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Planning of materials SAP - how to

Table of content

1 SELECTION OF PLANNING METHOD................................................................3


1.1 Forecast planning with a % planning (only with KMAT).........................................................................3

1.2 Forecast planning with product groups.......................................................................................................5

1.3 Forecast planning with planning material..................................................................................................6

1.4 Manual forecast planning.............................................................................................................................6

1.5 Min Max (reorder point) planning...............................................................................................................6

1.6 Demand planning...........................................................................................................................................6

1.7 Kan Ban (internal/external)..........................................................................................................................7


1.7.1 External Procurement.............................................................................................................................7
1.7.2 In-house Production...............................................................................................................................7
1.7.3 Stock transfer.........................................................................................................................................7

2 FORECAST PLANNING WITH A % PLANNING (ONLY WITH KMAT)...............8


2.1 Setup master data K-mat..............................................................................................................................8

2.2 Create Planning table..................................................................................................................................14

2.3 Maintain Planning table..............................................................................................................................18

2.4 Maintain Planning Profile...........................................................................................................................19

2.5 Maintain the percentage for the percentage planning.............................................................................21

2.6 Distribute requirements..............................................................................................................................23

2.7 Setup master data lower level items...........................................................................................................24

2.8 Adjust independent requirements..............................................................................................................30

2.9 Schedule Lines: reorganize.........................................................................................................................31

2.10 Delete History..........................................................................................................................................32

3 FORECAST PLANNING WITH A PRODUCT GROUP......................................33


3.1 Setup master data Product group..............................................................................................................33

3.2 Setup Product group...................................................................................................................................42

3.3 Setup planning for Product group.............................................................................................................44

3.4 Transfer planning to demand planning.....................................................................................................45

3.5 Distribute requirements..............................................................................................................................46

3.6 Setup master data lower level items...........................................................................................................46

3.7 Adjust independent requirements..............................................................................................................53

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3.8 Schedule Lines: reorganize.........................................................................................................................54

3.9 Delete History...............................................................................................................................................55

4 FORECAST PLANNING WITH PLANNING MATERIAL....................................56


4.1 Setup master data........................................................................................................................................56

4.2 Maintain the planning on the planning material......................................................................................62

4.3 Adjust independent requirements..............................................................................................................63

4.4 Schedule Lines: reorganize.........................................................................................................................64

4.5 Delete History...............................................................................................................................................65

5 MANUAL FORECAST PLANNING.....................................................................66


5.1 Setup master data........................................................................................................................................66

5.2 Maintain the planning on the planning material......................................................................................72

5.3 Adjust independent requirements..............................................................................................................73

5.4 Schedule Lines: reorganize.........................................................................................................................74

5.5 Delete History...............................................................................................................................................75

6 MIN MAX (REORDER POINT) PLANNING........................................................76


6.1 Setup master data........................................................................................................................................76

7 DEMAND PLANNING..........................................................................................82
7.1 Setup master data........................................................................................................................................82

8 KAN BAN (INTERNAL/EXTERNAL)..................................................................88


8.1 Create production supply area...................................................................................................................88

8.2 External Procurement Master Data setup................................................................................................90


8.2.1 Changing material master record.........................................................................................................90
8.2.2 Maintain Info Record...........................................................................................................................98
8.2.3 Maintain Source list.............................................................................................................................99
8.2.4 Maintain Control Cycle......................................................................................................................100

8.3 In-house production Master Data setup..................................................................................................104


8.3.1 Changing material master record.......................................................................................................104
8.3.2 Maintain Control Cycle......................................................................................................................110

8.4 Kan Ban Board..........................................................................................................................................113

8.5 Kan Ban signal...........................................................................................................................................115

8.6 Correction of Kan Ban..............................................................................................................................116

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1 Selection of planning method


You can materials with different planning methods. There are several factors important for
choosing the right method for the material.
Make To Order or Make To Stock planning
The longest delivery time form the parts in the order
The consumption during the time (constant or with peaks)
The wanted delivery time from you to the customer
Batch size
Do you want to plan on 3 nearly similar materials or on 1 material?

In the basis you can plan based on the following methods:


Forecast planning with a % planning (only with KMAT)
Forecast planning with product groups
Forecast planning with planning material
Manual forecast planning
Min Max (reorder point) planning
Demand planning
Kan Ban (internal/external)

In the following chapters you will get a description when you use a method.

Please contact the service desk: servicedesk@kvernelandgroup.com if you want to change the
planning. They can also help you with setting up test scenarios.

It can happen that it gives sometimes some unwanted result therefor first test it in AS1, AS2
or AT1. Not all effect are 100% written down in this instruction, because than it will be more
than 200 pages.

1.1 Forecast planning with a % planning (only with KMAT)

This can only be used in combination with a KMAT.

With this you can give a percentage planning on the materials. This is based on the
characteristic and characteristic values used inside the KMAT.

See an Example in the figure on the next page.

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If you plan wheel set A for 60% and B for 40% and the highest level on stock are the rims and
tube. That means:
KMAT 5PC 10PC 20PC
Rim A 6PC 12PC 24PC
Inner tube A 6PC 12PC 24PC
Outer tube A 6PC 12PC 24PC
Rim B 4PC 8PC 16PC
Inner tube B 4PC 8PC 16PC
Outer tube B 4PC 8PC 16PC

It is only needed if the wanted delivery time from you to the customer is shorter than your
production time + the longest delivery time of your supplier(s).

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1.2 Forecast planning with product groups

Forecast planning with product groups are working on a similar way as the Percentage
planning of the K-mat.

With this you can give a percentage planning on the materials. This is based on the
percentages in the product group.

See an Example in the figure

If you plan wheel set A for 60% and B for 40% and the highest level on stock are the rims and
tube. That means:
KMAT 5PC 10PC 20PC
Rim A 6PC 12PC 24PC
Inner tube A 6PC 12PC 24PC
Outer tube A 6PC 12PC 24PC
Rim B 4PC 8PC 16PC
Inner tube B 4PC 8PC 16PC
Outer tube B 4PC 8PC 16PC

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It is only needed if the wanted delivery time from you to the customer is shorter than your
production time + the longest delivery time of your supplier(s).

1.3 Forecast planning with planning material

This way of planning is used if you have materials that are 99% similar. So instead of
planning on 2 or more materials you just need to plan on 1 material. Be aware if you plan on 1
material and the only difference is the colour and you plan the painting you may got request to
paint the parts in the wrong colour.

With this way of planning you can use it in 2 ways.


1. You can produce the planning material
2. You cant produce the planning material

With the second way you will prevent that you produce something that you dont need. The
only thing is you must maintain an extra material with BOM and routing.

It is only needed if the wanted delivery time from you to the customer is shorter than your
production time + the longest delivery time of your supplier(s).

1.4 Manual forecast planning

This planning method is the basis of the last two described planning method. Also for this
method:
It is only needed if the wanted delivery time from you to the customer is shorter than your
production time + the longest delivery time of your supplier(s).

1.5 Min Max (reorder point) planning

The Min Max (official: reorder point) planning can only be used on a material with a regular
consumption. The reorder point (minimum) must be setup, so that when the order goes to the
reorder point, that you will have enough stock for the consumption in the (internal/external)
delivery time of this material.

Disadvantage of reorder point planning: It is not possible to see the demands from planned
orders in the MD04. This means the demands from planned orders are not taken into account,
when you determine if the article has reached the reorder point. So it only shows the demands
from Production orders, Sales orders and delivery notes.

1.6 Demand planning

The easiest way of doing the planning is a demand planning. The demand planning has 1
basic. If I create a sales order. I get a requirement for that article. If I dont have it on stock the
MRP will generate a planned order or a purchase req.

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So the basic is it will try to get the stock is 0 (if no safety stock on the material) and for all
requirements I will have stock. This way of planning is also used inside the forecast planning.

1.7 Kan Ban (internal/external)

There are 3 ways to do Kan Ban:


External Procurement
In-house Production
Stock transfer

Be aware before starting with 1 of the ways contact the service desk
servicedesk@kvernelandgroup.com

In most cases IT must set up some customizing to make it possible.

1.7.1 External Procurement

With external procurement you dont plan on a material. You use the signal empty bin to order
the parts at the vendor. When you receive the materials you scan the bin full. If it is scanned
full you have done the goods receipt.

1.7.2 In-house Production

With in-house production you also dont plan the material. You use the signal empty bin to
order the parts at your own production. When you receive the materials you scan the bin full.
If it is scanned full you have done the goods receipt and confirmed the production order.

1.7.3 Stock transfer

With this method you can still plan on a material. You use the Kan Ban to move the stock
from 1 storage location to another storage location in your plant. Example: Move the stock
from the warehouse with a fixed quantity to the production floor.

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2 Forecast planning with a % planning (only with KMAT)


This can only be used in combination with a KMAT.

With this you can give a percentage planning on the materials. This is based on the
characteristic and characteristic values used inside the KMAT.

2.1 Setup master data K-mat


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Master Data Material
Master Material Change Immediately
Transaction code MM02 (MM01 for create, MM03 for display)

2. Fill in the material and continue

3. Select the views MRP 1/4, Work scheduling and continue

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4. Fill in the plant and Storage Location and continue.

5. Fill in the following:


MRP group: Choose a group with planning strategy 99 (if not sure ask service desk)
MRP Type:
o P3 if you want to use a planning time fence
o PD if you dont want to use a planning time fence
Planning time fence: Number of workdays for the frozen period (only working with MRP Type
P3)
Lot size:
o EX Exact lot size
o FX Fixed lot size Fill also the Fixed lot size in

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6. Procurement type: E

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7. Leave the fields in Planning part empty. This figures are default filled with the MRP group, if you fill
it in here you will overwrite the defaults. This can make sure that it is not working anymore as
expected.

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8. Individual/coll.:1 and continue

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9. Fill in the right production scheduling profile and save the material

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2.2 Create Planning table

Check if this already exists. If not you must create it. This must be done for all planning
relevant characteristics. If all are maintained go to 2.4

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Master Data Combination
Table Create
Transaction code MDP1(MDP2 for change, MDP3 for display)

2. Click on behind the planning table.

3. Make all fields empty and click on

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4. Click twice on the column header Table to see the last used VT number. Choose this one by
double clicking on it.

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5. Choose the next number (this case VT9000002719 becomes VT9000002720) and continue

6. Click on behind the planning table.

7. Give it a logical description and set the status to 1 (released) and click on

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8. Fill in the characteristic where this table is linked to and save it.

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2.3 Maintain Planning table

Check if this already exists. If not you must create it. This must be done for all planning
relevant characteristics. If all are maintained go to 2.4

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Master Data Combination
Table Maintenance
Transaction code MDP4

2. Click on to maintain the planning table.

3. Maintain all needed characteristic values of the characteristic in the table and save it

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2.4 Maintain Planning Profile


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Master Data Planning
Profile
Transaction code MDPH

2. Fill in the material (k-mat) and click on

3. If it is not maintained yet you will find screen below otherwise you have the screen of the next

point. Maintain in this screen a logical name and select that and click on

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4. You will get a similar screen as below.

With you can add tables (VT)

If you select a table and click on you delete this table in the planning
With the tick mark behind the Characteristic value you say that one is relevant for this K-mat
If maintained completely save it.

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2.5 Maintain the percentage for the percentage planning


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Planned Independent
Requirements Create
Transaction code MD61 (MD62 for change, MD63 for display)

2. Fill in the material (k-mat) and version an continue

3. Maintain the planning figures (this can also be change by other transactions, like MC94)
Double click on the moment where you want to change the Percentage. For Example week
18.
For more info transactions please contact the service desk.

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4. Here you can maintain a percentage. You see also the total percentage use on a table in the
case below this is 121%. Based on the quantity you get some demands. Save the changes.

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2.6 Distribute requirements

A K-mat can only be used in an inactive planning. This means you cannot get any
independent requirements on the K-mat material itself. So the figures maintained in the
MD61/MD62 must be transferred to the lower level items.

This is normally be done by a job.

To be able to do this there must be a job set up that runs the following transactions:
1. MS01 this distributes the figures from the K-mat to the lower level item (visible in
the MS04)
2. MS66 Transfer the independent requirements to the planning see the settings in next
chapter

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2.7 Setup master data lower level items

This must be done for all materials on the highest level on stock of the K-mat. Please dont
do it on 2 levels than you have the requirements twice!

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Master Data Material
Master Material Change Immediately
Transaction code MM02 (MM01 for create, MM03 for display)

2. Fill in the material and continue

3. Select the views MRP 1/4, Work scheduling and continue

4. Fill in the plant and Storage Location and continue.

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5. Fill in the following:


MRP group: Choose a group with planning strategy 70 (if not sure ask service desk)
MRP Type: PD if you dont want to use a planning time fence
Lot size: What you need in your situation

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6. There are here no specific settings needed

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7. Leave the Strategy group empty. All the figures in the marked area are default filled with the MRP
group; if you fill it in here you will overwrite the defaults. The Mixed MRP = 1 makes sure that this
material gets the independent requirements
Ask service desk for determing the consumption mode and the periods backward and forewards
consumption.

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8. No special settings needed.

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9. If it is an in-house produced part maintain production scheduling profile and save the material

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2.8 Adjust independent requirements

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Adjust requirements
Transaction code MD74

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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2.9 Schedule Lines: reorganize

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Schedule Lines
reorganize
Transaction code MD75

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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2.10 Delete History

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Delete History
Transaction code MD76

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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3 Forecast planning with a product group


3.1 Setup master data Product group
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Master Data Material
Master Material Create (General)
Immediately
Transaction code MM01 (MM02 for change, MM03 for display)

2. Fill in the material, material type PROD (product group) and continue

3. Select the views Basic Data 1/2, MRP 1/4, Work scheduling and continue

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4. Fill in the plant and Storage Location and continue.

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5. Fill in the Following and continue.


Base unit of measure = PC
Division = 04
Lab Office = your own
X-plant material status = BU
Valid from = today

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6. Nothing needs to filled in and continue.

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7. Fill in MRP Type = ND and continue

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8. Procurement type = E and continue

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9. Fill in the availability check and continue

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10. Nothing needs to filled in and continue.

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11. Nothing needs to filled in and save the material

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3.2 Setup Product group


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production SOP Product group
Change
Transaction code MC86 (MC85 for display)

2. Fill in the material, Plant and continue

3. Choose if you want to assign materials or product groups and continue

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4. Fill in Materials, Plant and Proportion (=percentage) and save it

5. If the percentage is not 100% you get a similar screen as below.

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3.3 Setup planning for Product group


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production SOP Planning For
Product group Create
Transaction code MC81 (MC82 for change, MC83 for display)

2. Fill in the material, Plant and continue

3. Fill in the version and continue

4. Fill in the figures and save it

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3.4 Transfer planning to demand planning


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production SOP Planning For
Product group Transfer PG to Demand Planning
Transaction code MC75

2. Fill in the following and click on


Product group
Plant
From which figures (advice use production plan)
Dates
Requirements type (Depending on the planning strategy of the material)
Version (Depending on the planning strategy of the material)
Active or not Active (Depending on the planning strategy of the material)

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3.5 Distribute requirements

In several cases it is needed to transfer the demands from the higher level materials to the
lower level materials. So the figures maintained in the MC81/82 and MC75 must be
transferred to the lower level items.

This is normally be done by a job.

To be able to do this there must be a job set up that runs the following transactions:
1. MS01 this distributes the figures from the K-mat to the lower level item (visible in
the MS04)
2. MS66 Transfer the independent requirements to the planning see the settings in next
chapter

3.6 Setup master data lower level items

This must be done for all materials on the highest level on stock of the K-mat. Please dont
do it on 2 levels than you have the requirements twice!

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Master Data Material
Master Material Change Immediately
Transaction code MM02 (MM01 for create, MM03 for display)

2. Fill in the material and continue

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3. Select the views MRP 1/4, Work scheduling and continue

4. Fill in the plant and Storage Location and continue.

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5. Fill in the following:


MRP group: Choose a group with planning strategy 70 (if not sure ask service desk)
MRP Type: PD if you dont want to use a planning time fence
Lot size: What you need in your situation

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6. There are here no specific settings needed

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7. Leave the Strategy group empty. All the figures in the marked area are default filled with the MRP
group; if you fill it in here you will overwrite the defaults. The Mixed MRP = 1 makes sure that this
material gets the independent requirements
Ask service desk for determing the consumption mode and the periods backward and forewards
consumption.

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8. No special settings needed.

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9. If it is an in-house produced part maintain production scheduling profile and save the material

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3.7 Adjust independent requirements

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Adjust requirements
Transaction code MD74

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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3.8 Schedule Lines: reorganize

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Schedule Lines
reorganize
Transaction code MD75

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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3.9 Delete History

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Delete History
Transaction code MD76

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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4 Forecast planning with planning material


This way of planning is used if you have materials that are 99% similar. So instead of
planning on 2 or more materials you just need to plan on 1 material. Be aware if you plan on 1
material and the only difference is the colour and you plan the painting you may got request to
paint the parts in the wrong colour.

4.1 Setup master data


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Master Data Material
Master Material Change Immediately
Transaction code MM02 (MM01 for create, MM03 for display)

2. Fill in the material and continue

3. Select the views MRP 1/4, Work scheduling and continue

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4. Fill in the plant and Storage Location and continue.

5. Fill in the following:


MRP group: (if not sure contact the service desk)
o With a link to planning strategy 60 if it is a planning material with assembly
o With a link to planning strategy 63 if it is a planning material without assembly
o With a link to planning strategy 65 if it is linked to planning material
MRP Type:
o P3 if you want to use a planning time fence
o PD if you dont want to use a planning time fence
Planning time fence: Number of workdays for the frozen period (only working with MRP Type
P3)
Lot size: that you want to use

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6. No special settings on this view needed.

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7. The mixed MRP:


Strategy 60 = 1
Strategy 63 = 3
Strategy 65 = 1
Strategy 65 Fill also in:
Planning material
Planning plant
PLNG conv. factor
Optional:
Consumption group
Backwards planning
Forwards planning

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8. No special settings are in this view needed

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9. Fill in the right production scheduling profile for in-house produced materials and save the material

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4.2 Maintain the planning on the planning material

This is only for the planning material (Strategy 60 and 63.)

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Planned Independent
Requirements Create
Transaction code MD61 (MD62 for change, MD63 for display)

2. Fill in the material and version and continue

3. Maintain the planning figures (this can also be change by other transactions, like MC94) and
save it.

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4.3 Adjust independent requirements

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Adjust requirements
Transaction code MD74

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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4.4 Schedule Lines: reorganize

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Schedule Lines
reorganize
Transaction code MD75

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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4.5 Delete History

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Delete History
Transaction code MD76

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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5 Manual forecast planning


This method is used to manually plan materials.

5.1 Setup master data


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Master Data Material
Master Material Change Immediately
Transaction code MM02 (MM01 for create, MM03 for display)

2. Fill in the material and continue

3. Select the views MRP 1/4, Work scheduling and continue

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4. Fill in the plant and Storage Location and continue.

5. Fill in the following:


MRP group: With a link to planning strategy 40
MRP Type:
o P3 if you want to use a planning time fence
o PD if you dont want to use a planning time fence
Planning time fence: Number of workdays for the frozen period (only working with MRP Type
P3)
Lot size: that you want to use

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6. No special settings on this view needed.

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7. The mixed MRP: 1


Optional (this will overwrite the Default from the MRP group):
Consumption group
Backwards planning
Forwards planning

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8. No special settings are in this view needed

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9. Fill in the right production scheduling profile for in-house produced materials and save the material

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5.2 Maintain the planning on the planning material


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Planned Independent
Requirements Create
Transaction code MD61 (MD62 for change, MD63 for display)

2. Fill in the material and version and continue

3. Maintain the planning figures and save it.

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5.3 Adjust independent requirements

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Adjust requirements
Transaction code MD74

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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5.4 Schedule Lines: reorganize

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Schedule Lines
reorganize
Transaction code MD75

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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5.5 Delete History

This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Delete History
Transaction code MD76

2. Fill in the following and continue:


Plant: Your Plant
Material: Optional
Key date: date before you want to delete it (advice last day of the last month)
Tick marks on as below

3. Now you see the result of the job This can be exported to Excel with the

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6 Min Max (reorder point) planning


The Min Max (official: reorder point) planning can only be used on a material with a regular
consumption. The reorder point (minimum) must be setup, so that when the order goes to the
reorder point, that you will have enough stock for the consumption in the (internal/external)
delivery time of this material.

Disadvantage of reorder point planning: It is not possible to see the demands from planned
orders in the MD04. This means the demands from planned orders are not taken into account,
when you determine if the article has reached the reorder point. So it only shows the demands
from Production orders, Sales orders and delivery notes.

6.1 Setup master data


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Master Data Material
Master Material Change Immediately
Transaction code MM02 (MM01 for create, MM03 for display)

2. Fill in the material and continue

3. Select the views MRP 1/4, Work scheduling and continue

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4. Fill in the plant and Storage Location and continue.

5. Fill in the following:


MRP group: With a link to planning strategy 40 or 70
MRP Type:
o VB Manual reorder point planning (SAP standard)
o ZV Manual reorder point planning (SAP standard + requirements from STO + dep.
Requirements)
Reorder point: Fill in the reorder point for this material
Lot size: that you want to use

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6. If you fill in a safety stock, this must be lower than the Reorder Point. The advice is not to use a
safety stock with a reorder point planning.

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7. Leave the selected fields empty

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8. No special settings are in this view needed

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9. Fill in the right production scheduling profile for in-house produced materials and save the material

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7 Demand planning
Demand planning is the simplest planning method. There is a sales order created. After the
MRP run the system will suggest the needed planned orders or purchase requirements.
Convert those requirements into an order and deliver the sales order.

7.1 Setup master data


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Master Data Material
Master Material Change Immediately
Transaction code MM02 (MM01 for create, MM03 for display)

2. Fill in the material and continue

3. Select the views MRP 1/4, Work scheduling and continue

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4. Fill in the plant and Storage Location and continue.

5. Fill in the following:


MRP group: With a link to planning strategy 40 or 70
MRP Type:
o P3 if you want to use a planning time fence
o PD if you dont want to use a planning time fence
Planning time fence: Number of workdays for the frozen period (only working with MRP Type
P3)
Lot size: that you want to use

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6. No special settings on this view needed.

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7. Leave the selected fields empty

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8. No special settings are in this view needed

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9. Fill in the right production scheduling profile for in-house produced materials and save the material

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8 Kan Ban (internal/external)


There are 3 ways to do Kan Ban:
External Procurement
In-house Production
Stock transfer

Be aware before starting with 1 of the ways contact the service desk
servicedesk@kvernelandgroup.com

In most cases IT must set up some customizing to make it possible.

8.1 Create production supply area

For each Location where you would like to have Kan Ban on you must have a production
supply area.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production KANBAN Production
Supply Areas Maintain
Transaction code PK05 (PK06 display, PK05S fast entry)

2. Fill in your plant and continue

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3. Select to create a new supply area

4. Fill in the plant, Supply Area, Supply Area description, Storage Location and Responsible MRP
controller and save

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8.2 External Procurement Master Data setup

Before you are changing a material to Kan Ban several things must be done:
Contact the supplier over the change
Count the current stock
Check on which locations it is used
Check the quantity/bin that is needed on each location
Check how many bins (minimum 2 bins) you need on each location

In SAP you need to do the following things:


Delete the open purchase orders
Do stock correction if needed. Be aware if the material is now set up as bulk do this
after changing the material master
Delete the LTP requirements

8.2.1 Changing material master record


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Materials Management Material
Master Material Change Immediately
Transaction code MM02 (MM01 create, MM03 display)

2. Fill in a material that you want to change and continue

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3. Select the following views and continue

4. Fill in the plant, Storage Location, Sales organization and Distribution channel which you want to
change

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5. Make sure that the item category group in NORM and continue

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6. Make sure that the MRP type is PD, Delete all lot size data (except the lot size itself) and continue

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7. Make sure that the bulk indicator is empty and a Planned delivery time is filled in and continue

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8. Make sure the planning selection is empty and continue

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9. Change the SLoc MRP indicator to 1 and continue

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10. Make sure that the valuation class is following the table and save the material
Valuation class Material type
1100 Raw material (ROH)
8000 Semi-finished material (HALB)
9100 Finished product (FERT)

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8.2.2 Maintain Info Record


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Materials Management Purchasing
Master Data Info Record Change
Transaction code ME12 (ME11 create, ME13 display)

2. Fill the Material, Vendor, Purchase organization and Plant and continue

3. Make sure that the planned delivery time is the real time (most likely 7 days (every week)) and
save

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8.2.3 Maintain Source list


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Materials Management Purchasing
Master Data Source List Maintain
Transaction code ME01 (ME03 display)

2. Fill in the material and plant and continue

3. Leave the fields Agmt, Item and MRP empty and save

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8.2.4 Maintain Control Cycle


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production KANBAN Control
Cycle Control Cycle Maintenance
Transaction code PKMC

2. Fill in the plant and continue

3. Click on to create or change the control cycles

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4. Click on to create a control cycle This must be done for all locations individual

5. Fill in the material, plant and production supply area and continue

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6. Fill in the following figures and continue:


Supply area
Storage bin
Number of Kanbans (number of bins)
Kan Ban quantity in each bin
Switch the radio button to Ext. Procurement and choose there 0001

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7. Fill in the purchasing organization and vendor and save

Repeat this for all possible locations

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8.3 In-house production Master Data setup

Before you are changing a material to Kan Ban several things must be done:
Count the current stock
Check on which locations it is used
Check the quantity/bin that is needed on each location
Check how many bins (minimum 2 bins) you need on each location

In SAP you need to do the following things:


Delete the open production orders
Delete the LTP requirements

8.3.1 Changing material master record


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Materials Management Material
Master Material Change Immediately
Transaction code MM02 (MM01 create, MM03 display)

2. Fill in a material that you want to change and continue

3. Select the following views and continue

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4. Fill in the plant and Storage Location which you want to change

5. Make sure that the MRP type is PD, Delete all lot size data (except the lot size itself) and continue

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6. Make sure that the bulk indicator is empty and In-house production time is filled in and continue

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7. Make sure the planning selection is empty and continue

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8. Change the SLoc MRP indicator to 1 and continue

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9. Fill in a production supervisor and save the material

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8.3.2 Maintain Control Cycle


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production KANBAN Control
Cycle Control Cycle Maintenance
Transaction code PKMC

2. Fill in the plant and continue

3. Click on to create or change the control cycles

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4. Click on to create a control cycle This must be done for all locations individual and Fill in the

material, plant and production supply area and continue

5. Fill in the following figures and continue:


Supply area
Storage bin (only with WM)
Number of Kanbans (number of bins)
Kan Ban quantity in each bin
Switch the radio button to In-house prod. and choose there 0003

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6. Fill in the person responsible and save

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Repeat this for all possible locations

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8.4 Kan Ban Board


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production KANBAN Control
Kan Ban Board Demand-Source View
Transaction code PK13N (PK12N is similar only more filtering
options)

2. Fill in the plant and continue

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3. In this Kan Ban board you can see the different statuses of all Kan Ban bins

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8.5 Kan Ban signal


Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production KANBAN Control
Kanban Signal Manual entry
Transaction code PK21 (or PKBC)

2. Select the radio button Kanban ID Number and the status (full, empty or wait) Place the cursor in
Kanban ID Number and type in or scan the Kan Ban ID and save it

For a new Kan Ban Bin you can only set them on wait or empty for the first time.
Within 10 minutes you can not change the status twice.

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8.6 Correction of Kan Ban

This transaction is used to change the status or quantity in a bin. You use this transaction.
With this transaction you can also set the status to wait. This is needed for deleting a bin for a
location.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production KANBAN Control
Kanban Correction
Transaction code PK31

2. Fill in the material, plant, supply area and continue

3. Select the item that you want to correct and click on

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4. Make the corrections in the status and/or quantity and click on or in cases

like this with an error click on to return the error message

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