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MRP Configuration
MRP Configuration
MRP configuration
The following are the Major Configuration items explained in detail:
Path; SPRO ➤ IMG ➤ Production ➤ MRP ➤ Planning File Entries ➤ Activate MRP
and set up planning file.
T code; OMDU
Path; SPRO ➤ IMG ➤ Production ➤ MRP ➤ Plant parameters ➤ Carry out overall
maintenance of plant parameters
T code; OPPQ
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
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
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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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.
Reporting
This configuration is used for the following
purposes.
MRP Controllers
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
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.
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.
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.
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.
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.
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.
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
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.
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.
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.
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 2 – Define the plants or MRP areas to be included in the planning run arranged in a
sequence.
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.
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.
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”.
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.
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.
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
Receipt
Receipt Day’s
Number of Days Stocks will Cover the Requirements Day’s Supply Day’s
Supply 2
Supply 1
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
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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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