SAP PP Material Planning PDF

Testing: Unit Testing / User Manual Module: PRODUCTION PLANNING
ENVIRONMENT
SYSTEM : SAP R/3 ECC 6.0
CLIENT :
UNIT TESTING SCENARIO
SCENARIO NUMBER : PP01- 03
DESCRIPTION : Matera! P!a"""#
PREPARED BY
NAME : Pra$ee% D. &a!a%'re
DATE : 03/01/0(
TEAM : Pr)$'*t)" P!a"""#
APPROVED + TESTED BY
NAME : Na",e Ba-' .P/C0
DATE :
TEAM : Pr)$'*t)" P!a"""#

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T,e C)"*e%t O1 MRP I" SAP
MRP is the planning tool in SAP which will look at all aspects of a material and is highly based upon
the master data of the material.
MRP looks at current inventory, current requirements, and open purchase requisitionorders and so
on. So if a material is required to satisfy a sales order and there is no inventory, MRP will create a
%!a""e$ )r$er if the item is t) -e %r)$'*e$ " ,)'2e. !his planned order can then be converted
to a production order by the master scheduler.
"f the item is t) -e %r)*'re$, then MRP will create a %'r*,a2e re3'2t)" which the #uyer will
convert to a purchase order. !his is $ust one scenario, the system is highly configurable and will do
pretty much whatever you tell based on config and master data.
!he 4a" 1'"*t)" of material requirements planning is to guarantee 4atera! a5a!a-!t6, that is,
it is used to procure or produce the requirement quantities on time both for internal purposes and
for sales and distribution. !his process involves the monitoring of 2t)*72 and, in particular, the
automatic creation of %r)*'re4e"t %r)%)2a!2 for %'r*,a2"# a"$ %r)$'*t)".
MRP O5er5e/
MRP analy%es the demand from sales orders and forecasts. "f stock is needed then a planned order
is created. A planned order consists of a suggested order quantity, a start date and a finish date.
!he bill of material of the planned order is e&ploded, creating dependent requirements.
!hese are processed later by MRP, to determine if planned orders are needed for the components.
"n order to replenish stock, we must convert the planned order to a production order 'if it is for a
manufactured item(, or to a purchase requisition 'if it is for a purchased item(.
MRP can create purchase requisitions directly, for purchased materials, depending on runtime
settings. "f the purchased material is part of a scheduling agreement with a vendor, MRP can create

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schedule lines. )hen the planned order is converted to a production order, the dependent
requirements for its components become reservations.
P!a"""# Pr)*e$'re
Planning procedures automatically generate order proposals to purchasing and to production. R*
planning procedures can be divided into Material Requirements Planning and +onsumption,based
planning.
"n MRP, the system compares available stock plus planned receipts with demand. "f the available
quantity is less than the required quantity at a point in time, then an order proposal is created.
MRP at P!a"t )r MRP Area Le5e!
-ou can plan material requirements at %!a"t !e5e! or for different MRP areas. )ith MRP at plant
level, the system adds together stocks from all of the individual storage locations, with the
e&ception of individual customer stock, to determine total plant stock. !he requirements are
combined in the planning run and procurement elements are created for these pegged
requirements with unknown sources. "ndividual storage locations can be planned separately or
be e&cluded from planning.
"n the case of material requirements planning on an MRP area !e5e!8 only the stocks from the
storage locations assigned to the respective MRP area are taken into account.
.nly the requirements in this MRP area are combined and procurement elements are created for
them. !his enables you to plan material requirements specifically for certain areas.

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+onsumption,based planning procedures use past consumption data 'history( to calculate future
requirements. !hese procedures are sometimes used for e&ternally procured materials or for low
value low demand items.
+onsumption,based planning can be divided into forecast,based and reorder point planning.
Re)r$er %)"t %!a"""# can be divided into automatic and 4a"'a! re)r$er %)"t %!a"""#.
/orecast,based planning uses the SAP forecasting module to calculate future requirements from
historical data.
Re)r$er P)"t P!a"""#
"n reorder point planning, procurement is triggered when the sum of plant stock and firmed receipts
falls below the re)r$er %)"t.
!he re)r$er %)"t should cover the average material requirements e&pected during the
replenishment lead time.
!he 2a1et6 2t)*7 e&ists to cover both e&cess material consumption within the replenishment
lead time and any additional requirements that may occur due to delivery delays. !herefore, the
Safety stock is included in the reorder level.
!he following values are important for defining the reorder point0
Safety stock
Average consumption
Replenishment lead time
!he following values are important for defining the safety stock0
Past consumption values 'historical data( or future requirements
1endorproduction delivery timelines
Service level to be achieved
/orecast error, that is, the deviation from the e&pected requirements
Automatic reorder point planning uses the forecasting module to determine the reorder point
quantity. A reorder proposal is generated when the stock falls below the reorder point.
I" 4a"'a! re)r$er %)"t %!a"""#, you must specify the reorder point quantity in the material
master record.

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MRP BOM E9%!)2)"
MRP begins by calculating demand for the finished product. !his consists of sales orders and
planned independent requirements. "f we don2t have enough supply to cover this demand, MRP will
create a planned order.
!he bill of material of the planned order for the finished product is e&ploded. !his creates dependent
requirements for the assemblies. A dependent requirement is demand that is derived from the bill of
material structure.
At the ne&t level of the bill, MRP calculates the requirement for each assembly. "f we don2t have
enough supply, MRP will create a planned order.
!he bill of material of the planned order for each assembly is e&ploded. !his creates dependent
requirements for the raw materials.
At the lowest level of the bill, MRP again calculates demand. "f we don2t have enough supply, MRP
will create a a purchase requisition.
MRP R'" Pr)*e$'re

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3. +reate requirement or demand in MD61
4. MRP run by MD01 for !otal Planning '"t will run in background(.
*. See the result in stock requirement list in MD0:.
MRP R'" ;e Ca" Carr6 O't B6
3 .MD01 5!otal planning for the plant
!hrough user e&it
, a. MRP Area 5 + class
, b. MRP +ontroller
, c. MRP !ype
4. MD0< , Single item multi level
* .MD03 , Single item single level
6. MD=0 , Multi,level, make,to,order production.
T)ta! P!a"""#
-ou can plan material requirements at %!a"t !e5e! or for different MRP areas. )ith MRP at plant
level, the system adds together stocks from all of the individual storage locations, with the
e&ception of individual customer stock, to determine total plant stock. !he requirements are
combined in the planning run and procurement elements are created for these pegged
requirements with unknown sources. "ndividual storage locations can be planned separately or
be e&cluded from planning.
1. Tra"2a*t)" C)$e/ Pat,
Me"'
Pat,
L)#2t*2 Pr)$'*t)" MRP P!a"""# T)ta! P!a"""# - O"!"e
T.C)$e MD01
<.1 I"%'t S*ree" Na4e > E"ter C)"tr)! Para4eter2

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De2*r%t)" )1 t,e ?e!$
Nat're )1
t,e ?e!$
Va!'e )1 t,e ?e!$
Plant Mandatory 1110
Processing 7ey NETC@
+reate Purchase Requisition 1
Schedule 8ines 3
+reate MRP 8ist 1
Planning Mode 3 .P!a"t S%e*1*0
Scheduling <
Planning 9ate SYS GENERATED
Parallel Processing TIC&
9isplay Material 8ist TIC&
A1ter ?!!"# T,e A-)5e Data A#a"2t T,e Re2%e*t5e ?e!$2
Press on !ab

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Press on !ab
After this system asks us before going further checks the input parameters

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After confirming the input parameters are correct, again
Press on !ab or press enter
.nce again the system asks us to press enter

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System carries out the MRP Run after this and shows us the summari%ed screen
C)"tr)! Para4eter2 ?)r T,e P!a"""# R'"

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U2e
1arious *)"tr)! %ara4eter2 are available for the total planning procedure and for single,item
planning, which you can set in the initial screen of the planning run.
-ou use these parameters to determine how the planning run is to be e&ecuted and which results
are to be produced.
?eat're2
!he control parameters include0
P!a"""# r'" t6%e
-ou can choose whether all materials are to be planned or only those with MRP relevant
changes.
Specifies the type of the MRP or MPS run. !he following types are possible0
a. net change planning , !he system only plans materials that have undergone a change
relevant to MRP since the last planning run.
b. net change planning in the planning hori%on
c. online regenerative planning
Creat)" "$*at)r 1)r %r)*'re4e"t %r)%)2a!2 1)r 4atera!2 t,at are %r)*'re$
e9ter"a!!6
-ou can choose whether planned orders, purchase requisitions or schedule lines should be
created for materials that are procured e&ternally.
Creat)" "$*at)r 1)r MRP !2t2
-ou can define whether MRP lists are to be created.
P!a"""# 4)$e
!he planning mode 'Planning mode indicator in the initial screen of the planning run( controls
how the system is to deal with %r)*'re4e"t %r)%)2a!2 'planned orders, purchase
requisitions, scheduling agreement lines( 1r)4 t,e !a2t %!a"""# r'", which are ")t 6et
1r4e$, in the ne&t planning run. /irmed procurement proposals remain unchanged.
#y choosing the correct planning mode, you avoid planning materials twice and thereby
optimi%e system performance.
!he following options are available0
a$a%t e92t"# %!a"""# $ata 'planning mode 3(

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re-e9%!)$e BOM a1ter *,a"#e t) BOM 'planning mode 4(
$e!ete %!a"""# $ata and recreate procurement proposals 'planning mode *(
!he planning mode set in the planning file for a material can be overruled by the planning
mode in the initial screen of the planning run.
!he following applies to this0
/or planning a particular material the planning mode that has the highest numerical value
takes priority.
Planning mode 4 're,e&plode #.M( thus takes priority over planning mode 3 'adapt planning
data(, planning mode * 'delete and recreate planning data( takes priority over planning mode
3 'adapt planning data( and planning mode 4 're,e&plode #.M(.
P!a"""# M)$e 1
Planning mode 3 is if you have only set the planning file entries 'net change planning
indicator and net change planning hori%on indicator( in the planning file for a material 'see
Planning Run !ype(.
"n the planning run in planning mode 3 the system reactivates the e&isting planning data, that
is, procurement proposals that are not firmed remain on the database and are only then
adapted, if the dates and quantities do not suit the new planning situation. !he system only
re,e&plodes the #.M for ad$usted procurement proposals. System performance is thus
improved.
E9a4%!e )1 *,a"#e2 t,at *a'2e %!a"""# 4)$e 1 t) -e 2et:
+hanges in date and quantity
Requirement changes
+hanges in the lot,si%ing procedure or MRP type
P!a"""# M)$e <
Planning mode 4 is if a material has planning file entries and the Re,e&plode #.M indicator
is also set in the planning file.
"n the planning run in planning mode 4, the system re,e&plodes the #.Ms for all e&isting
procurement proposals that are not firmed and also for those, for which the dates and
quantities do not have to be ad$usted.
E9a4%!e )1 *,a"#e2 t,at *a'2e %!a"""# 4)$e < t) -e 2et:
+hanges to the material #.M
+hanges to the sales order #.M
+hanges to the phantom assembly #.M
+hanges to references assigned within #.M
+hanges to material classification
+hange of production version in material master or planned order
+hange or conversion of #.M e&plosion number
P!a"""# M)$e 3

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Planning mode * is if a material has planning file entries and the Reset order proposals
indicator is also set in the planning file.
"n planning mode * e&isting procurement proposals that are not firmed are completely
deleted from the database and recreated. !he system then re,e&plodes the #.Ms.
E9a4%!e )1 *,a"#e2 t,at *a'2e %!a"""# 4)$e 3 t) -e 2et:
"n,house production time
Planned delivery time
Scheduling margin key
MRP controller
S*,e$'!"#
-ou can choose basic date calculation or lead time scheduling.
T)ta! P!a"""# R'" ;t, MRP C)"tr)!!er
Mention !he MRP +ontroller /or )hich )e )ant !o +arry .ut !he Planning Run "n !he :ser ;&it
Parameter. MRP +ontroller )ill #e Plant Specific.

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T)ta! P!a"""# R'" ;t, T,e MRP Area C- C!a22
Mention !he MRP Area /or )hich )e )ant !o +arry .ut !he Planning Run "n !he :ser ;&it
Parameter
T)ta! P!a"""# R'" ;t, MRP T6%e

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Mention !he MRP !ype /or )hich )e )ant !o +arry .ut !he Planning Run "n !he :ser ;&it
Parameter
S"#!e Ite4 M'!t Le5e! P!a"""#
;nter the menu path of the transaction code, which is going to be tested by the user.
Me"' Pat,
L)#2t*2 Pr)$'*t)" MRP P!a"""# T)ta! P!a"""# > S"#!e-
Ite48M'!t-Le5e!

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T.C)$e MD0<
De2*r%t)" )1 t,e ?e!$
Nat're )1
t,e ?e!$
Va!'e )1 t,e ?e!$
Schedule 8ines 3
+reate MRP 8ist 1

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Scheduling <
Press on !ab

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Press on !ab

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S"#!e Ite4 S"#!e Le5e! P!a"""#

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Me"' Pat,
L)#2t*2 Pr)$'*t)" MRP P!a"""# T)ta! P!a"""# > S"#!e-Ite4
8S"#!e -Le5e!
T.C)$e MD03
<. I"%'t Data

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De2*r%t)" )1 t,e ?e!$
Nat're )1
t,e ?e!$
Va!'e )1 t,e ?e!$
Schedule 8ines 3
+reate MRP 8ist 1
Planning 9ate Date O1 P!a"""# R'"
Press on !ab

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Press on !ab

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S"#!e Ite4 M'!t Le5e! P!a"""#

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Me"'
Pat,
L)#2t*2 Pr)$'*t)" MRP P!a"""# T)ta! P!a"""# > S"#!e-
Ite48M'!t-Le5e!
T.C)$e MD=0

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De2*r%t)" )1 t,e ?e!$
Nat're )1
t,e ?e!$
Va!'e )1 t,e ?e!$
Sales .rder <umber Mandatory :=0000<11=
Sales .rder "tem Mandatory 010
9elivery Schedules 3
Scheduling <
Press on !ab

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Press on !ab
MRP Re2'!t2 E5a!'at)"2

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!he stock requirements list is an important inquiry, which shows the real,time view of stocks,
receipts and requirements for a material.
;ach time the stock requirements list is called up, the system reads the database for the
appropriate
information.
!his list is accessed by material, by plant or by MRP area.
-ou can branch into various related transactions from the stock requirements list.
!he structure and content can be configured to individual requirements using various filters and
profiles.
Re2'!t

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!he system carries out total planning for the plant selected or for the scope of planning you have
defined. )hen you have completed the planning run you receive statistics with information on the
scope of planning, e&ceptional situations and terminations. -ou can also see how much time is
required for the planning run in total and for planning the individual materials.
E5a!'at"# t,e P!a"""# R'"
9uring the planning run, the system analy%es the requirements that e&ist for the planned materials
and creates procurement elements that cover these requirements. !he evaluations will display all
the re*e%t a"$ 22'e e!e4e"t2 for a material in the form of a table and enable you to gain a quick
)5er5e/ of the stockrequirements situation for the material.
?eat're2
!he following evaluations are available for analy%ing the planning result0
MRP list
stockrequirements list
planning result 'corresponds to the MRP list with individual evaluation layout(
planning situation 'corresponds to the stockrequirements list with individual evaluation
layout(
-ou can evaluate the planning situation or the result of a planning run using the stock
requirements
list or MRP list. -ou can use individual or collective access for this.
!he stock requirements list is a dynamic list0 it shows the current status of stocks, requirements
and receipts. +hanges are immediately visible as soon as the stock requirements list is called up
or the elements are read from the database using the refresh function in the stock requirements
list.
!he MRP list represents the result of the last planning run and therefore has a statistical nature.
+hanges that were made after the planning run are not visible. -ou can control whether an MRP list
is to be created during the planning run.
!he two lists have the same basic structure0
8inks are in the form of a tree in the MRP controller2s worklist 'optional(.
Above the list there is the header with the material number. "n addition, you can display further
information using the header details.
!he list itself contains the individual MRP elements and the corresponding available quantities.
:ser,specific settings enable you to adapt the lists to your own personal needs , this applies to both
lists 'see +ustomi%ing, ;valuation for MRP, =+onfigure MRP list stockrequirements list=(. -ou
can use a customer e&it to show additional data, which can then be called up using a function key
MRP L2t A"$ St)*7 Re3're4e"t L2t I"$5$'a! D2%!a6.

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Me"' Pat, L)#2t*2 Pr)$'*t)" MRP E5a!'at)"2 St)*7 Re3're4e"t L2t
T.C)$e MD0: )r MD0=

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De2*r%t)" )1 t,e ?e!$
Nat're )1
t,e ?e!$
Va!'e )1 t,e ?e!$
Material 1:11(011:0<B
A1ter 1!!"# t,e a-)5e $ata a#a"2t t,e re2%e*t5e 1e!$2
Press on !ab
Press on !ab

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"n the above displayed table
3( /irst 8ine shows the stock available is equal to >.
4( Second line shows the planned independent requirement is ?.
*( !hird line shows the planned order created against the P"R is ?.
St)*7 Re3're4e"t L2t C)!!e*t5e D2%!a6

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Me"' Pat,
L)#2t*2 Pr)$'*t)" MRP E5a!'at)"2 St)*7 Re3're4e"t L2t >
C)!!e*t5e D2%!a6
T.C)$e MD0A
"n *)!!e*t5e a**e220

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o ;nter the plant and one of the following parameters0 MRP controller, product group,
class or vendor.
"f you do not enter any further selection criteria, the system selects all the materials
assigned to this MRP controller, to this product group or to this vendor in the
respective plant.
o "f the work with MRP areas is activated for a single client, you enter either the plant '@
all MRP areas including the plant MRP area( or only one particular MRP area, and, in
addition, either the MRP controller, the product group or the vendor.
"f you do not enter any further selection criteria, the system selects all the materials
assigned to this MRP controller, to this product group or to this vendor in the selected
MRP area or in all MRP areas. Materials that are assigned to five MRP areas are
displayed, where applicable, with five MRP lists.
"f required, enter further selection criteria.
o Date0 for e&ample, all MRP lists that were created or processed within the last two
weeks, or MRP lists for all materials with insufficient stock for the ne&t two weeks.
o Exception groups0 for e&ample, MRP lists for all materials for which the planning run
was terminated 'e&ception group A(.
o Processing indicator0 for e&ample, all MRP lists that have not yet been processed.
o Material data0 for e&ample, MRP lists for all materials that are procured e&ternally.
"f required, choose a display filter
/or e&ample, a display filter that only displays the planned orders for the ne&t two weeks in
the stockrequirements list for the materials assigned to a selected MRP controller.
-ou can use 2e!e*t)" r'!e2 to define which MRP elements and which stocks are included
in the quantity and stock calculation. -ou hereby define your own -'2"e22 5e/2.
A 2e!e*t)" r'!e consists of particular time information, MRP elements and stocks that are
grouped together in a rule, which controls the selection 'or import( of the data in the
stockrequirements list and the planning table for Repetitive Manufacturing0
o !he system only displays MRP elements in the period that is defined in the selection
hori%on.
o !he system only displays the MRP elements that are selected in the selection rule.
o .f the MRP elements displayed, the system only takes those indicated as affecting
availability in the selection rule into consideration for the calculation of the quantity
available and the ranges of coverage.
o !he system only takes the stocks defined in the selection rule into consideration to
calculate the unrestricted,use stock.

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!his creates a new business view of the data in the lists.
-ou can use $2%!a6 1!ter2 to define which MRP elements and MRP segments are
displayed. !his enables you to reduce the information displayed to a *!ear 2e!e*t)".
A $2%!a6 1!ter consists of particular time information, MRP elements, and MRP segments grouped
in a filter that controls the display of the MRP list and the stockrequirements list.
o !he system only displays MRP elements in the period that is defined in the display
hori%on.
o !he system only displays segments in this period that are selected in the display filter.
o )ithin these segments, the system only displays MRP elements that are selected in
the display filter and that, if necessary, correspond to particular additional selections
'for e&ample, customer, vendor, storage location(.
!he data in the lists is thus reduced to a clear selection.
"n contrast to selection rules, the calculation of the quantity available and the ranges of
coverage is not influenced by display filters.
-ou can define the 2e!e*t)" ,)rB)" for the selection rule as well as the $2%!a6 ,)rB)"
and the a$$t)"a! 2e!e*t)"2 for the display filter in two ways0
o company,specific in +ustomi%ing
o user,specific in the respective analysis list
1. Select the With filter field 'initial screen( or choose 'main screen( in order to show the
Display filter and Selection rule fields.
4. Select a display filter andor a selection rule.
3. +hoose and, if necessary, enter a display hori%on for the display filter or a selection
hori%on for the selection rule, which means a period to which you want to limit the display.
4. +hoose and, if necessary, enter additional selections for the display filter, for e&ample if
you want to see MRP elements for a particular vendor or a particular customer.
"f you always work with a particular display filter andor selection rule, choose . !he
system displays the Settings dialog bo&. :se this to define that this display filter or
selection rule should always be activated when you access the lists.


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De2*r%t)" )1 t,e ?e!$
Nat're )1
t,e ?e!$
Va!'e )1 t,e ?e!$
MRP +ontroller
Set up 8ists in back ground TIC&
Press on !ab
MRP C)"tr)!!er .Matera!2 P!a""er0
Specifies the number of the MRP controller or group of MRP controllers
responsible for material planning for the material.

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Stock Requirement 8ist as per the MRP +ontroller then get displayed

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Select the individual lines and click on tab it will show the
requirements for the particular item code B the planned orders generated against the requirement
qty.

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