations of statuses can be selected
or exclude them.

Q: How can we shut off the "automatic costing indicator" and the "automatic scheduling indicator" which go on when the production order is released?

A: For "no automatic costing" follow the IMG path

Production -> Production orders ->Master data -> Order - >Define order type dependent parameters.

Select the order type for which u automatic costing is not required. In the controlling settings, select "no automatic costing"

For "no automatic scheduling" , follow the IMG path :

Production ->Operations - >Scheduling -> Define control parameters
Select the order type and go to details. Deselect " automatic dates "

Alternatively, you can find indicators in the control key, which is in the routing. Transaction OPL8 gives you costing indicators (Order type dependent parameters), and OPJU (control table for scheduling) gives some scheduling options.

Variable Size

Q: How can I use variable size items?

A: For example, consider an item A with 'kg' as base Unit Of Measurement(UOM) and 'm3' as stock keeping/issue unit.
Conversion factor is 1kg = 2.4 m3.
In the BOM of 'B' ,number of A required are specified (say 5).
Specify the 3 variable dimensions i.e. length, width & thickness- say 2000mm X 3000mm X 4mm = 0.024 m3

As per BOM - 'B' , the quantity of A required is 0.024 X 5 = 0.120 m3
If a production Order is released for 15 numbers of 'B' , the quantity of variable size unit will be 1.20 m3.

You can change the length, width or thickness in the production order & check the resulting variable size item quantity. At the same time this requirement can be seen in 'kg' in stock/requirement list.

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2007-12-01T14:12:00.000+05:30

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SAP PP FAQ

SAP PP Frequently Asked Question

Sales & Operations Planning

Q: We defined SOP in months. However during SOP transfer to demand management, our independent requirements are appearing in weeks. How can we correct this from weeks into months ?

A: Check transaction OMPA for general split. OMPS - based on the MRP group. Ensure that MRP group assigned to the material. Delete any allocations in these tables. Then periods will be transferred to Demand Management with the same splits as in SOP. Also check whether the value of period is set as "month" at your plant level in Transaction 'OMP7'

Demand Management

Q: Sales quantities in SOP for certain days are transferred into Demand Management and are shown as planned independent requirements. We need to keep the settings in SOP and change the periods in Demand Management? We would like to have a rolling horizon, for ex: the following 4 weeks on a daily basis, after that on a monthly basis. What is the best way to do this?

A: Use the automatic period split function.

M R P

Q: We have a lot size procedure here which is creating more order proposals. How do you set the limit value for maximum number of MRP order proposals per date in IMG?

A: Under customization, try materials management->consumption based planning->maintain all plants.

Q: What is the difference between "planned consumption" and "Unplanned consumption"? Can safety stock calculation be done on either of these?

A: While customizing movement types (OMJJ) it is defined as to which set of consumption values gets posted during the material movement. For some it may always be the total consumption and for some it is always the unplanned one and for some it is dependent on whether the issues were done with reference to a reservation ie., a planned consumption. The way these consumption values are taken into account in MRP is defined in the customizing of MRP types.

For Reorder point planning (VM) the total consumption is used to calculate the safety stock and the reorder point.

For Forecast based planning (VV) the total consumption is used to build the forecast which will be used to compile the order proposals. For Deterministic MRP (PD) the unplanned consumption is used to calculate the forecast which in turn is added to the actual demand.

Q: We want the system to run a single level MRP automatically on receipt of sales order. How to configure triggering event based MRP?

A: This can only be run if material master has planning strategy 41 (made-to-order) in the MRP2 view. We need to run for other MRP types. We have to create a user exit in the sales order processing (VA01) to start MRP based on data from our sales transaction.

Q: We have an assembly 'A' using a subassembly 'B'. 'B' in turn uses raw material 'C'. Item 'A' is an MPS and is duly marked in Material Master. Item 'B' and 'C' are marked as 'PD'. When demand for 'A' is entered and MPS is run , upto which level the requirements are taken care of?

A: MRP can be run depending on your requirement. For example:

Single Item / Single Level from MPS - Transaction Code MD42 - Only the top MPS item ( 'A' in this case) is planned and dependent requirements will be passed to MRP item ( 'B' ) . Run MRP, Transaction MD02 on 'B' to plan it and all MRP items below .

Single Item / Multi Level from MPS - Transaction Code MD41 - All levels are planned - A , B & C.

Total Planning from MPS online or background - Transaction Code MD40 or MDBS Without marking the checkbox " Process MRP materials" is like case ( 1)above and with the checkbox marked is like case (2 ).

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2007-12-01T13:26:00.001+05:30

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SAP PP FAQ

SAP PP Frequently Asked Question

Bills Of Material

Q: We have a BOM - 'A' with two packing materials 'X' and 'Y'. For 1000 units of 'A', 1 packing material of 'X' is required and for 50 units of 'A', 1 packing material of 'Y' is required. Base quantity of 'A' is defined as 1000. How can I define 'X' & 'Y' or in fact 'A'?

A: Make the base quantity of 'A' as 5000. The resulting component quantities would be 5 of 'X' and 100 of 'Y'.

Work Centers

Q: Can we have more than 6 standard values in standard value key?

A: One way to achieve this is to create another operation step using the same work center. However this shall be with a control key that is not a milestone. When the milestone operation is confirmed, the previous operations up to the next milestone are automatically confirmed. To get the desired number of standard values , all the 'non milestone' steps can be built depending on the need.

Routing

Q: Can we use same routing for materials undergoing the same process/operations? Can we avoid separate routing for each and every material produced?

A1: Presume that there are 50 products and the fabrication shop uses a set of 10 machines. If all these products use the same settings of the machines, Reference Operation Sets (task list type S) can be setup for common processes that use the same work centers. However costing, scheduling and capacity will be affected if each product has different setup time and Reference Operation sets can not be used.

A routing for each material number ( type N or R) has to be set up and within that routing, the Reference Operation Set can be used. However you can by try utilizing the KMAT material and product variants invariant configuration to avoid separate routing for each material.

A2: You may create a routing group. Go into routing creation and enter the plant and the group name. If you want you may name the group , else name is assigned by internal counter). Create the routing with the work centers, operation times, etc.

Go to the "Header overview" screen and click on the "Mat Alloc" screen. Fill in the blanks with all the material masters that use this routing.

Q: Scheduling times can be defined in the material master record by;

# entering the in-house production time. This value can be updated from the routing by the system. # entering the setup, tear down, processing, and interoperation times. If these values are maintained, the system determines the in-house production time on the basis of lot size. How do you get the system to update this value from the routing?

A: In routing, carry out scheduling. Go into the routing operation overview and follow Extras -> Scheduling -> Results. The pop-up window displays the scheduling data. At the bottom there is a pushbutton to copy the scheduling data to the material master Check this push button to update master data.

Q: We have deleted a group key in an operation in routing and the same does not appear for this routing (CA02). But we noticed that entries are maintained in table PLPO and the deletion indicator is not set. How does the system remember this deletion of group key?

A: You may look at the tables PLKO, MAPL and PLAS.

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2007-12-01T13:08:00.000+05:30

>>previous>>

SAP PP FAQ

SAP PP Frequently Asked Question

Q: How to configure the planning calendar for the ATP calculation where goods are shipped every other working day?

A: Use Transaction MD25 and define calculation rule for every other working day. Check the lot size settings in OMI4 and maintain relevant data in MMR.

Q: We have two different production lines with different operations. One production line works 5 days a week and the other 7 days a week. The factory calendar is assigned to the plant for 5 days a week. This calendar is checked when MRP is run.

How can we assign 5 day a week and 7 days a week against a factory calendar to the related resources? Is it possible to have two types of calendars?

A: Assign factory calendars to the work centers.

Q: What is the difference between by-product and co-product and how do you differentiate them in a BOM?

A: In case of Co-product costs are settled with a apportionment structure. In case of By-product the price of this by-product is credited to the order or the material stock account of the lead material being manufactured. Co-Product as well as by-product are defined as BOM Components/Items.

Both of them have negative quantities. ( Not all negative quantity items fall under these categories!). When BOM is created for FERT , you can see one indicator in COMPONENT DETAILS screen for co-product. You need to define the co-products with this special indicator .

Q: What are some important tables used in PP ?

For orders:

CUAFVD dialog structure for order headers and items

AFPO - Order item
AFFLD Order: Dialog table for order sequences (AFFL)

MOPER Operation for production order
KBED Capacity requirements

AFRU Order completion confirmations
RESB Reservation/Dependent Requirements
AFFHD Structure of PRT's in orders
SOPER Sub-operations

SAFRU Sub-operation confirmations
SKBED Capacity requirements for sub-operation

MRP table is MDTB.

For PI:

CAUFV - AFVC Operation within an order

AFFT Order Process Instructions
AFFV Order process instruction values

Some other tables of interest:
PLKO, MAPL , PLAS.

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2007-10-12T05:55:00.000+05:30

SAP PP-CRP-LVL - Capacity Leveling Profile Setup

Capacity leveling is used in various areas of a company and at different planning levels with the following objectives:

- High capacity load
- Adherence to dates
- Short lead times
- Low stocks

The objectives of capacity leveling include:

- Leveling overloads and under loads at work centers

- Achieving optimum commitment of machines and production lines

- Selection of appropriate resources

Show here is an example on how to customize the Capacity Leveling Profile.

Define time profile in OPD2.

Assuming you want to create a time profile for 2 months.

Database Read Period	Entry Type	Start Date	End Date
Database Read Period	J	-3	3

The database read period specifies the period in which capacity requirements are read
from the database. All requirements are accessed which are partially or completely
within the database read period.

Evaluation Period

The evaluation period specifies the period over which data is formatted and displayed.
The evaluation period must lie within the database read period.

Planning Period

The planning period defines the period in which the SAP system can carry out planning.
The planning period is smaller than or equal to the evaluation period. You cannot move
operations outside the planning period. Equally, when automatic finite scheduling is
carried out for an operation the system only searches for a new date within the planning
period.

Dispatch of backlog

Backlog dispatch Date = 0

The date for dispatching the backlog is of importance in period-related planning.
You use the date for dispatching the backlog to determine the date backlogs are to be
allocated.

The following types of entry are available:

Actual date specifications

These date specifications (for example, calendar day, calendar year) are only useful in the profiles in exceptional cases.

Relative date specifications

These date specifications (for example, number of calendar days, number of calendar years) are always calculated from the current day.

For every period, you can specify in what form you want to enter the date by using the respective field "Type of entry".

Define the strategy profile in OPDB.

In this menu option you define strategy profiles to control capacity leveling with theplanning tables.

You can copy the standard strategy profile like SAPSFCVER1 or SAP_T001.

Assuming you copy the strategy profile to ZAPSFCVER1 ticking the followings:-

1. Dispatch at earliest point in time.

2. Change production version on error.

3. Cancel dispatching due to error.

4. Use operations floats.

5. Use float before production.

6. Use float after production.

and copy the strategy to ZAP_T001 ticking the Change Planning direction.

Define the Overall profiles in OPD0.

The overall profiles are used as follows to control capacity planning:

If you select the menu options:

Capacity planning -> Leveling -> Work center view -> Planning table, then the profile
SAPSFCG001 is processed in the standard version.

You can change the profile, but the SAP sub-profiles should remain unchanged as far as
possible.

You can define your own profiles and allocate them to particular users by means of user
parameters. (See user parameters CYA -> CYX)

For example, when you access the planning table enter using the application menu
"Capacity planning" -> Leveling -> Work center view -> Planning table
the user parameter "CYA" is operative.

You can select any overall profile you like by entering via the application menu
"Capacity planning" -> Leveling -> Variable.

Your details of the profile can be as follows:-

Profile	ZONLINE	ZBACKGRD
Selection profile	SAPSFCS005	SAPSFCS001
Control profile	SAP__C001	SAP__C002
Time profile	ZTIME	SAP__Z002
Evaluation profile	SAP__A001	SAP__A001
Strategy profile	SAP__T001	ZSTRATEGY
Period profile	SAP__P002
Planning table profile		SAPSFCL010
Prof. Plan tab (tab)	SAPSFCR011
List profile	SAPSFCI001	SAPSFCI001

2007-10-12T05:53:00.000+05:30

Restricting Good Receipt Unless Production Order Confirmed

SAP Production Planning Ticket:

Restricting good receipt in MB31 unless the production order is confirmed.

My client uses CO11N for activity confirmation. They are not using auto goods receipt for this transaction. Instead they are using MB31, 101 movement type. This 2 transactions are independent of each other. Now the user wants that unless the order is confirmed there should not any goods receipt. Means the system should not allow MB31-101 movement against the order if it is not confirmed through CO11N.

1. Use Tcode BS02 ( Customising USer status profile).

2. Select the order type which you want to configure (eg:PP000001) and choose "Details" button.

3. In the User status table do the following:

a. In the status no field type"1" , status field "Sta1", short text"GR not allowed", lowest no "1", Highest No "2". Mark a tick in the initial stats check box.

b.Next line, type status no field "2" ,status field "sta2", short text"Gr allowed", lowest no "2" , highest no "2".

4. Select the STA1 line and choose details. select the "create"button.select the "GR for prod order", mark "forbidden radio button" and "set radio button".

5. Select the STA2 line and choose details. Selct the "create"button. select "confirm order", mark "permitted radio button" and "set radio button". Next choose "GR for prod order" , mark "permitted radio button".

6.Save.

Create a prod order and check whether the required scenario is working.

2007-10-12T05:50:00.000+05:30

Stock in Transit - liquidation or remove the stock which is in transit

I am transfering a product from one plant (say 1000) to another plant (say 2000). By using MB5T, I could find the stock in transit. Unfortunately, the lorry met with a fire accident and all my goods destroyed. Now I have a scenario where I need to remove the stock which is in transit.

How do you wish to remove the stock? Are you going to scrap it or issue it to a specific GL account for insurance purposes?

It is for both scrap and for insurance purposes.

You have two options. Option number one being the simplest of the two. You will need to know the stock transport PO number or numbers. If you do not know them you can perform a search using transaction MB5T enter in the receiving plant, check the stock transfer order and the cross-company-code box and execute. All in transit PO's will be displayed for that plant. You can drill into document flow by double clicking on the PO number.

Option 1.

You complete the transactions into the intended plant and then perform the scrap transaction.

MB01 or MIGO (goods receipt against a purchase order) depending on which you use to perform goods receipts and LT06 bin put away,( if the plant is warehouse managed).

Scrap the goods using transaction MB1A movement type 551 or MB1A misc issue to a specific GL account. Use movement type 201. LT06 to remove the goods from the put away bin if the receiving plant is warehouse managed. If the receiving plant is not warehouse managed then MB1A is all that you need to do to complete the scrapping of the goods.

Option 2.

You wish to reverse the goods movement back into the supplying plant and then perform the scrap transaction.

VL09 reverse good movement. (You will need the delivery number in order to do this)

LT0G (if using warehouse management) to reverse the goods back into a bin.

VL02N to cancel the delivery

ME22N to cancel the PO.

MB1A choose the bin location in which you placed the goods when you performed the reversal. (again if you have warehouse management). If non warehouse managed MB1A is all that needs to be completed to remove the goods from inventory.

2007-10-12T05:48:00.000+05:30

Steps for Subcontracting

Like to share with you my Subcontracting Steps:

1. Define all the materials in your plant (subcontracting and packaging etc).

2. In the material master MRP 4 view there is one field in which you can mention that this material is not relevant to MRP planning, use this field for subcontracting material so that it will not be planned in MRP runs ( generally use this field for re-order point planning).

3. In the BOM for the subcontracting material put the special procurement key as Subcontracting and do not keep relevance for costing.

4. If you're using packaging material of your company and want to capture the cost of these materials in the subcontracting production order then put relevance for cost.

5. Define alternate BOMs for each customer.

6. Generally the routing will be the same but materials will change, define different prodcution versions for each alternate BOM and assign to the routing.

7. Define the activite types for packing and mixing in the work center and assign them to the cost center, use these for your routing.

8. Whenever you recive a sub-contracting order, use the relevant production version depending on the customer.

In my place all the palnts belong to the same client in sap and they want to use the same material code in both plants, so I think my subcontracting scenario might be different from yours but it give you some ideas to go about it.

Note: To Define Subcontracting Cost Center : Goto - ca02 - double click operation number. It is at the section call External Processing. (Subcontracting will be tick).

2007-10-12T05:45:00.000+05:30

Goods receipt and goods issue through a PI sheet

Can anyone explain to me how the goods issue and goods receipt are done through a PI sheet. What's the logic behind calling the functional module.

Process instructions contain information on:

1. The individual processing steps to be carried out

2. The process data needed for further processing in process management such as process parameter,process data calculation formula,inspection results request etc. During maintenance of PI sheet, the material quantity consumed in each phases and the actual quantity produced are entered (confirmed). Based on the confirmed quantity the system generates GR for the process order for the finished product and a goods issue for the material withdrawal as soon as the process messages are sent.

Hope this may clear your doubt.

Thanks You, if the materials are warehouse managed, how does the goods receipt work, does it work as a normal transaction in the background...

In general scenerio of warehouse management, GR and GI takes in different stages. When you post the GR (both for purchased material and finshed goods) the material stored in entry storage type.

Based on the transport order materials are picked and moved to the permanant storage type. This will be taken care by warehouse controller. After entering the material quantity in PI sheet and posting the process messages, transfer request will be generated and the warehouse controller then convert the transfer request into transfer order. Based on the transfer order material will be picked from the permanent storage type and moves to exit storage type and from there material moves to shop floor.

I have no experience in this but this is the general procedure.

2007-10-12T05:41:00.000+05:30

Goods Receipt (101) for Process Order

We are currently working on SAP 4.7. Currently experiencing a problem where the Goods Receipt (101) for Processorder is taking place before a confirmation is done. This causes a recon variance during month-end, meaning the 101 movement takes place

E.g. last month and the confirmation done in the current month. Is there a way that I can customize/set the system NOT to process a 101 movement UNTIL a Process order is confirmed? So, whatever quantity was confirmed, the 101 movement should take place for that quantity and not more.

Note: I have set the control key to NOT process an automatic 101 movement.

solution 1)

You have 2 options.

1. You can use User Statuses for this. You define the Confirmed user status and this user status lets goods receipt to be done. If not active, you don't let goods receipt. And you set this user status during confirmation, manually or you may use user exit to do this automatically. Settings for this option can be done in Customizing.

2. You should be careful for this option! You can edit the Standard statuses for this. The system has PCNF and CNF statuses for partially confirmed and fully confirmed. As far as you have explained, it seems that these statuses, when active, is configured that the system lets goods receipt done.

You can edit these statuses, to not to allow goods receipt done, if inactive. Settings for this option is done throught Status Editing transactions, BS23 for display, and BS22 for edit. I repeat, you should be careful, and extra careful if this is the first time you are using these transactions.

Solution 2)

That is one good TYPICAL problem of Production Planning. I would suggest not to go for big developments which will take long time to validate (may take even 3 or 4 months) because all other process related to settlement is also involved for your RECONCILIATION.

Development for sake of adjusting the quantities that you have calculated in EXCEL/Lotus - Can be considered. That is : you will be actually trying to upload the EXCESS Production Quantities or REDUCE Production Quantities in the existing Production Orders.

Because - You will definitely be doing a reconciliation outside SAP once. This data need to be punched in to SAP. Typically by 3rd or 4th day of the Month you will be doing this - I believe.

After your adjustment/reconciliation for the last month - you have to give clearance for running the SETTLEMENT process.

2007-10-12T05:34:00.000+05:30

PP - Define the default components reservation movement type

During order creation, SAP will automatically creates reservations for the components that are kept in stock.

The reservations are assigned a movement type for the material issue with transaction OPKA.

You can control the material issue using the movement type.

Changes are only necessary if you do not wish to use the SAP default setting.

Movement types are predefined in the standard SAP R/3 System.

The default movement types used are:-

Dev. cl.	GR	GR-canc.	GI	GI canc.	GI-by-prod	GI-canc-by-prod
CO	101	102	261	262	531	532
IWO1			261	262

2007-10-12T05:31:00.001+05:30

Serial Number For Component

I have a FG (A/C) which has a serial number. This A/c has a compressor in its BOM.

The client requirement is to link the compressor to A/c using serial number. So, I maintain serial number profile for the compressor also. But when I do mfbf (backflush) for the A/c, the system asks only for the serial no. profile only for the A/c & not for the compressor. How do I link the two?

You can assign componenets (with serial nos.) to assembly ( also with serial nos.) with COIB after goods receipt.( Menu path --Logistics -> Plant maintenance -> Management of technical objects -> Installed base -> Create (special) -> With reference to production data.)

Example: Say assembly sr. no. is 1 And components serial no. are- 1,5,10,20 and so on.

After assignment of components it can be viewed on right part of screen, You can have the assignment history--- ie for which assembly no. which components are assigned or vice versa. In production order i.e in descrete mfg. it can be directly done at the time of operation confirmation.

The following is the detail steps:

1. T code--COIB

2. Enter material code ( Assembly). You can select specific serial no. of assembly --- by putting sr. no. in serial no. field.

3. Click on list tree- you will find all assembly with serial numbers.

4. Click on explode-- it will show the BOM ( in bottom left corner of screen)

5. Select the assembly numbers for which you want to assign the componets

6. Clik on tranfer

7. Select the component

8. Also select the assembly no. on right side screen.

9. Select the serial no. which you want to assign to an assembly

10. Click on assign

11. You will find all the components will get assigned to assembly with serial numbers.

12. Now on right side screen there is "save" button. ( It will ask you create/ change as built in foreground or background?

13. Select as foreground

14. Save

15. You will find a message at the borttom --- saved.

16. Now you will find tick mark ( in front of assembly material) in right part of screen ( indication
of assignment of components)

2007-10-12T05:27:00.000+05:30

SAP flow for REWORK activity

Question:

What is the SAP flow for REWORK activity in PP-PI.

Sample Scenerio:

1. Initial Process Order qty: 10pc

2. Confirmed QTY.: 9 PCS.

3. Rejection qty .: 1 pc.

4. Now that one pc. is to be reworked in operation no.0020.

How is it possible to understand later that, it is in this particular process order, so much of rework is carried out, and thats the reason the process cost has increased.

Rework during production depends on the client's decision. Like some companies want a separate process order to process this rejected quantity and some clients want to use the same process order, some even want to identify this rejected by assigning a new batch number.

But in some company, they do rework rarely but not as frequently as you do.

What they do is by inserting the new operation/phase after the actual operation/phase, and the operation quantity/base
quantity, queue times, etc will be according to the users decision. in u r example down 1 pc will be the operation/phase quantity.

and one more thing is that remember to PCNF the 9 pc if you want to identify the 1 pc with the new batch.

Additional comments::

You also need to remember the product costing aspect.

The primary costs of material should not be repeated while doing the rework. so, the generally accepted trend is that you create a separate order type for it and a common recipe with a rework operation and the materials you can assign while creating the process order.

Doing it in the same process order will have a problem of treacability of cost.

2007-10-12T05:23:00.000+05:30

How Costing takes place in Production Orders

Can anyone please explain me the how the Costing takes place for the Production Orders.

Actually, I am new to this package , In Other Package (RAMCO ERP)
(The Process is like follows:

a. Production Work-Order Resource Cost Posts to Finance directly

b. Material Consumption postings happens from OSV(Order Settlement Variance) of MAC Module(Management Accounting).

Please somebody explain me as above in SAP.

The following are considered in costing,

1) cost of materials that you have issued for order

2) activity you have performed in terms of labour hours that you entered while confirming the order (the rates for the labour are defined in the activity planning tables of controlling module)..which is generally associated with a formula key and attached to a workcenter that is linked to a cost center also

3) overhead as applicable with respect to that cost center based on a predetermined cost center planning and its rate...

Costing updation in production order

How is costing updated for production order? After goods issue, conformation & GR, we do TECO. Before closing the order, costing details should be updated. Is it not?

Could you please guide me as to how this is done? Also, what is the transaction code to be used?

Planned cost is caculated if you click 'cost calculation' in production order. GI go production order will update actual material cost. Confirmation of production order will update actual activity cost. You can settle cost once production order has status TECO or DLV. From PP side, the transction is CO02

In IMG we can define that when we calcu. the planned cost.

There are 3 ways.

- Determine planned costs when saving,

- Do not determine planned costs when saving,

- Determine planned costs when saving if released.

But the actual cost is posted when we draw the material, when we confirm the order......We can use co02 and click the calcu. cost to update the cost in the prd order.

Error in Cost Calculation

I am using 4.7. When I was saving my production order, there was this error message that told me that there was an error in cost calculation. Do you have any suggestions what I couldn't have done? What can I do to fix this?

Check the log file in the Production Order -> Goto -> Logs -> For costing

Then take it from here....

Check whether the material for which you have created a production order has a price define in material master like Moving average price or Std price.

2007-10-12T05:19:00.000+05:30

What is Backflushing?

Can anyone tell me what is backflushing for? When is it use?

Back flushing is nothing but automatic goods issue. System will automatically posts the goods issue when you confirm the operations.You have no need to make manual issue. It will reduce the effort.

Backflushing is automatic accounting (Goods issues - 261 mvt) of material consumed for production, at the time of confirmation. Eg. When a 4 wheeler automobile is rolled out from assy line, 4 wheels & Tyres are deemed to be consumed and issued to production order automatically by way of backflushing by the system.

Assy line picks the material from stores/ Assy line and use.

No Physical issue & Manual posting ( Goods Issue) by Stores.

Backflush is used for material which are a must and having fixed relationship.

This can be configured in MRP2 Screen,Work centre, Routing and production order.

Each has some special function.

If you configure this in routing or production order you have no need to activate this in MRP2 or Work center screen.

MRP2 Screen defines whether material components are backflushed are to be made at the work center.

When we do the back flush the backlogs are being created for the BOM components and we are getting the message "Backlogs from backflush were created or changed" - its just an informative message. Do you think this has got something to do with the negative postings ?

Backlogs are created due to different reasons.

This message tells that "there is no sufficient stocks for the bom component/not able to backflush all the material due to plant data locked etc" at the time of backflushing the BOM Material and hence the Post-processing list is created that you have to Re-process for stock updation of each material.

To avoid this you can confirm the following things.

1.Ensure that suffecicient stock is available in the backflushing locations of each materail.

2.To prevent the generation of "post-processing list" you can block the BOM from getting backflushed if sufficient stock is not available in specified location for the BOM COMPONENTS. To do this change the "REM profile" to "002"in MRP4 view for the BOM MATERIAL.(if the profile is not available you can crate it through SPRO).

3. To clear the existing Backlog use transcation MF47 and re-process(be ensure that required stocks is available for each bom component)

2007-10-12T05:16:00.000+05:30

Regarding Production Order Confirmation

Production order confirmation with future date is not allowed

Future dates can be configured in the confirmation configuration.

In configuration OPK4, define confirmation parameters.

When this configuration comes up, in the "Checks" Sections, the last parameter says

"Date in the future."

Check this box if you want your dates in the future.

It determines whether dates in the future can be used in a confirmation.

If the indicator is not set, you cannot make any confirmations using dates in the future.

If you try to do so, the system will issues an error message.

What is the importance of Production Order confirmation? Is there any specification to use type of confirmation ie., CO11 or CO15 or CO11N ?

A confirmation documents the processing status of orders, operations, suboperations and individual capacities.

You can enter a confirmation

- For an Opeartion (co11/co11n)

You have the following options:

- To confirm quantities, durations, activities or personnel data.

- To make a confirmation at a particular point in time (for example, at the start of setup or the finish of processing) enter a confirmation.

- When you confirm time events, the system calculates the required duration. For example, the setup duration is the time between setup start and setup finish.

- For an Order : CO15

If you enter a confirmation at order header level, the system confirms all the operations that have a control key in which confirmation is optional or necessary. The quantitiesconfirmed in the operations are proportional to the quantities confirmed in the order header.

I want to stop the confirmation of production order whenever there is no goods issue to the production order so that I can get the correct material accounting report. I can't set backfliush indicator to the material at Routing level because we are handling the raw material in batches, so I have to assign the batches to issue the raw material.( tcode CO27 ).

We have set the criteria to release the production order is only availability of raw material in plant, so system checks only the availability of raw material & releases the order. Is it possible after issuing the raw material the release of order took place?

Goods issues before release of order is not possible in SAP.

You can think of following things.

1) In opj4,you can block release of order if it has missing parts.

2) By using 'user exit' it is possible to disallow confirmation if goods issues are not posted against each component.

2007-10-12T05:15:00.001+05:30

Automatic Conversion to Production Orders

Is there anyone out there who knows if it is possible to make an automatic change of planned orders to production orders right away - or perhaps even to skip the planned orders and create pp - orders instead?

I have a customer who want to do this (skip the manual conversion).
Perhaps it is impossible?

To create production orders in MRP run without checking first the order proposals (planned orders) is not a recommended process at all. It is against the accepted norms in production/inventory management and its MRP-2 logic on which SAP software is also based on.

If you have complex production - you'd have a nightmare closing all the production orders with the errors not resolved at the prior to conversion stage. On the other hand, if it is too simple production with only a handful of operations and no strict requirement of production control (which seems to be your case, for me), then please do away with production orders, and use the repetitive manufacturing where planned orders are the final.

I am confident that a consultant who can see the need and benefit for the wisdom of planned order conversion as a separate manual process, should ALWAYS be able to convince customer.

As always, the question is, whether you want the right shoe to fit the foot, or cut the foot to fit the shoe.

2007-10-12T05:12:00.000+05:30

Material Stock in Production Order

I have the problem in stock against production order:

Our scenario is we don’t want to create a sales order. I create a production order that has 5 operations. The first operation is sub contracting. Through control key (External operation) I create the purchase requisition and convert purchase order in that operation. Through the PO I can issue the ROH and received HALB. When I received the HALB the stock of ROH is automatically reduced. But HALB stock doesn’t increase. In this case where is my HALB material for second operation?

In this case how to proceed?

Do you have a material code for HALB? if you have material code than you can have stock increased. I think there's some mistake with the process. the subcontracting in operation is only for the operation, not the material.

In your configuration, you subcontract the first operation of the FERT production. and there's no stock increase of FERT or HALB when the first operation is completed (confirmation by purchase order...)

And what you want could be possible like this:

You create the HALB material code, and you make it external procurement (F in standard) and with special procurement key subcontracting (30 in standard) (enter these fields in material master mrp2 view).

Then you can create purchase order for the HALB material when needed, and send ROH material to the subcontractor for the purchase order and post goods receipt for HALB material and stock increases.

And accordingly, since the production of HALB is a different process, not a sub process of FERT material, you should change the routing of FERT material to 4 operations, omitting the first operation, which is subcontracted production of HALB. And you should also change the BOM of the FERT material, and remove the ROH (which is used for producing HALB) and put the HALB material itself.

2007-10-12T05:10:00.000+05:30

Production Setup Time

My client has a production setup where there is a particular activity which has a setup time of 8 hrs when it is executed for the first time, but if another production order is taken up for the same material then the set up rime is zero. That is if I produce a material x at a particular work center the for the first time the set up time is 8 hrs, but if another production order of same material x is executed right after this order then the setup time is zero. Now, if we give the setup time as 8 hrs in routing then the system will calculate total time taking 8 hrs as setup time each time. Is there any way in which the system takes the setup time as zero when a production order for a particular material as repeated.

Take a look at the functionality associated with the set up group and transition matrix, if I remember rightly though the setup times are only adjusted after production orders have been despatched in the planning table as this is the first time SAP is aware of the sequence of manufacture

If I am not wrong, setup matrix and transition matrix can be made use of when you go from one operation to the other in a particular routing. But, here there is only 1 operation in the routing and that operation is being repeated for different production orders of the same material. Can this different setup times be given for this same operation.

If I remember if setup group key is defined in the operation in the routing and then the transition times between setup keys is maintained in configuration.

So it's possible to create something like the following:

From Key 1 To Key 1 30 mins
From Key 1 To Key 2 8 hours

So different the operations in orders for the same material should both have the same key and should have a setup time on 30 mins between them.

Then when a different material with a different setup key comes along in the manufacturing sequence it will pick up an 8 hour setup time

I am facing a much similar problem. We have 15 work stations and daily 50 - 60 production orders are printed. I am maintaining production time as well as set up time in the routings ( There exists a separate routing for all the part no's ). When a production order is printed it copies the setup time from routings. Suppose in one work station there happens has to be 2 production orders processed one by one then the setup is only once. but due to the fact that setup is present in the routings the production order shows a non-conformity of setup time for the 2nd production order. How to solve this problem.

We have a similar situation in the company I work for, we don't actually maintain routings at material level but use reference operation sets at an aggregate level to represent the different production footprints (the link to each material is then made through the production version in the material master).

We measure the actual setup time confirmed in each order belonging to each footprint / family over a rolling three month period and maintain an average setup time in the reference operation set. This gets copied to each production order, but is only to make sure that a time allowance is left in each production week for set up to create meaningful capacity planning data.

When the planners develop the manufacturing schedule using the graphical planning table they then update the setup time in each order automatically with the setup times maintained in the transition matrix so it's more accurate, as it takes account of the order being made on the workcentre previously. So in our case two orders sharing the same footprint will have different setup times.

2007-10-07T03:53:00.001+05:30

What is Discrete Manufacturing, REM and Demand Management?

1. What is Discrete Manufacturing?
2. What is REM?
3. What is Demand Management?

Here are difference between Discrete and REM and small explanation about discrete and repetative manf.:

- A typical characteristic of discrete manufacturing is the frequent switching from one manufactured product to another. The products are typically manufactured in individually defined lots, the sequence of work centers through production varying for each one of these. Costs are calculated on the basis of orders and individual lots.

- In Repetitive Manufacturing, products remain unchanged over a longer period and are not manufactured in individually defined lots. Instead, a total quantity is produced over a certain period at a certain rate.

- Discrete manufacturing typically involves varying the sequence of work centers through which the products can pass during production. The order of work centers is determined in routings, which can often be very complex. There can be waiting times between the individual work centers. Also, semi-finished products are frequently placed in interim storage prior to further processing.

- Repetitive Manufacturing, on the other hand, normally involves a relatively constant flow on production lines. Semi-finished products are usually processed further immediately without being put in interim storage. Routings tend to be relatively simple.

- In discrete manufacturing, component materials are staged with specific reference to the individual production lots. Completion confirmations for the various steps and processes document the work progress and enable fine-tune controlling.

- In Repetitive Manufacturing, components are often staged at the production line without reference to a particular order. Completion confirmations are less detailed, and the recording of actual data is simplified.

- The function of Demand Management is to determine requirement quantities and delivery dates for finished products assemblies. Customer requirements are created in sales order management. To create a demand program, Demand Management uses planned independent requirements and customer requirements.

To create the demand program, you must define the planning strategy for a product. Planning strategies represent the methods of production for planning and manufacturing or procuring a product.

Using these strategies, you can decide if production is triggered by sales orders (make-to-order production), or if it is not triggered by sales orders (make-to-stock production).You can have sales orders and stock orders in the demand program. If the production time is long in relation to the standard market delivery time, you can produce the product or certain assemblies before there are sales orders. In this case, sales quantities are planned, for example, with the aid of a sales forecast.

2007-10-07T03:50:00.000+05:30

Functions of Production Version

Can somebody enlighten me on the functions of production version and some tips on its configuration?

Production Versions are used to describe the production process to be used for planned / production order.

You can use the production versions based on:

1. Lot size qty
2. Bom explosion dates
3. Based on MRP Group

Why is it required?

Suppose you have 2/3 production lines and 2/3 alternative BOMs to produce one FG.

How system will come to know which BOM and Routing to be used. This is done thru Prod.Version.

In production version we maintain the combination of BOM and routing.
Also it can be designed with lot size or validity period.
Go to MM02--->MRP4 / Work scheduling view ----> Prod.Version.
Enter the validity period and lot size.
After entering the reqd. routing no. and BOM alternative , carry a check.
After getting the Green signals ,Continue.
Thus you have saved the prod. version.
Mass processing TCode- C223.

Does this mean that I have to activate all the BOM’s if in case I have 3 alternative BOM’s? if yes, then, will it these 3 BOM’s be exploded in MRP? I’m just worried ‘coz I might bloat our inventory if there are three active BOM’s.

No.First of all need not worry about the BOM explosion.

As I told you earlier which BOM and which Routing is decided by Prod.Version.

So in MRP the active prod.version only will be considered. Thus active BOM and active Routing will be used for MRP.

How to deactivate the alternative BOMs and Routing?

Two Ways:

1. You lock all other non-relevant Prod.Versions in MM02 of the FG/SFG material.(Every alternative BOM and routing forms a Prod.Version) Thus even if there are 2/3 prod.versions System will go and check for Unlocked prod. version and use it.

2. If you don't want to do this business of "Lock & Unlock" just place the required version at the first place in list of prod.versions in MRP4 view of the material.
Once system finds the first prod.version it will not spend energy in searching other alternatives.

Also please.don't forget to maintain the selection value of "2" in MRP 4 view for BOM selection.

This will enable you to start the use of prod. version functionality in SAP-PP.(very good tool for practical purposes, costing and MRP).

2007-10-07T03:40:00.000+05:30

What is Firming Type in the MRP Types

The firming type dictates the behavior of planning with PTR (Planning Time Fence), i.e whether the system should automatically firm the unfirmed planned orders and purchase requisitions, which are outside the PTF as they move to fall within PTF as days progress and also if new planning proposals are needed to be created to cover the shortage within PTF.

There are five firming types, viz. 0, 1, 2, 3, and 4.

Listed below are the characteristics of these four firming types:

0 - PTF has not effect on planning.

1 - All unfirmed planning proposals (planned orders/purch reqs) moving into PTF will automatically be firmed by the system, thus protecting them from anymore automatica changes due to subsequent planning runs). At the same time, if the MRP engine identifies any shortage within PTF, the system will create new planned orders, but schedule them to lie JUST outside the end of PTF, thus leaving them as unfirmed elements.

2 - All unfirmed planning proposals (planned orders/purch reqs) moving into PTF will automatically be firmed by the system, thus protecting them from anymore automatica changes due to subsequent planning runs). BUT, the system will NOT create any new planning proposals to cover the shortages identified within PTF. The shortage is left as a -ve qty for the planner to deal with manually.

3 - No automatic firming of any unfirmed planned orders, even if they move into PTF. They will be moved out to lie JUST outside the PTF. The system will create new proposals to cover the shortage but schedule them outside the PTF and keep them as unfirmed.

4 - No automatic firming / No automatic creation of planning proposals to cover shortage.

2007-10-07T03:39:00.000+05:30

Batch Characteristics while Running MRP

Can batch characteristics be considered while running a MRP? I have a finished good that has acid value as its batch characteristics. Based on this acid value I am trying to pick up a certain batch of raw material that is also batch managed and has its characteristics as acid value.

While running MRP qty requirements are transferred and stock is reserved but the required batch qty (having the acid value required) of raw material is not picked.

MRP does NOT use batch data.

Because, while entering PIR, there's no field to enter batch number. When system creates planned order, also there's no field to enter batch number, both for the header material and planned order components.

There's one exception in PP-PI, where you can use batch specific unit of measure. That is, you can define batch level alternative unit of measure. For example, you may have a liquid, and it may have Liters as base unit of measure, and it may also have the percent based active ingredient, that is Liters of the Active Ingredient can be an alternative unit of measure.

So, every movement of material in the system will be done using 2 unit of measures at the same time. e.g. goods receipt of 100 Lt liquid (which is also 80 Liters of Alcohol, because of 80% alcohol potency), for the first batch. also goods receipt of another 100 Lt liquid (which is 60 Liters of Alcohol this time, because of 60% alcohol potency) When you look at your stock, you will see 200 LT liquid, which is equivalent to 140 LT Alcohol ingredient.

What's the use of this active ingredient data during MRP?

When you define the batch unit of measure, you define limits for it. Say, our liquid in previous example can only be between 50% and 90%, therefore we define it like that. Every time we receive this material from vendor, we make the quality inspection and determine the Alcohol percentage. however, while running MRP, system will create purchase requisitions, but it doesn't know the percentage of the liquid our vendor will send.

How will it determine the correct quantity?

In this case, we define a percentage for MRP, and MRP will use that percentage for calculation. e.g. if there's an industry standard that all vendors of that liquid produce it at 75%, or if we are always working with a vendor who produces 68%, then we can enter this data (per material) and MRP will calculate with that percentage.

2007-10-07T03:38:00.001+05:30

Lose of link between sales order and production order

Issue with production order confirmation

Due to lose of link between sales order and production order due to credit check problem The production order for higher level component lost link and was hanging out in limbo status.

Now the production order at lower level component also loose track and they were already released where as production orders at higher level were not released

So now lower level production orders were tecoed with BDC program as there were 1200 production orders to be tecoed at lower level .

So once I deleted lower level, I saw that there were planned orders for same component and same sales order and item, this was because MRP was running at same time .

So this MRP generated planned orders as the production orders at highrt level were still hanging there and to full fill those production orders lower level component planned orders were generated

So now cleared the production orders in top level and ran MRP in display mode and found that there were no planned orders for lower level component.

But still there were two more planned order created at higher level has I previously tecoed them and did zero confirmation due to some other reason, So I had to unteco them to delete these planned orders and also cancel confirmation to get the production order element on to MD04 screen. Once Iam done with that it show a message 26

So It should be clear that if the exception message is 20 ie cancel process then that production order must be deleted as there is no requirement to consume this order. As all this context was made in MTO stock product.

2007-10-07T03:33:00.000+05:30

How to Configure Range Of Coverage Profile

I am trying to configure the range of coverage profile to provide a 6 months safety stock, in which the 'target cov' field should be populated with 180 days, but the that field only accepts 2 characters max. Is there another way of accomplishing this or am I doing something wrong. Please let me know. The current setup is:
- Period Indicator = M (Month)
- Type of Period = 1 (Workdays)
- Range of coverage in the first period:
- Min = blank; Target = 90; Max = blank
In this Target value accepts only digit numbers.

Yes the system accepts only two digits. But since you want stock coverage for 180 days. Use target as say 60 and the number of periods as 3 . Try it and keep us posted. But the one other issue is the system calculates the dynamic safety stock.
It easy to calculate the stock for the first period but for the later periods its difficult. So if later there is a problem with the quantity then its difficult to calculate or cross check what system has proposed.

Using target as 60 and number of periods as 3, only results in system maintaining safety stock for 60 days for first 3 periods. I found out that there is no way out of this. Strange that SAP wouldn't let the companies plan for inventory coverage more than
99 days. This is a pharmaceutical client whose procurement lead times are more than 5 months for some of the materials, where they want to maintain a 6 month coverage and SAP wouldn't allow to achieve it. Am I doing something wrong here. Is there another way of maintaining dynamic safety stock for 180 days requirements coverage? Please share your knowledge.

Please let me know in details how the profile coverage works in SAP. In details means how it is being calculated and what is being considered. As I am figuring how I could make use of this function that my customer require us to keep 15 days inventory and customer forecast flucuates drastically every week.

In customizing in MRP calculation menu , you have Range of coverage. Define the range of coverage you want , as you said 15 days for a period of 3 months. Then in the profile first fill the Avg. daily req data and then the range of coverage data.
Use this profile in the material master mrp II view(I think), in range of coverage.
As far as calcualtion are concerned its very to calcualte the Qty for the first period and then for the later periods its difficult.
May be I am wrong, just try and keep us posted

The Range of Coverage profile is define specific to a plant in IMG and then assigned to materials in master data MRP 2 view. To define the profile, use menu path
IMG->PP->MRP->MRP Calculation->Define Range of Coverage Profile. In the definition, there are two sections of data that you need to fill in.
1. Parameters for calculation of average daily requirements and Period indicator.
2. Minimum, Target, and Maximum stock calculation parameters.

PARAMETERS FOR AVERAGE DAILY REQUIREMENTS CALCULATION:

Choose the period indicator as Month, Period, or Week.
Specify the number of periods. This is used by system to calculate the average daily requirements.
Select the "Type of Period Length", ie. as workdays or calendar days or standard days (days per period). If the type of period length is selected as standard days, they you have to specify the "days per period". Using these three parameters, the system calculates average daily requirements using the formula:
average daily requirements = Sum of requirements in the number of periods / number of days in the number of periods.

PARAMETERS FOR TARGET STOCK AS DAY'S OF SUPPLY

Then you have to specify how many workdays of supply you want to maintain as target stock, in your case 15 workdays. If you wanted to maintain a constant 15 days of supply as inventory through out the planning horizon, just specify the target stock as 15 days and leave rest of the fields as blank, i.e min, max, and number of periods. The number of periods in this section simply maintains the target stock for that many periods from the date of MRP run. This way you can tell the system to maintain different target stock levels for three different period intervals. For example, if you wanted to maintain 15 days stock for first 3 periods, then specify the target stock as 15 days and number of periods corresponding to it as 3. The system then will maintain 15 days supply as inventory for first 3 periods from the date of MRP run and subsequent months zero inventory will be maintained. This will allow you to maintain your 15 days supply constantly for 3 periods.

2007-10-07T03:30:00.000+05:30

Reservation Not Created During MRP Run

I have created a planned order thro MRP run, but reservation for raw material is not created, even though stock is available. After conversion to Production order reservation is created. After confirmation and goods reciept MB31 final product is updated in storage location, but raw material quantity is not reducing.

Can any one give solution for this.

PART I

After MRP run, based on the demand Planned order will be created and for the BOM components sytem will create dependent requirement if stock is available. If stock is not available system creates a planned order or a purchase requistation. Once the planned order of the Header material is converted into a production order , then system converts the dependent requirement into reservations.

PART II

After confirmation and goods reciept if the item components are not consumed, it means you have not defined backflush process. If you want to issue manualy to the order u can use T-CODE MB1A, for the same.

1. Check backflush indicator either in routing /workcenter or in material master.
2. In customization production control -operations-confirmation ( general individual entry screen ) check-- post open reservation . It will post open reservation while confirmation.
3. After doing this cross check failed goods movements.

2007-10-07T03:29:00.001+05:30

MRP Monthly lot size

Appreciated if some guide can be provided.
MRP lot size has been set to MB (Monthly lot size)

It is known that with this setting, material are always bring in on the first working day of the month.
Ex: Dep requirement 26-10-04 100 pcs
Dep requirement 30-10-04 190 pcs

When MRP completion, the PR item shown 1-10-2004 290 pcs, is that any possible to bring in material just right before dependant requirement 26-10-04 say about 24 or 25 of the month.
Because. we dont tend to keep more stocks until actual requirement.

Any comment are welcome.

In that case you might like to consider lot size key WB (weekly). It will bring in material at the first working day of the week. In your case it is Oct 25, 2004

But in this case, I will have increase administrative cost on monitoring the material lot weekly.
I want to have monthly lot size that group all the requirement, but bring in material as close as possible on the first requirement.
Any comment are welcome..

How about manually change delivery date in PO item

Check your config. in OMI4 - scheduling may by ''1'" for Lot size of MB.
Change to Blank.

Friend PPS is correct, Schedule the "REQUIREMENTS DATE = DELIVERY DATE" option in Customizing for Lot Size MB (use Blank instead of 1) & your reqt 'll be met...

We have similar problem and when I applied your solution, the proposed requirement date is perfect.

2007-10-07T03:24:00.000+05:30

Planning Strategy Selection

Selection priority for planning strategy is:

First material, second MRP group and last plant parameters. E.g. System first checks for material, if strategy is defined there, that is used, if it's not maintained there, then it checks if it's defined in MRP group.

That is the same for all MRP parameters, not only strategy.

If you wanna test how it works, try this:

1. create an mrp group, say 0001, and assign strategy group "40 - planning with final assembly" in the MRP group parameters.

2. create a material, say product1 and define planning strategy as "20 - make to order". And also enter the MRP group 0001 in material master.

3. Create a sales order and create an order item for product1.

4. In the sales order header, go to the Procurement tab. There, you will see the requirement type for product1, which is automatically selected by system according to the planning strategy it uses. That requirement type should be "KE" if strategy 20 is selected, or it should be "KSL" if strategy 40 is selected by system.

5. In my test, system selected KE requirement type, which indicates that system used strategy 20, and which I have entered in the material master. It didn't select KSL, which indicates that system uses strategy 40, which is entered in the mrp group. Finally, this test shows that system takes the planning strategy in material master (if it's entered), not the strategy in MRP group.

I think you can now make another test how system uses MRP group's planning strategy. (hint: Delete planing strategy from the material master and repeat the previous test steps. That would end up using strategy 40, which is selected using the MRP group parameters.)

When do we use planning without final assembly strategy?

We have mainly MTS, MTO, planning with final assembly and planning without final assembly. Now when we are dealing with planning with final assembly, we would usually produce subassemblies (HALBs I guess) using make to stock, so do we use a planning strategy 70 for subassemblies and do a MRP run. To my knowledge I thought we run MRP only for final products (with final assembly) so in that case how would we plan for subassembly products.

I get to understand you are using strategy planning with final assembly. So you are using strategy 40 for the finished product.

Just to clarify certain things, MRP can be run for any material...be it finished or semi finished or raw material. Actually when you run a MRP for the finished product using MD02, you are doing a multilevel run.

Secondly, when you are using 40 for the finished product you may or may not use any strategy for the semi finished goods. It depends on your business. If you are going to produce semi finished goods independent of the finished goods, you may have a make to stock strategy 10 (one of the many options) and produce them independent of the finished good requirement. Now when a requirement will be generated for the finished good and a MRP run will be taken, it will show that the Semi Finished is either in stock or a planned/production order exists and thus only the remaining quantity will be planned for (there is a better strategy existing for this type of a scenario.....

However if you do not put any strategy for the Semi Finished, then planned orders will be created for the Semi Finished for the same quantity as the orders created for the Finished goods.

2007-10-07T02:36:00.000+05:30

Why Planning file entry still Exists?

Does anyone know why a planning file entry would exist for NETCH or NETPL when there has been NO activity on the material since the last planning run? No movements, no PO's created, no Orders taken, no activity whatsoever . . . and MRP ran, created a planned order, which was converted to a requisition and then a PO. This PO was converted for a date earlier than what MRP recommended.

Now each time MRP runs, we get exception #15 - delay the order until later (gives date). We don't change it and the planning file entry doesn't go away, even after the run.

Found a note that seemed to apply, but . . . I guess it doesn't really.

"If the planning run terminates for a material with planning file entry on account of an error message, the planning file entry is not deleted if this is not explicitly set in customizing. In transaction OMDY, you can set for which errors (message number) you want the planning file entry being deleted."

I thought this was my answer. However, after looking in OMDY - the message #015 = Dates incorrect (start date > finish date). And message #15 = Enter value for version number increment (VersNumIncr.).

Neither of these defines my MRP List exception message 15 = "Postpone process (28.06.2004/26.06.2004)" - on a current date of 03/06/2004. It's CLOSE, but not the first message.

So if I set the field for the deletion of the planning file entry, it still wouldn't affect my real problem - trying to get this entry to 'go away' after doing what it was supposed to do.

Please Check CS15 - where used list. May be this material has been added to a BOM of a product/Assy, which has caused an entry in planning file.

Check MD04 for the source of reqt.

Also check MD63, if a PIR exists.

If not, delete from planning file. Try report RMMDVM10 - consistency check.

THE COMMON PLANNING

2007-10-05T02:52:00.000+05:30

PP - The Common Planning Strategy used

The planning strategies are maintained in Customizing for Demand Management in SM30 - V_T461S.

Define the Planned Requirement Type and assign the requirement class in OMP1.

Define the requirement class in OMPO.

Check the independent requirement and consumption of requirement class in OMPC.

Maintain the message for invalid requirement type in OMPJ.

You define the strategy group in SM30 - V_T461P.

You define the Plant to MRP group in SM30 - V_T438M_S.

Maintain the consumption mode and period of adjustment in SM30 - V_T438M_V.

Listed here are some common used planning strategies :-

Strategy 10 in summary :-

1. Sales Order creation - no impact.

2. Goods Receipt - reduce the planned independent requirement during MRP run
For e.g. if PIR is 100, quantity remained as 100 in PIR, however during MRP run,
100 will not be included in the MRP planned as stock is available.

3. Delivery - minus the quantity for the oldest planned independent in demand management.
For e.g. if PIR is 100 and delivery 90, PIR becomes 10 (withdrawal 90).

LSF

Make-to-stock production

KSL

Sale from stock without independent requirement reduction

Choose this strategy if you want production to be determined by a production plan (Demand Management) and if you do not want sales orders to influence production directly.

You must maintain the following master data for the finished product:

Strategy group 10 on the MRP screen.

Item category group (for example, NORM) on the Sales Organization screen.

Availability check field in Customizing so that you perform an availability check
without replenishment lead times (in the standard system, you must enter 02 here).

In net requirements planning according to strategy 10, the order does not create a requirement; the sales order is displayed, but does not generate planned orders.

The planned independent requirement is reduced during processing of the goods issue.
Old quantities can still be retrieved by using either
Goto -> Schedule line history in Demand Management, or by using the total requirements list
(Evaluations -> Display total requirements from the Demand Management menu).
The quantities issued are displayed in the Withdrawal quantity field.

The system always reduces the oldest planned independent requirements unless the consumption fields (Consumption mode, Fwd consumption per., Bwd consumption per.) are maintained in the material master or in the MRP group.

BSF

Gross planned independent requirements

KSL

Sale from stock with out

Independent requirement reduction

Strategy 11 in summary :-

1. Sales Order creation - no impact.

2. Goods Receipt - minus the quantity for the oldest planned independent in demand management.
For e.g. if PIR is 100 and delivery 90, PIR becomes 10 (withdrawal 90).

3. Delivery - no impact as delivery is issue from sales order.

This strategy is particularly useful if you need to produce, regardless of whether you have stock or not. For instance, steel or cement producers might want to use this strategy because they cannot shut down production; a blast furnace or a cement factory must continue to produce, even if this means having to produce to stock.

You need to maintain the following master data for the finished product:

Maintain strategy group 11 on the MRP screen.

Set the Mixed MRP indicator to 2 on the MRP screen.

Maintain the item category group (for example, NORM) on the Sales Organization screen.

Maintain the Availability check field so that you perform an availability check without the replenishment lead time (checking group 02 in the standard system).

Strategy

Stock is taken into account

Yes

Reduction of planned independent requirements takes place during … … 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).

Planning separately

2007-10-05T02:47:00.000+05:30

Planning separately via Storage Location or Vendor with MRP Area

Steps 1 :-

You must convert the existing planning file (table MDVM) to the new planning file (table DBVM)
in order to be able to use MRP areas in materials requirements planning. Transaction OM0F.

1. During the conversion, the system creates a plant MRP area for every plant.
2. The existing planning file entries are copied from the planning file used up to now into
the new planning file.
3. The system deletes the planning file that had been used up to now after the conversion has
taken place.
4. At client level, the indicator Planning file entries for MRP area converted is set in a
system table. This indicator causes material requirements planning to be carried out using
planning file entries at MRP area level from this point onwards.
5. The report also converts the individual customer planning file entries at plant level to
individual customer planning file entries at MRP area level.

Steps 2 :-

Activate MRP Area in SM30 - T000MD.
(Material requirements planning with MRP areas cannot be reversed once activated).

Steps 3 :-

During conversion in Steps 1, SAP will automatically create a MRP area for all your existing
Plants.

Now, you can start creating the MRP area for storage location or vendor to be planned
separately. That's is the whole purpose for using MRP area.

Define MRP Area in SM30 - V_MDLV.
Here you define whether the MRP area type :-
01 - Plant
02 - Storage Location
03 - Vendor

Steps 4 :-

In Material Master MRP 1, the MPR area section will appear once you successfully complete
the above Steps.

Assign MRP Areas to Materials

You assign the MRP areas to the materials by creating an MRP area segment for each MRP area
in the material master. You can assign several MRP areas to one material.

MRP with MRP areas for the material is not activated until an MRP area has been assigned to
a material. If you have not assigned an MRP area to a material, that is, you have not created
an MRP area segment in the material master, the material will continue to be planned in the
plant MRP area only. If you have assigned an MRP area to the material, the system can plan it
in the plant MRP area and in the assigned MRP area.

You can display an overview for all materials in an MRP area. To do this, you go into
Customizing for MRP and choose the IMG activity Define MRP areas. Call up an MRP area by
double-clicking and choose Material overview for MRP area.

Steps 5 :-

Check Storage Locations

If you have already entered a storage location in the BOM (BOM item), in the work center
(supply area) or in the production version, you should check whether this storage location
is the storage location for the MRP area that you have assigned in the material master.

The materials are assigned to an MRP area via the storage location that the system
determines during the planning run. You should therefore check the storage locations that
you have maintained in the material master. The storage location in the material master
must be a storage location for the MRP area, for which you have created an MRP area segment
in the material master. You can therefore ensure that material requirements planning will
be carried out for the correct MRP area

The MRP area represents an organizational unit for which material requirements planning is
carried out independently.

Basically, there are three types of MRP area:

Plant MRP Area
The plant MRP area initially contains the plant together with all its storage locations and
stock with subcontractors.

When you have defined MRP areas for storage locations and for subcontractors and you have
assigned the materials, the plant MRP area is reduced by exactly this number of subcontractors
and storage locations. This is because they are now to be planned separately.

MRP Areas for Storage Locations
You can define an MRP area that consists of a particular storage location, by creating an MRP
area and assigning the storage location to it. Material requirements for this storage location
are then planned separately from the rest of the plant.

You can also group several storage locations into one MRP area, by creating an MRP area and
assigning the storage locations to it. These storage locations are then planned together.

A storage location of a plant may be assigned to only one MRP area.

MRP Areas for Subcontractors
You can also define an MRP area for each subcontractor.

A subcontractor may be assigned to only one MRP area.

An MRP area of the subcontractor type may also only contain one subcontractor.

MRP areas of the storage location or subcontractor type are only suitable for:

1. components that are planned and produced for stock

2. finished products that are planned and produced for stock.

By assigning a storage location in a sales order or by entering an MRP area when creating
the planned independent requirements, you can define whether a material is planned in the
plant MRP area or in the MRP area of the storage location.

Material requirements planning for each MRP area allows you to have specific control over
the staging and procurement of parts produced in-house and purchased parts for each shop
floor and assembly area. If, for example, you define an MRP area for the production
storage location of an assembly line, the system plans the material requirements for the
assembly line separately from all other requirements.

Example: Subcontractor

You can also carry out planning for components to be provided in subcontracting using an
MRP area by defining an MRP area for every subcontractor and assigning the components to be
provided to the MRP area of the subcontractor. You therefore plan the requirements to be
provided for these components for one subcontractor separately from all other requirements.

Depending on the requirements situation, the system creates either stock transfer reservations
from the plant to the stock of material provided of the subcontractor or it creates purchase
requisitions within subcontracting/third-party order processing, according to the special
procurement key settings.

The planning run takes into account the planning with MRP areas as follows:

If you do not enter a separate scope of planning, the system plans the whole plant, that is,
all MRP areas in the plant, during the total planning run. If you want to carry out a total
planning run for a particular MRP area only, you must specify the required MRP area in the
scope of planning.

During single-item, multi-level planning, the system plans the selected material in the MRP
area entered. In addition, the system takes into account planning file entries from other
MRP areas, for example, if the material is to be procured using stock transfer.
During single-item, single-level planning, the system plans the selected material in the
MRP area entered only.


You define the MRP areas in Customizing for MRP. You can thereby assign the following to
an MRP area: one or more storage locations (example: you want to carry out planning for a
particular 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. For this, you
create an MRP area segment for a material for every MRP area, in which it is used. In this
MRP area segment, you can define MRP parameters such as, for example, the lot size or MRP
type. This allows you to plan the material differently in the MRP area from how you plan it
in the plant MRP area.


MRP with MRP areas for the material is not activated until the material has been assigned
to an MRP area. If you have not assigned a material to an MRP area, that is, you have
not created an MRP area segment in the material master, the material will continue to
be planned in the plant MRP area only. If you have assigned an MRP area to it, the system
can plan it in the plant MRP area and in the assigned MRP area.

MRP Group and MRP Controller

2007-10-05T02:43:00.000+05:30

Questions on MRP Group and MRP Controller

MRP groups are used when the plant division for planning is not enough for the division of the different materials MRP requirements. You assign different groups according to the requirements to run MRP (different Settings). These settings will be taken in account when you run MRP for single item or total planning.

MRP controller is the person in charge of the MRP run for the materials. It is still a further division on your MRP. This is work load related. You can have one MRP controller for materials with different MRP groups.

On your MRP group, you will define the parameters for the MRP run. These parameters are calculated in accordance with the settings on your material master MRP views.

Available stock = Plant stock - safety stock + receipts of (purchasing orders + purchasing agreements + production orders) - required quantity.

This means that all the requirements are calculated in the bases of your material master settings and your MRP group settings.

What if nothing happens when you run MRP?

The reasons could be :-

- You have purchase requisitions that are delayed but the delivery time has not been updated on the system.

- The settings on your material MRP screens are not correct, i.e. your material have not yet
entered the re-order point level.

- Your requirements have not been taken in account when running MRP.

Assuming that everything is well and the requirement has been calculated, go to transaction code MD04 and verify that the different requirements are reflected in the MRP list and also if there is any purchase requisition scheduled by the system. Verify also if there is any other delivery schedule that will exceed the actual requirements.

If the purchasing requisition is there, the only thing that you have to troubleshoot is the message to tell you that the purchasing requirement was calculated.

If the requirement is not there, re-visit your material master and check your settings for the MRP group.

What is the real meaning and usage of the followings configured in PP:

1. MRP Controller;
2. Schedule margin key;
3. MRP group;
4. MRP profile.

1. MRP Controller;

This will help you to group the material for some controlling purpose. You can run mrp by mrp controller.

you can do evaluation by mrp controller. This will help us if have different people in one organisation involved in purchasing.

2. Schedule margin key;

This will help you to determine the floats. In case if you have production order you can see the impact of floats

3. MRP group;

This will help you for the material to reac in tems of the settings made relavant to each group. To know more details on the group you can chek the tcode oppr.

4. MRP profile

We can have some prefixed datas in the profile and and we can enter teh profile for diff material so the values will copied as defaulted in the profile.

Safety Stock Availability

2007-10-05T02:30:00.000+05:30

Define Safety Stock Availability

The IMG can be set in SM30 - V_438M_S

You define per plant and per MRP group the percentage of the safety stock that is to be available for planning. This helps to avoid a situation where order proposals are created unnecessarily by the system to cover small shortage quantities.

For example:

	Mat. 1	Mat. 2	Mat. 3
Safety stock:	100 pc	100 pc	100 pc
available for planning:	0%	50%	50%
Shortage quantity	1 pc	1 pc	51 pc
Order proposal quantity for lot-for-lot order qty	1 pc	0 pc	51 pc

Purchasing processing Time

2007-10-05T02:27:00.000+05:30

Purchasing processing Time - OPPQ

Please refer above subject and would like to do following. External Processing Time I have set in using OPPQ. My client want this time set differently for different Vendor. Is there any userexit or customization settings?

For MRP to take lead time by supplier, you need to have 3 settings:

1) The config in OPPQ - External procurement at plant level (or OPPR at MRP grp - Scheduling/doc. type) should have the check box marked to read SchedAgreem/Inforecord leadtime (T399D-GTERM)

2) You should have a contract/schedule agreement, or a purchase info record maintained for that plant-material-vendor combination

3) You should maintain source list (ME01) for the contract/schedule agreement, or info record. This changes the default behavior of MRP to use leadtime by supplier, rather than material master leadtime. When both contract and info record exist, the contract will take precedence.

Please watchout for the case if you're already using contracts/info records in procurement, but not using them for planning.

In this case your leadtime data in these documents may be incorrect, or may be left blank - this will be interpreted as zero if you make this change implementation, as mentioned in the steps above.

The delivery date and release date

2007-10-05T02:21:00.000+05:30

Calculation to determine the delivery date and release date

There have been three parameters that SAP will take it into calculation to determine the delivery date and release date during material requirement planning.

They are -

1) Planned Delivery Time which is the vendor-dependent lead time being measured from the time PO is outputted (for sending to the vendor) till the time the shipment is delivered at the warehouse.

2) GR processing time represents the necessary period of time being required for receipting the shipment into the warehouse. This period is, usually, for quality and quantity inspection.

3) Purchasing Processing Time. This is the internal required time for processing the purchasing document (Purchase Requisition) till Purchase Order. You can set it up plant-wise via Transaction OMI8.

With these three parameters, it is possible that you can set it up correctly in your system to enable the appropriate planning of your material requirement.

MRP-3

2007-10-05T02:18:00.000+05:30

GR processing time in PP and MM

I have one material number that is procured externally but also produced inhouse. Now I have one problem with the GR processing time. As far as I can see the parameter on the material master on MRP2 view and Purchasing view is the same (MARC-WEBAZ). But in my case the GR processing time should be only used for goods receipts in MM (from purchase oders). This GR processing time must not be added to my lead time scheduled in production (when producing the material). How to solve this conflict?

We have a make to order enviroment, that means our production orders are created (and scheduled) directly from the sales order. The sales gets back a confirmed date and quantity from production order scheduling - and here this GR processing time is also added. Absolutely useless in this scenario, but MM needs this GR processing time for the external procurement of the material.

I'm hearing at least two problems here. Let me lumber through them as I see them.

#1 - We have a make to order enviroment, that means our production orders are created (and scheduled) directly from the sales order. The sales gets back a confirmed date and quantity from production order scheduling - and here this GR processing time is also added. Absolutely useless in this scenario, but MM needs this GR processing time for the external procurement of the material.

The GR processing time is quite legitimate, and needful. It represents the time it takes once a material is 'delivered', before it is usable. If that is instantaneous for you, then this field is blank. In fact if it is less than one day, the field should be blank. (MARC-WEBAZ) If you DO have to do testing or documentation or even just 'checking' to be sure the proper certificates
have arrived with this material, then it's nice to have a day here for this. --- I may have overlooked one thing, if you are ONLY thinking of the FERT that your customer ordered, then maybe this field seems trivial. However, if your process requires that the FERT be purchased from some other company (or even supplied from within YOUR company), then there IS a receiving process that has to happen . . . it does take time to back a truck up, get a fork truck to unload it, the
identification process, and then relocating the item to where it can be shipped to your customer.

Also, if you produce this item, then there are 'other' items that need to be 'built' into this item . . . THEY need the GR field, even if you produce the saleable item, it has to be 'received' from production into inventory for you to ship it out.

There is another field that should be considered. This is the procurement lead time. The time it takes for purchasing to "react" to the requirement. When the sales order is placed, the signal will come for 'purchasing' to occur (via MRP perhaps). Purchasing MAY take as long as a day to get that order to a vendor where the vendor can now react. This time is generally a 'standard' time for any given plant/purchasing org and is included using OMDT.

Thirdly, the vendor lead time has to be considered. This is what the field "Planned delivery time" (MARC-PLIFZ) is about. The vendor's turn around time - from the time they are notified of your intention (via a PO perhaps), until they can put it on your dock . . . that is what this field is about. And MRP knows the difference between this field and the others. Between the three fields mentioned, the 'purchased' item is properly planned for . . . except for the exceptions and the fact that this is all based on "norms" and averages which never seem to be exactly what is needed, but that's another discussion .

Next we think of the situation where the item requested is produced by us. In this case (as mentioned before), the GR is STILL legitimate - perhaps not needed if it takes less than a day for your company to receive material from production, inspect it, certify it, and load it up.

However, a "0" is a legitimate entry to this field.

What is also needed is a place to locate the time for "producing" this item. That is where there are options. One option in MRP 2 is the field "in-house production" (MARC-DZEIT). This is sometimes useful, but dangerous. It assumes that no matter how large an order is or how much of a material is needed, it can always be produced in the same period (in 'days', of course). The number of days fits in this field.

If that doesn't 'do it' for you, you can go to the "Work Scheduling" view of the Material Master and include the details for the fields under the "in house production time in days" grouping (Setup time; Interoperation; Processing time; and base quantity). At LEAST this gives the system a 'shot' at planning longer times for greater quantities. If you fill both data points in (in
house production time and " in days, the 'in days' will supercede the other).

Now you've put in all the data that you HAVE to input to have the system plan the length of time needed for telling your customer when you will have their product ready for them.

In the case of your conflict where you produce OR source the item, then you MAY have a problem with GR - look at both scenarios and see what your entry should be. You CAN use the Total Replenishment Leadtime (MARC-WZEIT) field to be the TOTAL TIME when producing the material in-house, because the external replenishment does not look at this field. So MRP will run and depending on how you have it set, it will consider purchasing the material, or making the material, and the fields we've mentioned will impact the result as mentioned.

Factory Calendar

2007-10-05T01:57:00.000+05:30

SAP Factory Calendar

Factory calendar contain company specific dates such as alternate working Saturdays, Plant shutdown etc.

You can create your company factory calendar via transaction code 'SCAL'.

Assignment of the factory calendar by plant is done in transaction code 'SM30 - V_T001W'.

An example of a SAP application that uses the factory calendar is the SAP MRP modules.

Assuming that you have a specified an alternate working Saturday, MRP will postponed the planned orders to the next working day if it happened to falls on a non-working Saturday.

MRP VS MPS

2007-10-05T01:38:00.000+05:30

Difference between MRP vs MPS

Explain the difference between MRP & MPS. Though both components gives you the requirement list, what we gain out of MPS run rather than running MRP. What is the main idea behind this?

The following might help in explaining the difference between MPS and its counter part MRP.

Master Production Schedule (MPS) :

MPS operates within only one level of the BOM, While MRP can be utilized throughout all levels of a material’s BOM. If a MPS is run on a material, the necessary orders are planned at that level. Dependent requirements (if any) are placed on the next BOM level down, and then the process stops.

Main Idea : Master production scheduling (MPS) is a form of MRP that concentrates planning on the parts or products that have the great influence on company profits or which dominate the entire production process by taking critical resources. These items are marked as ‘A’ parts (MPS items) and are planned with extra attention. These items are selected for a separate MPS run that takes place before the MRP run. The MPS run is conducted without a BOM explosion so that the MRP controller can ensure that the Master schedule items (MSI) are correctly planned before the detailed MRP run takes place.

The master production schedule is a line on the master schedule grid that reflects the anticipated build schedule for those items assigned to the master scheduler. The master scheduler maintains this schedule, and in turn, it becomes a set of planning numbers that drives material requirements planning.

It represents what the company plans to produce expressed in specific configurations, quantities, and dates. The master production schedule is not a sales item forecast that represents a statement of demand. The master production schedule must take into account the forecast, the production plan, and other important considerations such as backlog, availability of material, availability of capacity, and management policies and goals. Syn: master schedule.

Material Requirements Planning (MRP) :

A set of techniques that uses bill of material data, inventory data, and the master production schedule to calculate requirements for materials. It makes recommendations to release replenishment orders for material. Further, because it is time-phased, it makes recommendations to reschedule open orders when due dates and need dates are not in phase. Time-phased MRP begins with the items listed on the MPS and determines

(1) the quantity of all components and materials required to fabricate those items and

(2) the date that the components and material are required. Time-phased MRP is accomplished by exploding the bill of material, adjusting for inventory quantities on hand or on order, and offsetting the net requirements by the appropriate lead times.

MRP Interview Questions:

What is the need of mrp list if stock requirement list is already there?

The MRP list displays the result of the last planning run. Changes that have occurred between planning runs are ignored in the MRP list. In contrast to this, the system displays all changes in stock, receipts and issues, which have currently occurred, in the stock/requirements list.

Which tcode are used to run MRP?

- MD01 is generally used to run the MRP for all the materials in a plant normally just before go-live.
- MD02 is used to run MRP for materials which have a BOM i.e multi-level.
- MD03 is used to run MRP for materials which do not have a BOM i.e single level.

MRP-1

2007-10-05T01:35:00.000+05:30

Why used Planning tools like APO or I2?

APO and I2 are Finite PLANNING tools. When MRP runs with APO or I2 (or Red Pepper or Manugistics), it takes Capacity issues into consideration. MRP in SAP R/3 Core does not, it assumes infinite capacity available. (MRP only looks at material availablity.)

However, SAP R/3 DOES do finite SCHEDULING, which is where the system 'dispatches" operations on a production order until it fills up the capacity available, then moves to the next time period and dispatches until that period is filled up. In SAP speak, that is called capacity leveling.

I believe APO should only be used in very large companies (billions) because of the amount of master data that must be maintained, and that data better be ACURATE, or you've wasted a heck of a lot of time. By the way, APO stands for Advanced Planner and Optimizer tool, obviously a German sort of name!

Differences between planning and scheduling, finite and infinite

R/3 does planning without consideration for capacity situations. So if MRP says you need 500 parts on 3/1/04, it schedules them all to be built at the same time, even though you can only do 100 at a time. Assume you have a fixed lot size of 100, you'll get 5 planned orders for 100 to start on the same day. This is "Infinite Planning". APO would recognize that constraint, and instead schedule out the 5 orders over time. The important part of that is that it also will schedule out the deliveries of the components for 5 different days. This is "Finite Planning".

Now, assume old fashion MRP. It schedules all 5 orders for the same day, and the buyers go out an get all of the components for the same day. Then the planner realizes he can't do all 5, and manually changes the schedule, and manually spreads out the 5 orders. The buyers will recieve rescheduling notifications, but not until the scheduler does the manual rescheduling. You could call this "Infinite Scheduling", but that only means the same thing as Infinite Planning.

But, SAP has "Capacity Leveling". What that means is you run another program after MRP (CM27 and CM28), which can be run in batch mode overnight. (There is a ton of configuration and thinking that will be required to do this!). The capacity leveling program will recognize the constrant at the work center level, and fill up the first day, then re-schedule the next order to the next available capacity, then the next order searches for available capacity, and so on. This is called "Finite Scheduling". The problem with this is the opposite of Infinite Planning, which is it doesn't take Material availablity into consideration! The system will re-schedule a production order without thinking about whether the materials will be available or not.

Finite Planning does Finite Sheduling at the same time. If there is no capacity available on the desired date, the system looks for when capacity IS available. Then it stops to see if Materials will also be available (usually based on the lead-time for those components). If there is a material problem, then the system figures out when the materials WILL be available, and then
checks to see if capacity is available on THAT day, and if so, it blocks off capacity, and allocates the materials for that day.

Scheduling-6

2007-09-30T04:16:00.000+05:30

What Is Mean By Schedule Lines

What is mean by schedule lines?
Explain the schedule lines in md02?

1. no schedule lines
2. schedule lines in opening period
3. schedule lines

Schedule lines are created against schedule agreements. Say if you have a material which is procured from subcontract. If you want the delivery in particular days with schedule you can maintain schedule agreeement. In source list you will maintain vendor, schedule agreeement with validity dates and which agreement is relevant for mrp.

If you maintain 2 against the sch agreemetn mrp will generate schedule line which you can see in md04. Also this delivery schedules are updated in scheduling agreement (t cod ME33). When running mrp in initial screen delivery schedules--you have to maintain 3 create schedule line

Schedule line in opening period - Opening period is maintained in Configuration of "Schedule Margin Key" which is getting assigned to Material master in MRP2 view.

Your understanding of the result after MRP is needed.

Define Floats (Scheduling Margin Key)

In this step, you specify the floats for determining the basic dates of the planned orders. The floats are allocated to the material via the release period key in the material master record.

Opening period

The opening period represents the number of workdays that are subtracted from the order start date in order to determine the order creation date. This time is used by the MRP controller as a float for converting planned orders into purchase requisitions or into production orders.

Float before production

The float before production represents the number of workdays that are planned as a float between the order start date (planned start date) and the production start date (target start date). On the one hand, this float is intended to guarantee that delays in staging a material do not delay the production start. On the other hand, the production dates can be brought forward by means of the float to cope with capacity bottlenecks.

Float after production

The float after production should provide a float for the production process to cope with any disruptions so that there is no danger that the planned finish date will be exceeded. You plan the float after production between order finish date (planned finish date) and scheduled end (target finish date).

Release period

The release period represents the number of workdays that are subtracted from the order start date in order to determine the production order release. The release period is only relevant for production order management. Recommendation

The opening period should reflect the processing time the MRP controller needs to convert planned orders into purchase requisitions or production orders. The opening period should be at least as long as the interval between two MRP intervals, so that all planned orders can be taken into account during the conversion.

Scheduling-5

2007-09-30T04:13:00.000+05:30

What is Finite and Infinite Scheduling

What is finite and infinite scheduling? How it is carried out? What is to be done for each one? What are their significance?

Differences between planning and scheduling, finite and infinite

Finite Scheduling
Scheduling type within capacity planning that takes account of the capacity loads which already exist. Finite scheduling calculates the start and finish dates for operations in the order. It is a detailed scheduling strategy with which you schedule orders and operations, taking into account the existing resource load. A resource overload cannot occur.

Infinite Scheduling
A detailed scheduling strategy with which you schedule orders and operations, without taking into account the existing resource load. It is therefore possible for resource overloads to occur.

Now, assume old fashion MRP. It schedules all 5 orders for the same day, and the buyers go out an get all of the components for the same day. Then the planner realizes he can't do all 5, and manually changes the schedule, and manually spreads out the 5 orders. The buyers will recieve rescheduling notifications, but not until the scheduler does the manual rescheduling.
You could call this "Infinite Scheduling", but that only means the same thing as Infinite Planning.

But, SAP has "Capacity Leveling". What that means is you run another program after MRP (CM27 and CM28), which can be run in batch mode overnight. (There is a ton of configuration and thinking that will be required to do this!). The capacity leveling program will recognize the constrant at the work center level, and fill up the first day, then re-schedule the next
order to the next available capacity, then the next order searches for available capacity, and so on. This is called "Finite Scheduling". The problem with this is the opposite of Infinite Planning, which is it doesn't take Material availablity into consideration! The system will re-schedule a production order without thinking about whether the materials will be available
or not.

Finite Planning does Finite Scheduling at the same time. If there is no capacity available on the desired date, the system looks for when capacity IS available. Then it stops to see if Materials will also be available (usually based on the lead-time for those components). If there is a material problem, then the system figures out when the materials WILL be available, and then
checks to see if capacity is available on THAT day, and if so, it blocks off capacity, and allocates the materials for that day.

Scheduling-4

2007-09-30T04:10:00.000+05:30

Scheduling Background Jobs for MRP

Transaction code : MDBT

click Create Variant button (specified a variant name and click continue).

Then fill in the following fields :-

Scope of Planning : Optional (refer to Note if you want to specify a plant grouping)
Plant : Your company Plant
Processing Key : NETCH
Create PUrchase Req. : 1
Schedule lines : 1
Create MRP lists : 1
Planning mode : 1
Scheduling : 1
Planning date : default date

Click the Back button and you will be prompt Save Values.

Type in a Description and click the Save button.

After creating the variant, park your cursor at the variant and click the Schedule job button.

Fill in the Date and Time value.

Click Schedule periodically and you are prompt to choose the period.

Click the Create button and you are done.

To check, you can click the Show Scheduling button.

Note :

Define Scope of Planning for Total Planning in 'OM0E'.

1. Choose New entries.

2. Enter a key and a description for the scope of planning that you would like to define. Save your entries.

3. Select the scope of planning and choose Sequence of plants/MRP areas.

4. Choose new entries and enter the plants or the MRP areas in the sequence in which they are to be planned. The counter determines the sequence.

5. Save your entries.

Scheduling-3

2007-09-30T04:05:00.000+05:30

Work Scheduling View in Material Master

What is the importance of work scheduling view in material master and the standard values in Routing?

If I am maintaining Lot size dependent information such as set time, Interoperation time, Processing time in work scheduling view in material master and also Total in-house production time in MRP view under scheduling tab, what will effect on the system?

Means how will the system behave in this scenario?

In house production time in MRP2 view, specifies the time in workdays needed to produce the material in-house. In-house production time is independent of the order quantity. The system requires the in-house production time to determine the planned dates for planned orders in materials planning.

You can define work scheduling times in the material master record in one of two ways:

-Either you enter the in-house production time. If required, you can get the system to update this value from the routing.

-Or you enter the setup, teardown, processing, and interoperation times. If you maintain these values, the system determines the in-house production time on the basis of lot size.

What is the basic fundamental of "Independent lot size" and "Dependent lot size" in work scheduling view of a material master. I am jumbling a lot between this two to understand the basic requirement of my client.

Second thing is that you are saying that - You can define work scheduling times in the material master record in one of two ways:
-Either you enter the in-house production time. If required, you can get the system to update this value from the routing.
-Or you enter the setup, teardown, processing, and interoperation times.
But how the system update this first option.

I mean to say , is there any setting in configuration so that the system will update workscheduling time values from the routings?

You need scheduling data for 2 types of orders, planned orders and production orders.

And you can have the scheduling data in 3 ways:

1. Lot size independent in-house production time, in material master, MRP2 view. ex: if in house production time is 2 days, it will schedule the order for 2 days, and it doesn't matter if the order size is 1 or 1000, they are both produced in 2 days. (I never met any case that fits this situation)

2. Lot size dependent in-house production time, in material master, Workscheduling view. ex: if you have 5 day setup time, and 1 day production time for lot size of 10, then your order will be scheduled according to the order size. if your order is for 10, then your total production time will be 5 day + 1 day x 10 / 10, which is 6 days. If your order is for 100, then your total production time will be 5 day + 1 day x 100 / 10, which is 15 days. 5 day setup time will not change when the order quantity changes, because you make the setup once at the beginning of the production, and use the same setup during whole production.

3. Lot size dependent in-house production time, in routing. The same calculation of above will be used for this.

So, which of these data is used for the 2 order types?

For the planned orders, for default, system uses the times in number 2 above. If that data is not entered, system will use the time in number 1 above. If you want the system to use the routing data, then you should use lead-time scheduling parameter in MRP run, then system will use data in number 3 above.

(The idea behind this is, MRP run always takes long time, and if you want it to use routing data, that will also increase this run time. Therefore, you can use routing but take results after long MRP run time, or you can use approximate times but take the results after short MRP run. This was very crucial before, because at those times hardware technology was not enough to process too much data in short time, when MRP run was taking days and days. But now is not that crucial, that's my personal opinion. As I said before, you can use routing data but take results after long MRP run time, or you can use approximate times but take the results after short MRP run, however, there's one other way which is a combination of these two: You can use the system to update the data in number 2 using the data in number 3, which is called the update of material master from routing. In that case, the approximate production times in material master will be as close as possible to the actual production times. In that case, not only MRP run will not take long time, but also we will get much better results.)

For the production orders, always the routing data is used for scheduling.

Now, I am cleared that what is independent and dependent lot size. but still there is one confusion in my mind that where did we mentioned this lot size i.e 10,100 as per your example in case 2.
Secondly, I didnt understand your second last sentence (i.e.the approximate production times in material master will be as close as possible to the actual production times). Can you please clear me this sentence with suitable example.

You enter the lot size on the Work scheduling view of material master, for the lot size dependent times, for my example you enter 10 as lot size.

And the approximation is like this: In the material master, you enter the production times as DAYS, but in the routing you can use MINUTES, even seconds. Therefore the most detailed and accurate production times can be entered in routing, in material master you can enter only days, which will be the approximate value.

If your routing is, for lot size of 10, setup time is 3 hours and production time is 50 minutes, when you update the material master from routing, system will write 3/24 days for the setup time, and 50/1440 minutes for the production time, because it has to convert it to days.

But still I dont understand that where I have to mentioned that lot size 10 or 100?
And second thing is that, If I have to use routing data for planned order what should I have to do? Shall I have to mentioned lead time scheduling in MD02?

You enter lot size in material master, on workscheduling view.

and yes, you have to mention on md02 screen that you want lead-time scheduling.

You mean to say I have to enter that 10 or 100 in base quantity of work scheduling view of material master?

Yes.

Scheduling-2

2007-09-30T04:02:00.000+05:30

Schedule Margin Key in Production Scheduling

I want to know impact of schedule margine key in production scheduling in following changes in mateial master
1) if I have schedule key where all floats are zero but I enter in-house prodution time as e.g. 7 days .
2) if I have key where floats before prodution is 5 days and same values in next floats and in house production time as 1 day.
All above with MTO what is impact of above cases in scheduling.

While "Basic Scheduling" in MRP... Scheduling margin key is not considered. It takes the "In house production" days for fixing up the start date. This is only exact to "days".

Lead Time scheduling is carried out on request from the scope of MRP. Target dates are calculated from routing and Capacity requirement calculations are also done. The calculations are exact to the seconds (time).

SCHEDULING MARGIN KEY takes effect only for Lead Time Scheduling. For this you have to configure for "scheduling horizon" to limit the period for which lead time scheduling and capacity planning should be carried out. scheduling horizon is the period in working days. If a planned order has its basic start date within this period in future, lead time scheduling is carried out using the selected routing. The production times are calculated from the float times of the scheduling margin key in the material master record and the time from the individual operations. If the planned order has its basic start date further in the future than this scheduling horizon, the basic dates are calculated from the in-house production times in the material master and are transferred to the production times.

Could you explain what's function of opening period in Sched Margin key.

Opening period is like a "release window". The length of the opening period is the window of opportunity a planner has to convert the planned order to a purchase req.

For example - Component A has a lead time of 14 days and opening period of 5 days. Requirement on 12-22-03

Opening Date - 12-01-03
Start Date - 12-08-03
Finish Date - 12-22-03

Now the planner can convert the order starting Dec. 1st, instead of Dec. 8. It basically is a buffer in the lead time to get things on order a little sooner than needed.

What's the function for Plan order convert to production order?

As your example,
Requirement on 12-22-03

Opening Date - 12-01-03
Start Date - 12-08-03
Finish Date - 12-22-03

But I can convert plan order to production before 12-01-03 at random, so I wonder what is the opening period real function? it looks useless to restrict when to convert plan order to production order.

CO41 and MD15 are used for the conversion process. Here you enter the opening dates you wish to convert. Of course the opening period will not stop you from converting planned orders - hopefully your planner is not randomly converting orders or you have much bigger issues!!!!

The opening period is basically just to get the planned order to show up on the CO41 or MD15 lists in case you wish to convert it sooner than the lead time suggests.

Your answer make me clear to understand the opening period.

BTW,could you explain the release key ,float after production and float before production parameter in SchedMargin key?

I know the parameter affection in production,but I am not sure why to define how many days in each parameter.

for example, release key defined for 10 workdays,but you can release production order out of the release period randomly.any way to stop release out of the release period?

For example - Component A has a lead time of 14 days and opening period of 5 days. Requirement on 12-22-03
Opening Date - 12-01-03 ???
Start Date - 12-08-03 (from requirement date - lead time ?)
Finish Date - 12-22-03 (from requirement date ?)
Why Openning date = 12/01/2003 how system calculate , Could you please explain to me..

I know that when we run MRP system will check if the opening date is out of open period system will generate Plan order instead of PR .

The times in the sch. margin key are in workdays. That's how it gets the dates. The component I was describing originally would have been a purchased part, where lead time is in calendar days.

The order start date and the order finish date form the framework within which a production order is to be executed. Since malfunctions and disturbances in the production process can never be fully prevented, the system uses particular floats in a production order. The system takes into account so-called "before and after production floats" when scheduling an order.

The float before production is a start float. It has two functions:

It can compensate for delays in the staging of the material components.
If there is a capacity bottleneck at the work centers involved, the production dates can be moved forward in the future. In this way it serves as a float for capacity leveling.
The float after production is a finish float. It is used to compensate for unexpected disturbances in the production process, so that they do not delay the scheduled finish date.

The floats before and after production are defined for each material using a scheduling margin key. This scheduling margin key is automatically transferred from the material master when an order is created. However, you can change the times in the order.

The system calculates the scheduled start of the order by adding the float before production to the order start date. It calculates the scheduled finish of the order by subtracting the float after production from the order finish date.

The system deducts the number of days defined in the release period from the scheduled start of the order and thus determines the scheduled release date of the order. This date can be used for collective release.

Scheduling-1

2007-09-30T03:59:00.000+05:30

Rescheduling date does not take into account the GR Processing Time

If you look at MD04, the rescheduling date is based on the Stocks Requirement date.

It does not take into account the parameters in Procurement and Scheduling in the Material Master.

In the net requirements calculation, the system checks whether warehouse stock or firmed receipts are available to cover requirements. If a material shortage exists, the system usually creates a new procurement proposal.

The rescheduling check is used to change the dates of already existing firmed receipts not planned on the same day as the requirement to suit the requirement date.

For this purpose, the system displays the appropriate exception messages with rescheduling proposals for these firmed receipts to be processed by the MRP controller.

You defined the rescheduling parameters in Customizing for MRP.

An important parameters is the rescheduling horizon period to be included.

1. OPPQ per plant to Carry out overall maintenance of plant parameters.

2. OPPR per MRP group to Carry out overall maintenance of MRP groups.

You can also define tolerance values for the creation of exception messages.

These values define a time period in which no exception message is to be created, despite the fact that a rescheduling proposal may exist.

The MRP controller can thus avoid a situation where too many exception messages are created if a certain buffer has already been planned for scheduling basis dates.

Rescheduling Exception Proposal

Bring process forward (reschedule in)

Within this rescheduling horizon, the net requirements calculation checks whether, after a requirement, a firmed receipt exists, which can be used to cover this requirement. Then the system displays a rescheduling date as well as the exception message Bring process forward for this receipt. The net requirements calculation then uses this receipt and the
system will only create another procurement proposal if the receipt quantity is not sufficient to cover the complete requirement. Several firmed receipts can be used to cover one requirement.

The rescheduling horizon is always calculated from the MRP date.

Postpone process (reschedule out), or cancel process

The net requirements calculation checks over the complete time axis whether availability could still be guaranteed without the receipt in question. If this is the case, the system checks whether the receipt planned here could be used to cover a future requirement. If the system can find such a requirement, it then displays a rescheduling date as well as the exception message Postpone process for this receipt.

If the system finds no future requirement, for which the receipt is required, the system displays the exception message Cancel process.

TABLE-3

2007-09-30T03:52:00.000+05:30

Table of the Order Production Operation

Which is the table of the order production operation details? I need to get the activities for production order :
Setup, Labor, Machine, Confirmed and to confirm.
I can see look at this in CO02 / Operation Overview (f5) / Operation Detalis / Qty-Activities

That is probably the hardest information to piece together, I used 5 tables with multiple joins to get User Fields for operations in a production order. Maybe you can use something simular.

AFKO - this is for your basic production header info - order number, basic finish date etc

S022 - this is for your operation header details - operation number, Work centre etc if you are only after the header details such as setup time and execution time, you can probably stop here without going to AFVC or AUFV (you definitely need AUFK if you want order status)

AUFK - this is for your order master data - Order released flag, order complete flag, technically complete date, you'll need this to filter out closed orders

AFVC - this is to link to the detail table - however I used the control key field in it so I would know whether it was a MILE stone or GPP1 for confirmation's sake

AUFV - this is the user field table - you may want to replace this with whatever detail you are after

Delete all the automatic joins:

AFKO -> AUFK on:
AUFNR -> AUFNR

AFKO -> S022 on:
AUFNR -> AUFNR
PLNBEZ -> MATNR

AFKO -> AFVC on:
AUFPL -> AUFPL

S022 -> AFVC on:
WERKS -> WERKS
PLNFL -> PLNFL
VORNR -> VORNR

The join below is for user fields in operation detail, you will have to find your own relevant table, but I assume the two key fields will be the same??

AFVC -> AFVU on:
AUFPL -> AUFPL - Routing number of operations in the order APLZL -> APLZL - General Counter for order

TABLE-2

2007-09-30T03:49:00.000+05:30

SAP PP Master Data Tables

MASTER DATA

Engineering Change Management
AENR Customer and priority
AEOI Revision Numbers

Work Center
CRHD Workcenter Header Data
CRCA Workcenter Capacity Allocation
CRCO Workcenter Cost Center Assignment
CRHH Hierarchy Header
CRHS Hierarchy Structure
CRTX Workcenter Text
KAKO Capacity Header
KAZY Intervals of Capacity

Routing
PLPO Routing Operation Details
PLKO Routing Header Details
MAPL Routing Link to Material
PLAB Relationships - Standard Network
PLAS Task List - Selection of Operations
PLMZ Component Allocation
PLPH CAPP Sub-operations
PLFH PRT Allocation
PLWP Maintenance Package Allocation
PLMK Inspection Characteristics

Bill of Material
STPO BOM Item Details
STPU BOM Sub Items (designators)
STKO BOM Header Details
MAST BOM Group to Material
STZU BOM History Records
STAS BOM Item Selection
STPF BOM Explosion Structure

Line Design
LDLH Line Hierarchy Header
LDLP Line Hierarchy Items
LDLT Line Hierarchy Takt Times
LDLBC Takts/No. Individual Capacities per Line
LDLBH Line Balance Header
LDLBP Line Balance Items
LDLBT Line Hierarchy Entry and Exit Takts

PRT's
CRFH PRT Master Data
CRVD_A Link of PRT to Document
CRVD_B Link of Document to PRT
CRVE_A Assignment of PRT data to Equipment
CRVE_B Assignment of equipment to PRT data
CRVM_A Link of PRT data to Material
CRVM_B Link of Material to PRT data
CRVS_A Link of PRT Internal number to PRT External number
CRVS_B Link of PRT External number to PRT Internal number

TABLE-1

2007-09-30T03:46:00.000+05:30

SAP Production Planning Table

Demand Management
PBED Independent Requirements Data
PBIM Independent Requirements by Material

Repetitive Manufacturing
SAFK RS Header Master Data
S025 LIS -- Run Schedule Quantities
S026 LIS -- Material Usage
S028 LIS -- Reporting Point Statistics
CEZP Reporting Point Document Logs
CPZP Reporting Points - Periodic Totals

MRP Records
MDKP MRP Document Header Data
MDTB MRP Table Structure (no data)
PLSC Planning Scenario (Long-term Planning)
MDFD MRP Firming Dates
MDVM Planning File Entries
S094 LIS -- Stock/Requirements Analysis

Reservations
RESB Reservations/Dependent Requirements

Planned Orders
PLAF Planned Orders

Discrete Production
AFKO Order Header
AFPO Order Item Detail
AFVC Order Operations Detail
AFFL Order Sequence Details
AFFH Order PRT Assignment
AFBP Order Batch Print Requests
AFRU Order Completion Confirmations
AFFW Confirmations -- Goods Movements with Errors
AFRC Confirmations -- Incorrect Cost Calculations
AFRD Confirmations -- Defaults for Collective Confirmation
AFRH Confirmations -- Header Info for Confirmation Pool
AFRV Confirmation Pool
AFWI Confirmations -- Subsequently Posted Goods Movements

Classification
KLAH Class Detail
CABN Characteristic Detail
AUSP Characteristic Values
CAWN Characteristic Values
CAWNT Characteristic Value Texts
KSML Characteristic Allocation to Class
KSSK Material Allocation to Class

Transaction Codes-3

2007-09-19T02:03:00.000+05:30

Commonly Used Tcodes in PP Module Part 3

Material Requirement Planning

Menu Nodes           Transaction Activity


Master Data          MD25       Create planning calendar
                     MD26       Change planning calendar
                     MD27       Display planning calendar
                     MDSA       Display BOM explosion number
                     MDSP       Edit BOM explosion number
                     MEQ1       Maintain quota file
                     OPPP       Explode BOM by date
                     MDUS       Display project assignment
                     MDUP       Process project assignment
                     MDL1       Create production lot
                     MDL2       Change production lot
                     MDL3       Display production lot

Planning             MD20       Create planning file entry
                     MD21       Display planning file entry
                     MDAB       Set up planning file entry in background
                     MDRE       Check planning file entry
                     MD01       Total planning online
                     MDBT       Total planning in background
                     MD03       Single-item, single-level planning
                     MD02       Single-item, multi-level planning
                     MD43       Interactive single-item planning
                     MD50       Multi-level, make-to-order planning
                     MD51       Multi-level project planning
                     MF52       Display planning table
                     MF50       Change planning table
                     MF57       Planning table by MRP lists
                     MF51       Planning table by production list

Evaluations          MD04       Stock/requirements list
                     MD07       Collective access of stock/requirements lis
                     MD05       MRP list
                     MD06       Collective access of MRP lists
                     MDLD       Print MRP list
                     MD45       Planning result
                     MD46       Collective access of planning result
                     MD44       Planning situation for a material
                     MD47       Planning situation for a product group
                     MD48       Cross-plant planning situation
                     MD4C       Order report
                     MD09       Pegged requirements
                     CO46       Order progress

Planned Order        MD11       Create planned order
                     MD12       Change planned order
                     MD13       Individual access of planned order
                     MD16       Collective access of planned orders
                     MD14       Individual conversion of planned order into
                     MD15       Collective conversion of planned orders int
                     MDUM       Convert planned order into purchase requisi
                     CO40       Convert individual planned order into produ
                     CO41       Collective conversion of planned orders int
                     CO48       Partial conversion of planned order into pr
                     COR7       Individual conversion of planned order into
                     COR7_PC    Collective conversion of planned orders int
                     COR8       Partial conversion of planned order into pr
                     MDVP       Collective availability check
                     MDAC       Execute action for planned order

LONG TERM PLANNING

PALNNING SCENARIO    MS31       CREATE
                     MS32       CHANGE
                     MS33       DISPLAY
PLANNING RUN         MS01       ON LINE
                     MSBT       SA BACKGROUND JOB
                     MS02       SINGLE ITEM - MULTI LEVEL
                     MS03       SINGLE ITEM - SINGLE LEVEL
                     MS50       SINGLE ITEM - SALES ORDER
                     MS51       SINGLE ITEM PLANNING, PROJECT
                     MFSO       PLANNING TABLE

EVALUTIONS           MS05       MRP LIST MATERIAL
                     MS06       MRP LIST COLLECTIVE DISPLAY
                     MSLD       PRINT MRP LIST
                     MS04       STOCK/REQUIREMENTS LIST
                     MS07       STOCK/REQUIREMENT LIST COLLECTIVE DISPLAY
                     MS44       PLANNING SITUATION MATERIAL
                     MS47       SITUATION PRODUCT GROUP

MPS-MASTER SCHEDULE ITEMS

TOTAL PLANNING       MD40       ON LINE
                     MDBS       SA BACKGROUND JOB
                     MD41       SINGLE ITEM - MULTI LEVEL
                     MD42       SINGLE ITEM - SINGLE LEVEL
                     MD43       SINGLE ITEM - INTERACTIVE
                     MD50       SINGLE ITEM - SALES ORDER
                     MD51       SINGLE ITEM PLANNING, PROJECT

*** EVALUTION IS SIMILAR TO MRP

PRODUCTION CONTROL

ORDER - CREATE       CO01       WITH MATERIAL
                     CO07       WITHOUT MATERIAL
                     CO40       FROM PLANNED ORDER
                     CO41       COLLECTIVE CONVERTION OF PLANNED ORDER
                     CO08       FOR SALES ORDER
                     CO10       FOR PROJECT
                     CO02       CHANGE
                     CO03       DISPLAY

CONTROL              MD04       STOCK/REQUIREMENTS LIST
                     COHV       MASS PROCESSING
                     COMAC      COLLECTIVE AVAILABILITY CHECK
                     CO05N      COLLECTIVE RELEASE
                     CO04N      PRINT
                     CO09       AVAILABILITY OVER VIEW

GOODS MOVEMENT       MF65       STOCK TRANSFER FOR RESERVATION

MATERIAL STAGING     MF68       LOG
                     MB1A       GOODS ISSUE
                     MB31       GOODS RECEIPT
                     COWBPACK   PACK MATERIAL

CONFIRMATION         CO1V       TIME TICKET
FOR OPERATION        CO14       DISPLAY
                     CO13       CANCEL
                     CO1L       REQUESTED CONFIRMATIONS
                     CO1P       PREDEFINED PROCESSES

TOOLS-ARCHIVING      CO78       ORDER
                     KOAA       SETTELMENT DOCUMENTS

CAPACITY PLANNING

EVALUTION            CM01       LOAD

WORK CENTER VIEW     CM02       ORDERS
                     CM03       POOL
                     CM04       BACKLOG
                     CM05       OVERLOAD
                     CM07       VARIABLE
EXTENDED EVALUTION   CM50       WORK CENTER VIEW
                    CM51       INDIVIDUAL CAPACITY VIEW
                    CM52       ORDER VIEW
LEVELLING            CM21       PLANNING TABLE (GRAPHICAL)
WORK CENTER VIEW     CM22       PLANNING TABLE (TABULAR)
INDIVIDUAL CAPACITY VCM27       PLANNING TABLE (GRAPHICAL)
                     CM28       PLANNING TABLE (TABULAR)
ORDER VIEW           CM31       PLANNING TABLE (GRAPHICAL)
                     CM32       PLANNING TABLE (TABULAR)
AVAILABLE CAPACITY   CR12       CHANGE
CAPACITY             CR13       DISPLAY
                     OP4A       SHIFT SEQUENCE
                     OP43       FACTORY CALENDER

Transaction Codes-2

2007-09-19T01:57:00.001+05:30

Commonly Used Tcodes in PP Module Part 2

SALES AND OPERATIONS PLANNING

PRODUCT GROUP        MC84       CREATE
                     MC86       CHANGE
                     MC85       DISPLAY
GRAPHIC              MC91       PRODUCT GROUP
                     MC92       OVERVIEW
PLANNING             MC81       CREATE
FOR PRODUCT GROUP    MC82       CHANGE
                     MC83       DISPLAY
                     MC75       TRANSFER PG TO PLANNING
FOR MATERIAL         MC87       CREATE
                     MC88       CHANGE
                     MC89       DISPLAY
                     MC74       TRANSFER MATERIALS TO DM
                     MC9K       MATERIAL AVAILABILITY
VERSION MANAGEMENT   MC78       COPY
                     MC80       DELETE
FLEXIBLE PLANNING    MC93       CREATE
PLANNING             MC94       CHANGE
                     MC95       DISPLAY
                     MC9K       MATERIAL AVAILABILITY
TOOLS/PLANNING TYPE  MC8A       CREATE
MACRO                MC8B       CHANGE
                     MC8C       DISPLAY
EVENT                MC64       CREATE
                     MC65       CHANGE
                     MC66       DISPLAY
ROUGH CUT PLANNING   MC35       CREATE
PROFILE              MC36       CHANGE
                     MC37       DISPLAY
ENVIRONMENT          MC90       TRANSFER MATERIALS TO DM
ACTIVITY REQT.       KSPP       TRANSFER TO COST CENTRE
                     KSBL       COST CENTRE OLANNING REPORT
                     KSOP       TRANSFER TO ACTIVITY BASED COSTING
                     CPBL       PLANNING REPORT PROCESSES
                     MC9C       REPORTING
SETTINGS             MC96       FORECAST PROFILE
DISSAGGRIGATION      MC76       BREAKDOWN PG PLAN
                     MC77       DISPLAY PG PLAN
                     MC75       TRANSFER PG TO PLANNING
                     MC74       TRANSFER MATERIALS TO DM


FORECASTING


INDIVIDUAL FORECAST  MP30       EXECUTE
                    MP31       CHANGE
                    MP32       DISPLAY
TOTAL FORECAST       MP38       EXECUTE
                    MP33       REPROCESS
                    MP39       PRINT
                    MPBT       EXECUTE BACKGROUND
                    MPDR       PRINT BACKGROUND


DEMAND MANAGEMENT

PIR                  MD61       CREATE
                     MD62       CHANGE
                     MD63       DISPLAY
                     MD65       REQTS. FOR SCINARIO
                     MD66       COPY SIMULATED DEPENDENT REQT.
                     MD70       COPY TOTAL FORE CAST
EVALUATION           MD73       DISPLAY TOTAL REQT.
                     MD79       EXCELL INTERFACE
                     MD4C       ORDER REPORT
                     MD72       CHARECTERISTICS PLANNING
CUSTOMER REQT.       MD81       CREATE
                     MD82       CHANGE
                     MD83       DISPLAY


REPETITIVE MANUFACTURING

MASTER DATA          C223       PRODUCTION VERTION
PRODUCT COST PLANNING
COSTING RUN          CKMATSEL   CREATE
SELECTION LIST       CKMATCON   Edit
                     CK40N      EDIT COSTING RUN

Transaction Codes-1

2007-09-19T01:42:00.000+05:30

Commonly Used Tcodes in PP Module Part 1


MATERIAL

CREATE-GENERAL       MM01       IMMEDIETELY
                     MM11       SCHEDULE
CHANGE               MM02       IMMEDIETELY
                     MM12       SCHEDULE
                     MM13       ACTIVATE
FLAG FOR DELETION    MM06       IMMEDIETELY
                     MM16       SCHEDULE
DISPLAY              MM03       DISPLAY CURRENT
                     MM19       DISPLAY AT KEY DATE
DISPLAY CHANGES      MM04       ACTIVE CHANGES
                     MM14       SCHEDULE CHANGES
                     MM17       MASS MAINTENANCE
                     MMAM       CHANGE MATERIAL TYPE
OTHER                MMBE       STOCK OVERVIEW
                     MMPV       CLOSE PERIOD
                     MMRV       ALLOW POSTING TO
                                PREVIOUS PERIOD
                     MM50       INSTANT MATERIAL VIEW
                     MMSC       ENTER STORAGE LOCATIONS
                     MM60       MATERIAL LIST
ARCHIVING(MATERIAL)  MM71       ARCHIVE/DELETE
                     MM72       DISPLAY ARCHIVE


BILL OF MATERIAL (MATERIAL BOM)

                    CS01       CREATE
                    CS02       CHANGE
                    CS03       DISPLAY
EXTRAS              CS28       ARCHIVING
                    CS20       MASS CHANGES
EVALUATION/BOM      CS11       BOM MULTILEVEL
EXPLOSION/MATERIAL  CS12       STRUCTURE MULTILEVEL
BOM                 CS13       SUMMURISED BOM



WORK CENTRES

                   CR01       CREATE
                    CR02       CHANGE
                    CR03       DISPLAY
                    CA85       REPLACE
CAPACITY            CR11       CREATE
                    CR12       CHANGE
                    CR13       DISPLAY
HIERARCHY           CR21       CREATE
                    CR22       CHANGE
                    CR23       DISPLAY
LINE HIERARCHY      LDB1       CREATE
                    LDB2       CHANGE
                    LDB3       DISPLAY
REPORTING           CR60       W/C INFORMATION SYSTEM
                    CR05       W/C LIST
                    CR06       COST CENTRE ASSIGNMENT
                    CR07       W/C CAPACITIES
                    CR08       W/C HIERARCHY
WHERE USED          CA80       WORK CENTRE
                    CR15       CAPACITY
                    CR10       CHANGE DOCUMENTS
EXTRAS              CR09       STD. TEXTS TASK LIST
                    CR41       ARCHIVING


ROUTING


STAD. ROUTING       CA01       CREATE
                    CA02       CHANGE
                    CA03       DISPLAY
REF. OPERATION SETS CA11       CREATE
                    CA12       CHANGE
                    CA13       DISPLAY
RATE ROUTING        CA21       CREATE
                    CA22       CHANGE
                    CA23       DISPLAY
REF. RATE ROUTING   CA31       CREATE
                    CA32       CHANGE
                    CA33       DISPLAY
EXTRAS              CA85       REPLACE W/C
MASS CHANGES        CA95       REPLACE REF. OP. SET
                    CA75       REPLACE PRT
DELETE TASK LIST    CA99       WITH ARCHIVING
                    CA98       W/O ARCHIVING
REPORTING           CA80       WORK CENTRE
WHERE USED LIST     CA90       REF. OP. SETS
                    CA70       PRODUCTION RESORCE TOOLS


COST CENTRE

                   OKKP       MAINTAIN CONTROLLING AREA
                    KS01       CREATE COST CENTRE
                    KZS2       CREATE COSTING SHEET
                    KA01       CREATE PRI. COST ELEMENT
                    KA06       CREATE SEC. COST ELEMENT
                    KL01       CREATE ACTIVITY TYPE
                    KP26       ACTIVITY TYPE/PRICE PLANNING

Q n A on SAP PP

2007-07-31T04:08:00.000+05:30

Interview Questions and Anwsers on SAP PP

1. If you have released Prdn order today and it had gone to shop floor. Next day it was found that there is shortage of material. What will you?
2. How you define Standard Cost and Variable cost in PP?
3. Where can you find Read PP Master in SAP(PP)?
4. What are all the settings done for configuring integration of PP with FICO?

1. Do availability check. You will get missing parts list. Procure those missing parts. Then confirm the production order. One more thing you can do, change customize setting so that user cannot release if parts are missing during order release.

2. Standard cost is the cost which is fixed for a period, variable cost is varying with period. As for example cost of semi finished, finished materials are fixed & cost of raw materials are varied.

3. You will find in master data tab page of production header data overview, CO02 - Read PP Master Data. Also from Functions menu you will get Read PP Master Data.

4. Assigning of Cost center to work center. Assigning Activity type to work center, Standard Cost estimate, Costing Run, Order settlement, Product costing. *-- Chandan Majumdar

---

1. Can MRP be carried out for one particular level of a bom ( Level code : 0001/0002 etc).
Yes it can be done by running for specific materials (Single Material Single Level)

2 How Requiements( PIR,Sles Order, Customer Requirement) are reduced after they are produced?
Reqmts are reduced automatically after Delivery is made to the Particular Order
(In case of Strategy 11, the PIRs are consumed after the GR for Production Order)

3. Can't one material be assigned to more than one operation in a routing?
One material from a BOM CANNOT be assigned to different Operations.
It can be done by defining the material for so many times as required in the BOM

4. How to insert an inspection checkpoint at the end of an operation?
If in process sample is to be defined, assign inspection type 03 in the Material Master.
Then create MICs and assign them in the Routings.
System automatically generates the Inspection Lots

5. Where we have to specify the teardown time in one operation?
Teardown time can be defined as one of the Standard Parameters...

6. How the process time is calculated in a WC when both labour, Machine categories exist?
Scheduling is done based on the Capacity Category we define in the Workcenter

7. How to create opbject dependencies in a BOM FOR A CONFIGURABLE MATERIAL?
Go to Extras -> Object Dependency -> Assign
For this U need to create Characteristics and Class (of Class Type 300) earlier

8. Can any body explain me why work scheduling view is required for semi finished and finished products?
(Because we'll mention all details in MRP views)

A) We need to maintain working scheduling view in order to make that finished or semi finished goods available for
production as we assign production scheduler and production scheduler profile in this view, if not maintained
conversion of planned order to production will not be possible.

Test Qns (MCQ)

2007-07-31T04:04:00.000+05:30

1. A plant can be a physical plant or a logical section of a plant

a) Yes b) No.

Ans: a

Storage locations are areas where materials are stored within a plant

a) Yes b) No.

Ans: a

A purchasing organization can buy for a number of plants

a) Yes b) No.

Ans: a

A purchasing group is a sub-set of a purchasing organization

a) Yes b) No.

Ans: a

2. Strategy Group is relevant for Material Requirement Planning

a) True b) False

Ans: a

3. MRP can be caried out at :

a) Plant Level
b) All Routings
c) Single item – single level
d) Single item – multiple level

Ans: a, c, d

4. In Material Requirement Planning

a) Material availability is ensured
b) If shortage exists the corresponding elements are planned
c) Stock transfers are also possible
d) The availability of the components is ensured via dependent requirements

Ans: d

5. With Make – to Stock strategy 10

a) MRP run considers only Sales Orders
b) MRP run considers only PIR
c) MRP run considers both Sales Order & PIR
d) Sales Order can consume PIR

Ans: b

6. The Individual / Collective indicator in the material Master determines

a) Whether a component is procured for a special customer requirement in the individual segment
b) Requirement quantities of dependent materials are grouped together during MRP run
c) The Material Requirement Planning
d) The Special Procurement.

Ans: c

7. ATP – Available to Promise (Availability check)

a) System checks if all issues are covered by existing receipts
b) Checks if receipts’ quantity still available to cover newly received issues

Ans: a

8. Availability Check PIRs

System does not check against PIRs

a) True b) False

Ans: b

No ATP quantities, receipts or stocks are included

a) True b) False

Ans: b

Determines if sufficient PIRs are planned to cover a SO

a) True b) False

Ans: b

9. Consumption based planning is usually used for following materials

a) All A & B Class Materials
b) Materials with smooth consumption pattern.

Ans: b

10. For Planning at Phantom Assembly Level planned orders are created for Phantom assembly

a) True b) False

Ans: b

11. Stock Requirements List gives ___________________ situation of stock requirement for the material

a) Static : of the last MRP Run
b) Dynamic : Existing at current situation

Ans: b

12. Is Sales order A Qty. 15 PC and Sales order B Qty. 25 PC are booked on same date and stock is 0 PC

a) Separate Planned Order for each Sales Order shall be created if individual indicator is set
b) Only one planned order is created if individual indicator is set
c) Separate Planned Order for each Sales Order shall be created if Collective indicator is set
d) Only one planned order is created if Collective indicator is set

Ans: a, d

13. Planning can create the following after MRP run

a) Planned Orders
b) Production Orders
c) Purchase Orders
d) Schedule Lines

Ans: a, b

14. NETCH is

a) Used in Demand Management
b) Key to run MRP for Total horizon
c) Key to run MRP for Total Planning horizon
d) Not related to MRP

Ans: c

15. Regenerative Planning

a) Plans all material for a specified plant
b) Plans all material for a specified plant for total planning horizon
c) Stands practical for the first time planning run

Ans:

Sample Qns

2007-07-31T03:59:00.000+05:30

Sample Questions on SAP PP

1. Which is the highest organisational level in SAP

a) Plant b) Client c) Storage Location

Ans: b

2. For Material Master record PP Data which is the highest organisational level

a) Plant b) Client c) Storage Location

Ans: a

3. What is the difference between F1 Help & F4 Help.

a) F1 is for possible values and F4 is for application help
b) F1 is for Application Help and F4 is for Technical Help
c) F1 is for Field Help and F4 is for possible entries.
d) None of the above

Ans: c

4. Variant Configuration is typically used in

a) Make – to – stock Environment
b) Make – to – Order Environment
c) Spare parts Sale
d) Repetitive Manufacturing Environment

Ans: a

5. Configurable Material check for a material is set in _____________

a) Basic Data b) MRP View
c) Sales View d) Classification

Ans:

6. Basic Data screen contains general data such as

a) Material Number
b) Material description
c) Base unit of measure
d) Technical data

Ans: a, b, c

7. Functions of Classification are

a) To find an appropriate object
b) To find similar objects
c) To establish that no appropriate object exists.

Ans:

8. Entering “/o” in command field

a) Ends current transaction
b) Ends the current cession
c) Opens new cession
d) Opens new transaction

Ans:

9. For creating Material Master the following Transaction Code is used :

a) md01
b) mm01
c) me01
d) mc01

Ans: b

10. The unit in which the stock keeping is done in a company is called

a) Stock unit of measure
b) Base unit of measure
c) Unit of issue
d) Purchase unit of measure

Ans: b

11. Batch is

a) Same as material code
b) Partial quantity of material managed separately from other quantity of same material in stock
c) A non reproducible homogeneous unit with unique specifications
d) None of above
e) All of above

Ans: b

12. A _____________________________ is a complete, formally structured list of the components that make up a product or assembly.

Ans:

13. Component in the BOM are allocated to operation in

a) BOM
b) Material Master
c) Routing
d) Work Center

Ans: c

14. BOM contains the following

a) List of Components
b) Qty of Components
c) Operation to which components is attached.
d) Unit of Measure of components

Ans: a, b, d

15. BOMs are always created as

a) Single Level
b) Multi Level
c) Components
d) Along with routings

Ans: a

PP Qs AND As

2007-07-31T03:55:00.000+05:30

SAP PP Questions and Answers

What are the cutover activities followed for PP module?

I am listing some cut over activities to be followed (for PP - Discrete Manufacturing).

Production Planning / Master data:
For Production planning, only master data shall be migrated to SAP. In the 1st Stage, there is no master data. Following is the master data elements relevant for PP:

- Bill of materials
- Routing.
- Work Centres.

Transaction data:

As of the cut off date, ideally there should not be any work in process. All the open production orders should be closed and semi finished goods should be dismantled and should be added to Raw materials. This strategy should be followed for all production orders where lead time to complete the production order is not large.

Since, the production orders are for longer duration and it is not possible to dismantle the product and add it to inventory, following can be the strategy for migrating the data to SAP:

- Create a material master for the work in process and set the standard price as the cost incurred for that product (ie. Work in process)
- Create a bill of material (which will be used only for this production order) including this material and other materials still to be consumed.
- Create Routing for rest of the production process.
- Bring the work in process material into inventory as of the cut off date.
- Create the production orders in SAP for the Work in process and issue materials to production order.

Complete the production process after the cut off date of the project.

What happens to planned after it has been converted into production order?

When you convert Planned order to Production order. the planned order are offset by production order. Reference of planned order can be seen in the production order.

How to attach a drawing for a material to BOM? Is it possible?

Yes, you can attach a drawing.
First create a document using Transaction Code "CV01N - Create Document".
Attach your drawing in that document.
The system will generate a document number. Assign this document in the BOM with item category D.

Report in Long Term Planning - You use long term planning for your customers, what they need are very simple, just to calculate future requirements for 1 or 2 years.
Are there any reports in SAP to list of material requirement from LTP?
You need a list of material requirement from long term planning result for each item.

Use MS70 then use MCEC.

Scheduling planned order - How can you get planned orders scheduled so that you can do capacity leveling?
MD11 and then Schedule works fine but ideally you would want the the planned order scheduled automatically on creation? You have tried setting up an action to schedule the orders but cannot get that to work either.

When running MRP, try selecting "2" in the scheduling box this will bring planned orders into CM01 and CM21

Capacity planning CM01 - When you run capacity planning T-code: CM01, you found the plan orders are not included in the pegged requirement, you checked the profile, the check box for order and plan order are all actived.

Guess that planned orders have been created without capacity requirement indicator in MRP ("2" - Lead Time scheduling), if this is the case, then when converted to process orders they will have impact on the Resource. If you want to see them as planned orders, re-run the MRP or change in every planned order, going to the Menu: Edit --> Scheduling

Another couple of possibilities are to do with the routing/work centres used and whether it isactually calculates consumption of capacity of the category at the work centre being displayed in CM01 (it might consume a capacity pool or it might not consume the category).

MPS in Backgound/Online - You want to run MPS for a plant either online or in the background, but you do not get any results. If you run MPS for a single material/plant, then everything is 100% OK.

You need to run a planning file and a consistency check first, transaction OMDO and MDRE respectively you'll need to set up two jobs to do it but it is straight forward, once you've done this set up the background job for MPS to run and do it in NEUPL first time round and then change to NETCH after that.

What is the output of MPS run?

From MPS run you plan the materials which are of 'A' type in the abc analysis (80% dollar value) that have to be planned before hand.
MPS is also a type of MRP only in which components just below the materials on which MPS run is taken place, are planned.

Table for production order status - What is the table for finding status (for Ex TECO ed prodn orders). We are not able to find from AFKO and AFRU tables the status of production orders or at least the link tables if known can be mentionned. You are unable to link the structure caufvd and IOHEADER WITH AFKO and AFRU.

JEST is the table.

Data dictonary table for SOP planning data - You are using Standard SOP (Info structure S076), in which table can you see the planning values that you maintained in MC93 transaction?
You looked under table "S076" and did not see any values there.

Use T.Code MC95 to display your entries under the version which maintained the the table S076.

Production order operation's component allocation - How does SAP know that an operation has components as indicated by the component allocation indicator? Tcode CO08.

Component allocation is done via routing maintenance or BOM maintenance for the assembly. This is master data maintenance. As soon as a PO is created, the master data is read into the PO.

How to delete groups of products?
How to delete a group of products that was created in screen MC84?

Delete the members in the product group and then archive the product group in transaction SARA, object=MM_MATNR.
(The product group is created as a material master record with material type PROD and this record is deleted in SARA.)

Certification Qns

2007-07-31T03:51:00.000+05:30

SAP PP Certification Sample Questions

Caution: more than one answer may be correct.
Please mark ALL correct answers.

Question:
The following control parameters can be set in a long-term planning scenario :

A Planning period
B Opening stock
C Strategy group
D MRP type
E Version of available capacity

Question:
What is the name of the planning level for the MRP run?

A. SOP
B. MP
C. MRP
D. COPA

Question:
What are the main features of the MRP types 'PD' or 'VB'?

A. 'PD' can only be used with 'Net Change Planning'
B. 'VM' can only be used in total planning
C. 'PD' triggers a BOM explosion
D. 'VM' can use the forecast for the calculation of the safety stock

Question:
What is the meaning of the planning time fence?

A. It determines the planning period for the planning run
B. It determines the period in which the planned orders are to be converted into production orders
C. It determines the period in which no automatic changes are to be made to the production plan

Question:
In forecast-based planning, which forecast model does SAP support?

A. dynamic model
B. seasonal trend model
C. split trend model
D. Consumption model

Question:
What conditions must be fulfilled in Customizing if a production order is to be checked for availability?

A. Scope of check
B. Checking group
C. checking rule
D. Checking assignment
E. Inspection period

Answers for SAP PP Certification Sample Questions

Q) Can any body explain me why work scheduling view is required for semi finished and finished products? (Because we'll mention all details in MRP views)

A) We need to maintain working scheduling view in order to make that finished or semi finished goods available for production as we assign production scheduler and production scheduler profile in this view, if not maintained conversion of planned order to production will not be possible.

Q n A s n T. codes

2007-06-14T21:49:00.000+05:30

Q: How to configure the planning calendar for the ATP calculation where goods are shipped every other working day?

A: Use Transaction MD25 and define calculation rule for every other working day. Check the lot size settings in OMI4 and maintain relevant data in MMR.

Q: We have two different production lines with different operations. One production line works 5 days a week and the other 7 days a week. The factory calendar is assigned to the plant for 5 days a week. This calendar is checked when MRP is run. How can we assign 5 day a week and 7 days a week against a factory calendar to the related resources? Is it possible to have two types of calendars?

A: Assign factory calendars to the work centers.

Q: What is the difference between by-product and co-product and how do you differentiate them in a BOM?

A: In case of Co-product costs are settled with a apportionment structure. In case of By-product the price of this by-product is credited to the order or the material stock account of the lead material being manufactured.Co-Product as well as by-product are defined as BOM Components/Items. Both of them have negative quantities. ( Not all negative quantity items fall under these categories!). When BOM is created for FERT , youcan see one indicator in COMPONENT DETAILS screen for co-product. You need to define the co-products with this special indicator .

Q: What are some important tables used in PP ?

A: For orders:

CUAFVD dialog structure for order headers and items

AFPO - Order item
AFFLD Order: Dialog table for order sequences (AFFL)

MOPER Operation for production order
KBED Capacity requirements

AFRU Order completion confirmations
RESB Reservation/Dependent Requirements
AFFHD Structure of PRT's in orders
SOPER Sub-operations
SAFRU Sub-operation confirmations
SKBED Capacity requirements for sub-operation

MRP table is MDTB.
For PI:
CAUFV - AFVC Operation within an order

AFFT Order Process Instructions
AFFV Order process instruction values