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Lab’s Module: Consumption-based Planning: Reorder Point

SAP Username Name GBI-093 Rana Fathiya Kusuma

1.1 Create Raw Material
Menu Path Trans Code Logistics Production Master Data Material Master Material Create (Special) Raw Material MMR1

Enter RAW-### for material and select Retail for Industry Sector, then click on Select view(s): Basic Data 1, Purchasing, MRP 1, MRP 2, MRP 3, Accounting 1. Then click on enter.

SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia

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Enter DL00 for Plant, then click on enter icon (

).

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Basic Data 1 View Description Unit of Measure Material Group

RAW-### EA BIKES

Purchasing Purchasing group

N00

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MRP1 MRP Type manual reorder point planning Reorder point MRP Controller Lot size fixed Fixed lot size VB 80 000 FX 400 MRP2 SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 4 .

Procurement type SchedMargin key Plnd delivery time Safety stock external F 001 2 30 SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 5 .

MRP3 Availability check indv req 02 SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 6 .

SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 7 .Accounting 1 Valuation class Price control Standard Price 3000 (raw materials 1) S 8. then click on the save icon ( ) to save the new material master.5 Enter the data shown above.

If not. Click on the exception message. click on it and then click on the search icon. we are showing the available quantity as a negative 30. the stock is 0. then click on the search icon To see what the exception message is. then click on the enter icon ( ). enter them. and there is an exception message.2 Stock/Requirements List Menu Path Trans Code Logistics Materials Management Inventory Management Environment Stock Stock/Requirements List MD04 Material RAW-### and plant DL00 should be entered automatically. Because there should be a safety stock of 30 units.1. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 8 . Because this is a brand new material.

and why.Exception message 96 notifies us that the stock level is below the safety stock level. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 9 . Exception messages are particular useful when looking at a number of materials to see which need attention. Close the list of exceptions by clicking on the close icon ( ).

Click on the Create new session icon SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 10 .

we need to execute an MRP planning run. even though in practice it would probably be done for a group of materials (using an MRP Area) and would probably be scheduled regularly. follow the menu path: Logistics Production MRP Planning Single Level Single-Item Planning Menu Path Trans Code MD03 Enter material RAW-### and plant DL00. Because the inventory for raw material is below the reorder point. To run the MRP planning process for a single material.3 MRP Planning Run We will want to keep the Stock/Requirements List open so we can quickly see the impact of planning procedures. Click on the enter icon ( ) a second time and a screen very similar to the Stock/Requirements screen will be displayed. select Display results before they are saved. then click on the enter icon ( ). We will do the MRP planning run for just this material. To create purchase requisitions for the raw materials. so SAP is just reminding you to make sure that you have everything set correctly. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 11 . so we can see the planning results immediately. Use the default planning values. The following message will appear at the bottom of the screen: Depending on the situation. production planning can take a lot of computer resources.1. the SAP system should create a purchase requisition that can be converted to a purchase order so that raw materials can be acquired.

Switch back to the session with the Stock/Requirements List.This screen shows us that a Purchase Requisition for 400 raw materials has been created as we are below our reorder point of 80 (and below the safety stock of 30 units as well). Click on the refresh icon ( ) to update the Stock/Requirements list. The Stock/Requirements List will now show the Purchase Requisition that was created by the planning run: 0010000320/00000 SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 12 . Click on the save icon ( ) to save these planning results.

SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 13 . To convert the Purchase Requisition into a Purchase Order. (US00). which will call up the following pop-up window: Click here Click on the icon to convert the Purchase Requisition to a Purchase Order. click on the details icon ( ). Make sure the organizational data shown above is entered and drag the divider over to display more of the Document overview. Group (N00) and Company Code (US00) are entered. we need to convert the Purchase Requisition into a Purchase Order. Purch.4 Create Purchase Order from Purchase Requisition Next. and make sure that the Purchasing Org. which can be done from the Stock/Requirements List.1.

Click on the Vendor field. then click on the Adopt icon ( will copy data from the Purchase Requisition to the Purchase Order screen. then search vendor ### Portage Material. This Next. ). Click on the enter icon to retrieve data on the vendor. we need to assign a vendor to this Purchase Order. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 14 .Click on the Open requisition line in the Document overview.

Enter 8. there is no pricing data available. then click on the enter icon ( ) and a warning message will be displayed: Cick on the enter icon ( ) a second time. then click on the save icon ( ). Not much will change.5 for the Net price and USD for the Currency. except that the Purchase Requisition will now be shown as a POitem.As the material is new and has never been purchased. so the SAP system will request pricing data. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 15 . Switch back to the session with the Stock/Requirements List and click on the refresh icon ( ) to update the data.

1. To do this. We need to let the SAP system know this by performing a goods receipt. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 16 . we will assume that ### Portage Material has delivered on purchase order for 400 raw materials. switch back to the other session and follow the menu path: Menu Path Trans Code Logistics Materials Management Inventory Management Goods Movement Goods Receipt For Purchase Order GR for Purchase Order MIGO_GR Use the search Purchase Documents per Vendor to find your PO with purchasing organization US00 and purchasing group N00 to find your purchase order.5 Goods Receipt for Purchase Order Next.

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enter raw material (RM00) for Stor. execute ( ) on Where tab. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 18 .Then click. Loc. then click on the Post icon ( ). please select the Item OK checkbox.

Switch to the Stock/Requirements list. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 19 . then click on the refresh icon ( ) to see that the material is now available. Click on the refresh icon to see that the 400 raw materials are now in storage location 10.

1. but as it makes the exercise easier to issue the raw materials to a cost center.6 Goods Issue to Cost Center When materials are taken out of inventory to be used. It can be debated whether raw materials fall into this category. follow the menu path: Logistics Materials Management Inventory Management Goods Movement Menu Path Goods Issue Trans Code MB1A Enter: Movement type 201 (consumption for cost center from warehouse) Plant DL00 Storage Location RM00 Then click enter. but for low cost items. that is what we’ll do. this information needs to be recorded and the cost of the materials removed needs to be attributed to a cost object. a project. a customer order or a cost center. the effort to attribute their cost to a particular cost driver may not be worth the effort. In general. To issue raw materials to a cost center. which can be a production order. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 20 . costs should be assigned as closely to the activity that caused them.

Enter the information shown above. Click on the enter icon ( ). Enter NAPR1000 for the cost center. plant DL00. which tells the SAP system that we are going to charge a cost center for the material. and will be taking the material out of storage location RM00. then 100 units of material RAW-### and click on the save icon ( ) and a message like the following will appear at the bottom of the screen: SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 21 .

7 Planning File and MRP Planning Run Because we have made a change to the stock level of the material. Enter RAW-### for material and DL00 for plant. then click on the execute icon ( This will produce the planning file entry for your material: SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 22 . there should be an entry in the planning file. We can check the planning file for this material by following the menu path: Menu Path Trans Code Logistics Production MRP Planning Planning File Entry Display MD21 ).Switch to the session with the Stock/Requirements list and click on the refresh icon ( the changes? Available Stock berkurang menjadi 300 buah ). What are 1.

Note that the goods issue created an entry in the planning file for both NETCH and NETPL planning options. Perform an MRP planning run for the material by following the menu path: Logistics Production MRP Planning Single-Item. The results of the planning run should be like the following: SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 23 . Single-Level Use the default settings. except select Display results before they are saved. respectively The planning file entry means that the SAP system will check to see if a purchase requisition needs to be created the next time an MRP planning run is performed for the material. If you need more details on the MRP planning run. refer to Section 1.3.

Note that the planning run did not create any purchase requisitions. so an MRP planning run should plan the material. just that they might. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 24 . A planning file entry does not mean that plans will necessarily change. Planning file entries are made whenever a transaction is executed that COULD cause the creation of a purchase requisition (or planned order. for materials produced in-house).

1. enter NAPR1000 for the cost center. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 25 . To do this. Again.8 Second Goods Issue to Cost Center We will issue a second batch of raw materials to a cost center. then 200 units of material RAW-### and click on the save icon ( ). follow the menu path: Logistics Materials Management Inventory Management Goods Movement Goods Issue Enter: Movement type 201 (consumption for cost center from warehouse) Plant DL00 Storage Location RM00 Then click enter.

except select Display results before they are saved.3. it would appear that an MRP planning run should create a purchase requisition. As the reorder point is 80 units. To see whether this is the case. Again. Single-Level Use the default settings. if you need more details on the MRP planning run. is 70 units. perform a planning run again by following the menu path: Logistics Production MRP Planning Single-Item.Switch to the Stock/Requirements List and click on the refresh icon ( ): The inventory level. The results of the planning run should be like the following: SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 26 . excluding safety stock. refer to Section 1.

By doubleclicking on the material number. Is SAP broken? Is there a configuration setting missing? This question can be answered with a little investigation.Note: No purchase requisition was created Even though the available quantity is 70. To start the process. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 27 . Select the view MRP 2. switch to the Stock/Requirements list. no purchase requisition was created. which is below the ROP of 80. the material master will be displayed.

Click the safety stock entry of 30 and click on the F1 key to get information about this data field: In manual reorder point planning. the ROP (Reorder point) of 80 that we entered in view MRP 1 is assumed to include the safety stock of 30. the ROP is compared to the stock available INCLUDING the safety stock: An order is triggered when this quantity goes below 80 Not this one This is an important point. so we expect to consume 50 raw materials before the order is received. the safety stock value is assumed to be included in the reorder point figure. but they chose to make the safety stock entry an SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 28 . the way SAP has programmed reorder point planning. the demand during lead time is 50 and the reorder point of 80 INCLUDES a safety stock of 30 units. In other words. SAP could have chosen to subtract the safety stock entry from the stock level and compare that value to the reorder point. which is what has been specified for this material. Thus. In terms of the Stock/Requirements list.

Both approaches are valid.“informational” value. and the important thing with any software is to be clear how things are calculated by testing it thoroughly. 1.9 Third and Final Goods Issue to Cost Center To confirm that SAP compares the ROP to the stock level including safety stock. perform a final goods issue for 30 raw materials by following the menu path: Logistics Materials Management Inventory Management Goods Movement Goods Issue SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 29 .

SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 30 .6 for details. The results of the planning run should be like the following: A purchase requisition is created by the planning run Click on the save icon ( ) to save the plans. except select Display results before they are saved. Switch to the Stock/Requirements List and click on the refresh icon ( ) to see that the newly-created purchase requisition. Single-Level Use the default settings.See Section 1. Switch back to the Stock/Requirements list and click on the refresh icon ( ) to see that the stock level is now below the ROP: Stock is now below the reorder point of 80 Perform a final planning run by following the menu path: Logistics Production MRP Planning Single-Item.

Manager salah memperhitungkan jumlah barang yang sebenarnya dimiliki. Data berapa jumlah reorder point dan berapa jumlah safety stock ditentukan sendiri oleh perusahaan. Dalam lingkungan produksi yang sibuk. As you do this. SCM Ganjil 2013/2014 Faculty of Computer Science University of Indonesia 31 . ponder the questions:  What issues might there be when implementing this policy in a production environment? Kemungkinan human error ketika melakukan input data sangat besar. Print out a copy of the Stock/Requirements list to hand in.Click on the print icon to print the Stock/Requirements list to hand in. What could go wrong? Ketika demand sedang tinggi dan terjadi miskalkulasi penentuan waktu reorder barang sehingga dapat terjadi stockout karena stock dan safety stock tidak dapat memenuhi demand tersebut. Jika terdapat kesalahan ketika input data. lebih baik mengimplementasi prosedur automatic reorder point atau forecast-based planning untuk menghindari miskalkulasi atau kesalahan input dari user ketika ingin menentukan kapan harus melakukan reorder.   Jot down your answers to these questions on the printout. dapat mempengaruhi proses yang lainnya seperti salah menentukan kapan harus melakukan reorder lagi karena purchase requisition tidak muncul. How will the data be collected? Data demand didapatkan dari hasil Forecasting.