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MRP Doc 2

MRP configuration
The following are the Major Configuration items explained in detail:

 Activating MRP and Planning File Entry;

Path; SPRO ➤ IMG ➤ Production ➤ MRP ➤ Planning File Entries ➤ Activate MRP
and set up planning file.
T code; OMDU

 Material Requirements Planning (MRP)


This configuration allows you to choose the plant for which you would want to activate SAP
Material Requirement Planning (SAP MRP) Activating MRP for the plant allows one to use
the SAP MRP tool for the plant.

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 Activating Planning File Entries for a Plant.


T code; OMDO
Activating the Planning file entry for the plant allows you to collect all the material
in a planning file list, which has an MRP Type in the material master MRP 1 View
(other than MRP Type XO)
All the entries in the planning file will have a “change indicator” specifying that
material has undergone a change (change in receipts elements or issues elements).
This indicator will help you to choose only those materials that have undergone a
change, through the use of a planning key called “Net Change Planning” when
running MRP.
The planning file record for a material also has a “net change planning in the current
horizon” field which will be set if the change in the receipt of the material or issue
element is valid in the planning horizon. This indicator will help you choose only those
materials which have undergone a change in the planning horizon; through the use
of a planning key, in an MRP run, called “Net change planning in the planning
horizon”.

 SAP MRP Plant Level MRP Parameters Configuration


Plant-level configuration in MRP refers to the specific settings and parameters that are used to
optimize MRP for a particular manufacturing facility or plant. Plant level configuration can help
ensure that MRP is tailored to the unique needs of a particular manufacturing facility, allowing
for more efficient production and inventory management.

Path; SPRO ➤ IMG ➤ Production ➤ MRP ➤ Plant parameters ➤ Carry out overall
maintenance of plant parameters
T code; OPPQ

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As we go to OPPQ
there are 4 options
shown there,
To maintain the
parameter, click on
maintain and the
system ask for the
plant for which e want
to maintain the
parameter

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Here we have to maintain these all option to work MRP process

 Number range;
First, we have to maintain the number
range for option shown in image.
Here we assign number range ID to every
option.
To configure number range, we have to go
T code; OMI2

 Check rule; Backorder;

Here we have to assign check rule to plant.

As per standard SAP, the Availability checking rule for the backorder processing is “PP”,
though you can have your own availability check rules created or configured.
Every Availability checks rule (availability checking scope defined) has a set of receipts
(Purchase orders, Production orders) and issues (Sales orders, dependent requirements,
reservations, planned independent requirements etc) which are to be considered or not to be
considered during the SAP availability checks.

To have the checking rule work along with the configuration, you should have the Availability
checking groups maintained in the material master. The Checking groups are configured to
be associated with the checking rules (checking scopes).
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Path; SPRO ➤ Production planning for process industries ➤ Process order ➤


Operation ➤ availability check ➤ Define checking group

The availability checking rule (checking rule scope) has to be maintained, for a given SAP
functionality and it has to be assigned to the availability checking group maintained in the
material master. The SAP functionalities that use availability checks to check the availability
of the header materials as well as components at the plant at the time of sales order creation,
the availability checks of the header material at the time of sales order delivery, the
availability checks for components in production – thus reporting the missing parts list, the
backorder processing etc.

Path; SPRO ➤ Production planning for process industries ➤ Process order ➤


Operation ➤ availability check ➤ Define checking rule

 Reporting
This configuration is used for the following
purposes.

To configure the objects, which are to be


considered in the calculation of the “receipts days
supply” like the production orders/process orders,
firmed planned orders, purchase orders, assigned
planned orders, firmed purchase requisitions,
QM Inspection lots, reservations, safety stocks.

To configure the reporting of “period totals” in


terms of a defined period (day, week, month,
periods as per planning calendar) of in Stock
requirement list, MRP list, simulative MPR, or
interactive MRP.

 MRP Controllers

This is a mandatory configuration.

Here you can configure the list of MRP controllers


for the plant. An MRP Controller is a person or a
group of people, which is responsible for planning
material or a given list of materials. You have to
assign the MRP controller to the Material Master
MRP 1 View, so as to delegate the responsibility
of the planning and evaluation of planning for
that material.

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 Special procurement
The special procurement function helps you to configure and assign special procurement to
the materials which can be used during an MRP run while creating the procurement proposal.

The special procurement functions are withdrawal from the alternate plant, production in
the alternate plant, subcontracting, direct production, and phantom item planning.

 Floats

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Floats are buffers in the total lead time, that are provided in production/process orders or in
the planned orders created manually or during an MRP run. The schedule margin key is used
in the Material Master MRP 2 View. It is used in MRP as well as in production orders.

The floats are defined using the scheduling margin key.

Opening period: Number of working days between the date that the order is created and the
planned start date. This time is available for the MRP controller to convert a planned order
into a purchase requisition or a production order.
Float after production: Number of working days between the scheduled finish date and the
order finish date; used as a float in production scheduling.

Float before production: Number of working days between the order start date and the
scheduled start date; used as a float in production.
Scheduling release period: Number of workdays between the planned start date and the date
for releasing the order. If the order release indicator is set, the production order is released
by a background program that takes all dates into account.

 Planned order conversion

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In this configuration parameter, you can maintain the production order type or the process
order type, which the system should use as default during the planned order conversion.
Setting defaults in the plant parameters configuration allows the system to fix and select the
order type for a plant during the conversion process.
Also, for the purchase requisition conversion, you are given an option in the configuration to
define the maximum number of planned orders that can be converted in to Purchase
requisition.

 Dependent Requirements availability check


When carrying out the availability check for each of the components in an MRP BOM
explosion, the system needs to know the availability checking scope rule. Again, we would
maintain the standard Checking rule as PP or you could alternatively configure one for
yourselves.

 BOM/Routing Selection ID

This configuration parameter is really important and it is mandatory to maintain one, since
it helps selection of BOM and task lists in the planned orders. Though there is one more place
in the planned order Scheduling parameters MRP configuration, where you can maintain the
selection ID for selection of the Task lists (Routing/Recipe/Rate Routing).

A selection procedure is set to select BOM or Routing/Recipe on priorities set for the BOM
usage or for the task list types and the task list status. Knowing the selection procedures
allows the MRP run to select the right BOM and task list for the planned orders.

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 Parameters for detail scheduling

This configuration parameter is really important and it is mandatory to maintain one. It


allows you to set the control parameters for scheduling of planned orders of type LA at a given
plant and for a given MRP Controller. You can leave the MRP controller as “*” to have the
scheduling parameters true for all the planned orders across all the MRP controllers.

The following control parameters can be configured here:

 The Routing/Recipe Selection ID, specifying the routing/recipe that would be selected
for detailed scheduling, as per the priorities set for task list type and task list status.
 The Detailed scheduling, using the task list is only carried for the scheduling Horizon
mentioned, i.e., if the planned orders dates lie beyond the scheduling horizon, then the
basic date scheduling is used where the in-house production times from the material
master is used.
 Allow Scheduling Indicator allows the planned orders to be scheduled using the
detailed scheduling or basic date scheduling, either of the two, depending upon the
availability of the task list and scheduling type selected for the MRP run.
 Generate Capacity requirements indicator allows generation of the capacity
requirements for the work centres and loads them accordingly. The loading of the work
centres is as per the use of the work centre determined through the scheduling carried
out.
 The Task list selection, scheduling horizon, scheduling indicator and the capacity
indicator can also be set for rough cut planning used for Long term planning purposes.
 The next configuration parameter talks about the configuration of the selection of the
type of scheduling level that should be used for adjusting the basic dates of planned
orders. The various options available are rate based scheduling, lead time scheduling,
scheduling using takt times.
 The Adjust planned order dates configuration option allows you to readjust the
scheduling results or the basic dates every time you carry out Scheduling. Though
there is one more scheduling configuration option provided by the system for
overwriting/adjusting the existing basic dates by the new dates arrived at, through
rescheduling (using the scheduling level as mentioned).
The system not only offers an option to adjust the basic dates for the planned order arrived
at by using the scheduling level set, but it also setting the dates of the dependent
requirements to the operation start date or the order start date. This configuration not only
adjusts or sets the dates of the header planned order and the dependent planned orders, but
it also generates capacity requirements for the same.

See below for the details of adjusting dates in scheduling and adjusting dates for capacity
requirement generation:

 You can adjust the Basic Dates of the header planned order using the scheduling level
and adjust (or set) the dependent requirements to the start of the header planned
order
 You can adjust the Basic Dates of the header planned order using the scheduling level
and adjust (or set) the dependent requirements to the start of the respective operation
to which the dependent requirements are assigned to.
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 You can decide not to adjust the Basic Dates of the header planned order arrived at
by using the scheduling level and at the same time not-adjust (or not set) the
dependent requirements to the start of the header planned order.
 You can decide not to adjust the Basic Dates of the header planned order arrived at
by using the scheduling level and at the same time not-adjust (not set) the dependent
requirements to the start of the respective operations to which the dependent
requirements are assigned to.
 You are also provided an option to configure the scheduling type – whether forward or
backward scheduling. It is normal behaviour for the standard system to have this
configured as “backward scheduling” so that SAP MRP (material requirement
planning) never misses the customer delivery date or order availability date. An option
is also provided to not-to-schedule, any orders during the breaks set in the factory
calendar.
 Start date the in the past options allows you to push the start date of the planned
orders to a certain number of days in the past. If the order start date goes beyond the
number of days allowed, then the system uses the concept of ‘today’s scheduling” and
sets the start date of the planned order to today’s date and carries out forward
scheduling thereafter.
 One of the scheduling parameters is “reduction measures”, used to reduce the total
order lead time in circumstances designed. You can avoid the configuration of
reduction measures if you are not using them.

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 External procurement

For external purchasing, one can maintain the default lead time required for conversion of
Purchase requisition into purchase order, using the planned delivery lead times from the
purchase info record or purchasing agreement. So as to use the planned delivery times from
the purchase info record, one should also maintain the source list for the material, with the
same vendor in the source list and the purchase info record.
Using the planned delivery times from the material master or from purchase info record, is
totally a decision of the consultant.

 Planning Horizon
Maintaining a planning horizon helps the system to plan only those demands, which fall in
the planning horizon starting from today. When an MRP Run is taken, the planning horizon
is number of work days as mentioned (let’s say 180 days) from today’s date; the system would
not plan any orders whose start date lies beyond this horizon.

 Available stock for net requirement calculations


SAP MRP offers you a choice to select the most controversial stock types, in its net
requirement calculations. The stock types are – stock in transfer (stock in transfer is
considered as stock at the receiving plant as it is already issued from the sending plant),
blocked stock, restricted batch stock (stock of batches marked with restricted batch)

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 SAP MRP, MRP Group Level Parameters Configuration


The entire configuration that is created as a part of SAP MRP Plant level parameter in the above
steps can be also set for an MRP Group. You can group materials using MRP Groups. Each of the
MRP Group can have its own MRP Parameter set. You can set the MRP group in the material
master MRP 1 View.

Path; SPRO ➤ IMG ➤ Production ➤ MRP ➤ MRP group ➤ Carryout overall


maintenance of MRP group
T code; OPPR

Working with MRP groups can be convenient for a plant or an organization, since by assigning
the MRP groups to a set of materials, would allow planner to configure these materials (through
MRP Groups) to behave in a certain manner for planning purposes. The group could have its own
unique:

 Strategy group,
 Conversion order types,
 Planning horizon,
 Planning time fence and roll forward periods,
 BOM and task list selection ID’s,
 Direct procurement parameters,
 Planned order scheduling parameters,
 Start number of days allowed in the past
 Availability checking groups

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 Configuring SAP MRP Types

a) MRP Procedures
MRP Procedures defines the type of MRP to be used – Reorder point planning methods, Material
requirement planning or demand-based planning methods, Forecast based planning methods,
Time phased planning methods, MPS and the no planning procedures to mark a material with
an MRP types that does not plan a material at all.

b) Firming Type

In the category of MRP procedure called – MRP or demand-based planning method and MPS,
SAP offers 8 different MRP types with Firming namely P1, P2, P3, P4 and M0, M1, M2, M3, M4.

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When working with the planning time fence, one needs to set the firming methods & the
scheduling methods of the procurement proposals within the planning time fence.

c) Include External Requirements


The inclusion of external requirements in net requirement calculations is available to be set when
you are working with reorder point planning-based MRP types. Actually, there are 2 options in
this field, i.e., include external requirements in the total planning horizon or restrict the inclusion
of the external requirements only within the replenishment lead time.
SAP also offers an option to select the additional external requirements that should also be
included in the net requirement planning calculations like the - components supplied to the
vendor in a subcontracting case, reservations set for the components in production order,
reservations of components in plant maintenance orders, requirements to satisfy the Stock
transfer order to another plant, stock transfer requisitions created for Stock transfer orders,
requirements raised because of stock transfer delivery schedules.

d) Forecasting for MRP


Forecasting MRP Types have a “forecasting indicator” as obligatory, unlike other MRP types
which normally have the forecasting indicator set to optional. Also, the historical data is updated
in the material master as the total consumption (planned consumption plus unplanned
consumption) or unplanned consumption. When the consumption is planned as per the MRP
reservations, planned consumption is updated and when the consumption is not planned as per
the reservation or is greater than the reservation quantities, then unplanned consumption is
updated.
In MRP-type configuration, you have an option of choosing the type of historical consumption of
a material to be used for planning whether total consumption (planned + unplanned
consumption) or unplanned consumption.

After choosing the historical data type, you should configure, the type of forecast requirements
to be considered in the MRP planning run, whether total consumption (planned + unplanned
consumption) or unplanned consumption.
The reduction method for forecast requirements is also configurable. The default is a reduction
in consumption.

e) Planning method
The MRP type offers you to plan the materials in an external system, like the MRP Type “X0”.
The indicator called the planning method allows you to choose external planning so as to plan
materials in the external system.

f) Automatic Calculations
You can have the safety stock and the reorder point calculated automatically by the system when
you are using the automatic reorder point planning methods. In the automatic calculations, the
system uses the forecast data.

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 Configuring SAP MRP Scope of Planning for the Total Planning


Run
SAP provides an option to plan multiple plants together or multiple MRP areas in one planning
run in a sequence.

Transaction code OM0E can be used for configuration or the logical SAP

Path; SPRO ➤ IMG ➤ Production ➤ MRP ➤ Planning ➤ Define Scope of Planning for
Total Planning, can be used to configure.
T code; OM0E

Step 1 – Define the Name of the Scope of planning run

Step 2 – Define the plants or MRP areas to be included in the planning run arranged in a
sequence.

 Configuring SAP MRP Planning time fence and Roll Forward


Period
Path; SPRO > IMG > > Production > Material Requirements Planning > Planning >
MRP Calculation > Define Planning Time Fence and Roll Forward Period
T code; OPPD

The planning time fence


It is the number of work days, within which you can protect the master plan (or in other words
the procurement proposals of a master plan) from being disturbed or changed by any automatic
changes (of an MRP Run). The procurement proposals are firmed so as to protect them from any
changes. The firming of the procurement proposals (planned orders, purchase requisitions,
delivery schedules) in the planning time fence prevents the proposals in the time fence from being
adopted in the next planning run.

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Firming for automatically created procurement proposals:

The automatically created procurement proposals in the MRP Run are not firmed by the system,
so that they are available for adjusting dates and quantities in the next planning run, in cases
where there is change in BOM or task list.
You can though manually firm the planned orders individually or collectively using transaction
code MD19

Note - Automatically created planned orders in the planning time fence are only remain firm till
they are in the planning run.

Firming for manually created procurement proposals:

For manually created or changed procurement proposals or even when you reschedule the
planned order in the graphical planning table, the system always marks them with a firming
indicator. Though you can remove or delete this firming indicator.

Firming for component’s planned orders:

In case of a planned order, you can manually firm it by selecting the “firming planned order
Indicator” in the planned order header. And in order to make sure that the BOM levels below are
not exploded or changed in a planning run, you have to set the “firming components indicator”.

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Roll Forward Period

The Roll Forward Period adds the functionality of automatic deletion of firmed planned orders,
from the master plan. It also creates new proposals to cover any requirements pending during
the MRP run. This period can be defined for number of days in past or future. The system deletes
all the firmed planned orders that lie before the roll forward period.

Using the roll forward period, you can have the system delete all useless old firmed planned
orders, which otherwise the system would never had deleted, since they were firmed. This allows
for reorganizing the planned orders.

 Configuring SAP MRP Areas


Path; SPRO ➤ IMG ➤ Production ➤ Material Requirements Planning ➤ Master Data
➤ MRP Areas ➤ Activate MRP for MRP Areas.
T-code; OM01

Path; SPRO ➤ IMG ➤ Production ➤ Material Requirements Planning ➤ Master Data


➤ MRP Areas ➤ Define MRP Areas.
T-code; OMIZ

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Types of MRP Areas:


Plant MRP Areas:
You can create one MRP area for several plants, so that when you run the MRP for this
MRP area, the run is for all the plants configured in the MRP area.
Storage Location MRP Areas:
You can create MRP areas for several storage locations at a plant. You cannot use one
storage location in multiple MRP areas.
Subcontractors MRP Areas:
You can create MRP areas for several subcontractors for a plant. You cannot use one
subcontractor in multiple MRP areas.

 SAP MRP Dynamic Safety Stock (Range of coverage Profile)


The dynamic safety stock is a stock calculated based on the average daily requirements
for a period rather than the actual requirements over the period, therefore it is more
statistical value rather than an absolute value.
Safety stock as we know is used to cover the fluctuations in the requirements, so is the
dynamic safety stock, the only difference being, the safety stock is an absolute value
provided directly for a material whereas the dynamic safety stock is calculated by the
system on the basis of the coverage period and average daily stock calculated internally
by the system.
The Dynamic safety stock is calculated in every planning run.
Path; SPRO ➤ IMG ➤ Production ➤ Material Requirements Planning ➤ Planning ➤
MRP Calculation ➤ Define range of cover profile
T code; OMIA

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Range of coverage Configuration:


Configuration for calculation of average daily requirement for a period
Period indicator - Indicate the type of period, whether week or month or according to PP
planning calendar. (Let’s say it is W – Week)
Number of Periods – Number of periods used to calculate the average daily requirements
(Let’s say it is 10 Weeks)
Type of Period length – It defines the number of days in the period, if the period length
is in terms of workdays, then the factory calendar work days are considered, if the period
length is in terms of calendar days then it is considered in terms of Gregorian calendar,
and if it is terms of standard days, then you would have to enter the number of days in a
period in the configuration (Let’s say that the configuration was done with workdays and
the factory calendar has 7 days per week)
Therefore, Average daily requirement = Requirements in the period (Requirements in 10
Weeks – Let’s say 1050 Units) / (Number of Periods – Let’s say 10 Weeks) * (Number of
days in the period – Let’s say 7 days)
= 1050 / (10*7) = 15 Units

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Configuration parameters for calculation of Dynamic Safety Stock for the Range of
Coverage
You can define 3 different range of coverage – minimum, maximum, and target range of
coverage, which is used to calculate 3 different stocks using the average daily
requirements (range of coverage multiplied by the period length). The Target range of
coverage defined here would be used to calculate the Dynamic Safety Stock for the period
of the coverage.
The Period of the coverage is specified in the configuration. The coverage’s and the
periods for which they should work for, are defined for 2 separate period lengths and the
3rd period length is for the rest of horizon.
In the example, we have defined the safety stock to cover a period of 7 days (minimum,
target and the maximum range of coverage). The minimum, target and the maximum
stock is calculated for the average daily requirement over the respective coverage
periods. You can check the minimum, maximum, target stock levels, minimum range of
coverage, maximum range of coverage, target range of coverage in the MRP List or Stock
requirements list’s “Period Total Display” Section.
As per our example, for the first period of 13 weeks, all the 3 stocks levels – minimum,
maximum, and target stock levels would be 70 Units and for the next period of 26 weeks
it will be 70 units as well and for the rest of the horizon it will be 70 units again.
Normally when the available stock falls below the minimum stock level, SAP planning
run, would immediately create planned orders to suffice at least the target stock level.
For example, if the minimum stock level is 30 and the maximum is 80 and the target
stock is 50 units, then if the available stocks fall below the 30 units mark, SAP creates a
procurement proposal for 50 units to reach back to the target stock level. Whereas in the
example below, all the 3 stocks types are 70 units, therefore when the stocks fall below
the 70 units, the system will try to raise a procurement proposal to reach back to 70
units.

Dynamic safety stock Dynamic safety stocks Dynamic safety stocks


Dynamic safety stocks
formula summarized as = for the 1st period of 13 for the 2 Nd period of 26
for the rest of the
Average Daily Stock * weeks weeks
Horizon
Range of coverage
70 Units 70 Units 70 Units
Minimum safety stock
70 Units 70 Units 70 Units
Target safety stock
70 Units 70 Units 70 Units
Maximum safety stock

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 Configuring SAP MRP Days’ Supply and Receipt Days’ Supply


The days of supply is not a mandatory configuration, you can only configure the days’ supply if
you feel the SAP pre-configured ones are not what you want.

SAP offers 2 types of evaluations in SAP, the days’ supply and the receipt day’s supply.
In the SAP MRP Evaluation transactions such as stock requirement list or MRP list, the days’
supply would calculate the number of days on the time axis, till the material requirements can
be satisfied purely by the current available stock.

While the Receipt Day’s supply would indicate how long would the current stock and the expected
receipts would cover the requirements. There are 2 receipt day’s supply evaluations offered by
SAP called as the receipt day’s supply 1 and receipt days’ supply 2. SAP offers a configuration to
select the receipts elements for receipt day supply 1 and 2 evaluations. There is also an option to
have the receipt day’s supplies to be calculated when the stocks fall below the safety stock or
below the current available stocks.

The days’ supply values or the receipt days’ supply values can be correlated with the range of
coverage concept. These tools come with traffic lights – red, yellow and green which offer
warnings to the MRP Controllers/users and lets him/her strategically know when the material
stock would be totally consumed

Path; SPRO ➤ IMG ➤ Production ➤ Material Requirements Planning ➤ Evaluations


➤ Define Receipt Elements for Receipt Days' Supply
T code; OMIL

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Receipt
Receipt Day’s
Number of Days Stocks will Cover the Requirements Day’s Supply Day’s
Supply 2
Supply 1

Consider Current Stocks only in calculation of Days’ Supply

Only Consider Current available Stocks to cover


X
Requirements

Consider Receipts also along with Current Stock in Calculation of Days’ Supply

Firmed Planned orders, Planned orders assigned with Production versions, Purchase orders, Schedule
lines, Firmed Purchase Requisitions, Receipt Reservations, Shipping Notifications

Consider all the possible receipt elements along with the


plant stock

Example – Firmed Planned orders, Planned orders X


assigned with Production versions, Purchase orders,
Schedule lines, Firmed Purchase Requisitions, Receipt
Reservations,

Consider all the Most Certain receipt elements along with


the plant stock
X
Example - Production order, Shipping Notifications, QM
Inspection Lots

Days’ Supply for Material M1 on Today = 3 days


(Receipts are not considered)

Stock Balance Left after covering


Day Requirements Available Qty
Requirements

Today - 20 Current Stock = 100 100 – 20 = 80


2 Nd Day - 30 Stock Available = 80 80 – 30 = 50
3 rd. Day - 50 Stock Available = 50 50 – 50 = 0 (Stock = 0)
4 th Day - 52
5 th Day - 40
6 th Day - 20

Days’ Supply on Today = Coverage’s Considering without the receipts = 3 Days Exactly
Receipts Days’ Supply for Material M1 on Today = A little more than 4 days
(Receipts are also considered – This example can be for Receipt Days’ supply 1 or 2)
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Stock Balance Left


Available
Day Reqmts Expected Receipts after covering
Stock
Requirements

Firmed Planned order = 10


Available =
Today - 20 Production order = 5 (100 + 15) -20 = 95
100
Total Receipts on day = 15

Total Receipts on day = 0


2 nd Day - 30 Available = 95 (95 + 0) – 30 = 65

Production order = 25
3 rd Day - 50 Available = 65 (65 + 25) – 50 = 40
Total Receipts on day = 25

Planned order = 8
4 th Day - 47 Production order = 5 Available = 40 (40 + 13) – 47 = 6
Total Receipts on day = 13

Planned order = 5 (1 + 5) – 40 = - 34
5 th Day - 40 Available = 6
Total Receipts on day = 0 Shortage

6 th Day - 20

Receipt Day’s Supply on Today = Coverage’s Considering the receipts


= 5 – 1 + (6 / 40) = 4 + 0.15 = 4.15 Days

Kunal Y. Khadke |9665055863 Kunalkhadke11293@gmail.com| 25

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