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 SAP AG 2006

TERP10

5-3

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 SAP AG 2006

TERP10

5-4

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 SAP AG 2004

TERP10

5-5

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Organizational Levels are structures that represent the legal and/or organizational views of an enterprise. You can design your company structure based on your business processes.

The manufacturing planning and execution process uses the following organizational units: # Client – all manufacturing organizational elements exist within a client. # Company code – represents an independent accounting unit. Balance sheets and Profit & Loss Statements, required by law, are created at the company code level. # Plant – an organizational unit within a company. A plant produces goods, renders services, or makes goods available for distribution. A plant can be a manufacturing facility or a warehouse distribution center. # Storage location – an organizational unit within a plant. A storage location identifies the general area in the plant where material is stored. Plants can have multiple storage locations.

TERP10

5-6

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 SAP AG 2006

TERP10

5-7

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ďŁŠ SAP AG 2004

The material master represents the central source for releasing material-specific data. It is used by all of the SAP Logistics components.

The stored data can be used by all areas, such as purchasing, inventory management, materials planning, invoice verification, and so on.

The Material Requirments Planning (MRP) and Execution (Work Scheduling) views must be maintained for manufacturing.

Basic Data, Accounting, Quality Management, Forecasting, Purchasing, and Classification data is used by various manufacturing planning and execution processes.

ÂŠ SAP AG

TERP10

5-8

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ďŁŠ SAP AG 2004

Basic data in the material master is applicable to the entire company and is stored at the client level. This includes, for example, the product description, material number, the material group, the unit of measure and conversion factors for alternative units of measure.

The MRP (Production Planning), Work Scheduling (Production Execution), and Accounting views are specific to the plant.

ÂŠ SAP AG

TERP10

5-9

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ďŁŠ SAP AG 2006

The fundamental settings for Material Planning can be found in Material Planning views 1 to 4 of the material master.

The MRP type specifies how a material should be planned (MRP, consumption-based planning, no planning).

The lot-sizing procedure determines the lot size of each of the procurement proposals. The procurement type controls how a material is to be procured (in-house production or external procurement). The in-house production time or rather the planned delivery time specifies how long procurement will last.

A safety stock can be set.

The behavior of planned independent requirements is controlled by the strategy group. Moreover, control of the Available to Promise (ATP) check takes place on the basis of the availability check group.

A production procedure can be defined by a production version. In a production version, routing and BOM can be selected in particular.

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TERP10

5-10

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ďŁŠ SAP AG 2004

The material type is the most important value assigned to a material. The material type attached to a product identifies the business processes and functions allowed. It determines, for example: " The screens that appear in the material master record " The department-specific data that can be maintained " How the material number assignment is carried out " The procurement types that are allowed (in-house production or external procurement) " The general ledger accounts that are updated

Material type definitions are controlled through customizing.

Materials with similar basic attributes are grouped together by material type. This means you can manage your materials according to their business requirements.

You can create additional company-specific material types in Customizing.

ÂŠ SAP AG

TERP10

5-11

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The BOM contains the assemblies or components, that are to be included in the production of a material. BOMs are used in Material Requirements Planning, production, procurement and for product costing.

A BOM consists of a BOM header and the BOM items. The base qauntity in the BOM header specifies to which amount of the finished product the item quantities refer.

Bills of material are single-level. An item of a BOM can itself also contain components. In this way, multilevel production is described using the single-level BOMs of the finished product and those of the assemblies and where required, using the BOMs of the assemblies of the assemblies and so on.

A BOM can also contain documents or text items in addition to stock items that are required for the finished product.

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TERP10

5-12

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ďŁŠ SAP AG 2004

The settings that apply for the whole BOM can be found in the BOM header. BOM usage determines the business applications for which a BOM can be used. The status of the BOM controls whether the BOM is active for particular applications (MRP, for example).

Multiple BOMs, which consist of multiple alternative BOMs, can also exist in addition to simple BOMs. The different alternative BOMs can then be valid for each of the different lot-size areas, for example.

Components necessary for the production of the finished product are entered as items of the BOM. The item category specifies what kind of item you are dealing with: Stock items are executed in the warehouse and are used in production. In contrast, non-stock items are directly assigned to a manufacturing order (and not via the warehouse). Variable-size items contain variable-size data (a steel sheet with a certain surface area, for example) and finally, document items contain a supplementary document that describes production (a kind of design and construction diagram).

Individual items themselves can also bear a multitude of further settings, which then only refer to the respective item.

ÂŠ SAP AG

TERP10

5-13

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ďŁŠ SAP AG 2004

All bills of material are created and maintained as single-level bills.

The picture above shows 4 single-level bills of material.

A single-level bill of material describes an assembly by means of components and their quantities.

The Pump is comprised of components which are themselves comprised of components identifying Pump as having a multi-level bill of material.

A multi-level BOM structure is exploded automatically by MRP and Product Cost Planning. It can also be exploded as a master data evaluation.

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TERP10

5-14

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ďŁŠ SAP AG 2004

You must assign an item category to every component when you add or change components in a bill of material.

The item category influences the processing of the component.

For example, the item category controls whether a material number is required, optional or not allowed for the component. A stock item must have a material master. A non-stock item, on the other hand, does not require that a material master record exist. It can also be stored in a material group.

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TERP10

5-15

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Routings contain the steps that are necessary for production, that is, the corresponding operations, their sequence and the work centers in which these operations are to be executed. Routings can be transferred to SAP Advanced Planning and Optimization (APO) in the form of production process models (PPMs).

A routing can be defined using the routing group and the group counter. Moreover, the routing contains reference to the material whose production it describes. A routing can contain parallel or alternative sequences in addition to the standard sequence.

Alongside the standard values, the routing also contains the time elements that are relevant for scheduling operations. Therefore you need to make sure that each operation in the routing can contain its own base quantity, to which these time elements can refer.

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TERP10

5-16

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 SAP AG 2004

TERP10

5-17

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 SAP AG 2004

TERP10

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!"#$%&'(#)*+,-&%'(#) ďŁŠ SAP AG 2006

Material planning is divided into several steps. The process of demand planning, which is used to derive a future demand program from the demand figures in the past, begins with Sales and Operations Planning (SOP).

Demand management is the management of the independent requirements. The behavior of independent requirements in material requirements planning is determined by their requirements type or by the planning strategy.

Sales orders are entered from Sales Order Management. They represent an order made by a customer, whereby a certain quantity of a product is required by a given date.

Material Requirements Planning (MRP), a net requirements calculation is executed in the planning run to determine whether a material shortage exists for a certain material. The stock and the existing fixed receipts are compared with the safety stock and requirements. The result of this comparison is the quantity available for MRP.

Production, that is, the processing of manufacturing orders, is executed in Manufacturing.

ÂŠ SAP AG

TERP10

5-19

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Sales and operations planning (SOP) is a planning and forecasting module within the logistics area.

We can use SOP to help us forecast future sales, develop production plans and perform feasibility studies.

A sales plan could be developed, for example, from information in the Sales and Distribution module. We could use built-in forecasting tools to project future sales.

A production plan could be developed based on the sales plan.

The feasibility of the production plan could be checked at a rough-cut level against key resources. If necessary, we can change the plan.

We use a planning table in SOP to help us perform these functions. It resembles a spreadsheet.

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TERP10

5-20

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Standard SOP uses product groups to help in the planning process.

A product group can be thought of as a product family. It groups together products with similar planning characteristics.

A product group may have other product groups as its members. For example, product group 1 has product group A and product group B as its members. The lowest product group in the hierarchy must have materials as its members.

Product groups require a proportion factor. This is used when a sales plan or a production plan at a higher level is "disaggregated" to a lower level. The sum of the proportion factors at one planning level is usually 100%. A proportion factor could be zero.

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TERP10

5-21

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 SAP AG 2004

The SOP planning table is where we develop our sales and production plans. A planning table exists for all members of the product group hierarchy.

The standard SOP planning table has a row for the sales plan, the production plan, the stock level (system calculated), the target stock level, the days’ supply (system calculated) and the target days’ supply.

The time periods in the planning table could be days, weeks or months, or a combination. We also may define other time periods that correspond, for example, to accounting periods or sales periods.

A sales plan can created several ways: " By transferring data from the sales information system (SIS) " By transferring data from the controlling / profitability analysis module (CO/PA) " By using history to forecast future sales " By transferring data from another product group " By manual entry

Once a sales plan is developed, a production plan can be created based on the sales plan. A production plan can be created several ways: " Synchronously to sales (Equal to sales plan) " Target stock level " Target days supply " Inventory to Zero (reduces inventory on-hand to zero balance and then plans equal to sales plan) " Manual entry

TERP10

5-22

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Creating a sales plan or a production plan at one level of the product structure hierarchy does not automatically create lower level plans. To do this, we must disaggregate.

Many options exist when disaggregating. We could, for example, disaggregate the production plan of product group 1.

Another option is to disaggregate the sales plan of product group 1. It would become the sales plan for product groups A and B. Now we would develop production plans at this level, and disaggregate them to the materials.

Yet another option is to simply disaggregate the sales plans of all the product groups down to the materials, and develop production plans at that level.

We can transfer planning data of all members of a single level product group (such as product group A) to demand management. We could also transfer planning data for one material (such as T-F101) to demand management. After this, planned independent requirements exist in demand management.

We can have different planning scenarios for each product group structure, because each plan is saved with a version number and a description. Only one version is considered active, which is the default version A00. We may transfer the active version, or an inactive version, to demand management.

The plan that is sent to demand management is used in planning the material requirements.

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TERP10

5-23

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ďŁŠ SAP AG 2004

Demand Management pertains to the administration of so-called independent requirements. The way in which independent requirements behave in Material Requirements Planning (for example, if they affect requirements, if they consume other requirements) can be determined by their requirement type or their planning strategy.

Planned independent requirements are warehouse requirements that can be derived from a forecast of the future requirement situation. In make-to-stock production, you want to initiate the procurement of the materials concerned, without having to wait for concrete sales orders. Using such a procedure, delivery times can be shortened on the one hand, and on the other hand, it is possible, through foresighted planning, to debit oneâ&#x20AC;&#x2122;s own production resources as evenly as possible.

Sales orders (customer independent requirements) are created by sales and distribution. Customer requirements can be received directly in Material Requirements Planning, independently of their defined requirements type. This is desired when customer-specific planning takes place.

Sales orders can serve as exclusive requirements sources, for which procurement is then specifically triggered (make-to-order production), or, together with planned independent requirements, they can create the total demand. Consumption is also possible with planned independent requirements.

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TERP10

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The slide shows the Demand Planning cycle: Past sales order quantities form a basis for the forecasting of future demands. In addition, market intelligence or one-off events (such as trade fairs) can be included in the forecast. As a result of the forecast, the demand plan is released as a planned independent requirement. Planned independent requirements form a basis for procurement and production planning and can, for example, consume the current sales orders.

ÂŠ SAP AG

TERP10

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Sales orders are created in Sales and Distribution (SD). They portray an order made by a customer, whereby a certain quantity of a product is required by a predetermined date. Sales orders represent a requirement in the supplying plant.

Make-to-stock planning is realized in a DC or a production plant via planned independent requirements. Planned consumptions are thus forecast. Procurement takes place as a result of this planning and forecast. Ideally, if concrete requirements subsequently exist (in the form of sales orders or dependent requirements, for example), these can be met from the warehouse.

ÂŠ SAP AG

TERP10

5-26

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ďŁŠ SAP AG 2004

A multitude of posibilities are available for planning for production with the help of planned independent requirements. The different mode of action of planned independent requirements is controlled by the so-called planning strategy.

If strategies are used for make-to-stock production, production usually takes place, without sales orders already having to be present for the material concerned. If sales orders are then received, these can be met by warehouse stock, so that shorter delivery times can be realized. Moreover, in make-to-stock production, it is possible to realize as consistent a production process as possible, independent of current demand.

Make-to-stock production can also be executed for assemblies. In this case, the finished products themselves are not produced to stock; rather the necessary assemblies are procured. A sales order for a finished product can then usually be fulfilled quickly, as it is only final assembly that has to be executed since the assemblies already exist.

Sales-order based production does not deal with planning in its actual sense; rather a product is procured for an existing sales order. Make-to-order production is often used in connection with subassembly planning for components, to keep delivery times as short as possible.

ÂŠ SAP AG

TERP10

5-27

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ďŁŠ SAP AG 2006

In planning with final assembly, a flexible or fast reaction to customer demand is prominent, whereby as smooth as possible a production process is also simultaneously strived for. Sales orders affect requirements and consume planned independent requirements.

The procurement and production of all components and assemblies including their final assembly is triggered by planned independent requirements before sales orders arrive.

You plan the planned independent requirements for the finished product in demand management. Incoming sales orders consume these planned independent requirements.

If customer requirements exceed planned independent requirements, the system automatically creates a planned order for the unplanned quantity in the next MRP run. (Sales orders thus affect requirements).

You can check availability from a sales order using the ATP logic.

The consumption of planned independent requirements by customer requirements depends on the settings defined for the consumption mode and the consumption periods.

ÂŠ SAP AG

TERP10

5-28

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ďŁŠ SAP AG 2006

The consumption mode determines the direction on the time axis in which the arriving sales orders are to consume the planned independent requirements.

In backward consumption (consumption mode 1), the sales order consumes planned independent requirements that lie before the customer requirement.

In forward consumption (consumption mode 3), the sales order consumes planned independent requirements that lie after the customer requirement.

You can combine backward and forward consumption provided that you take the consumption periods into account (consumption mode 2 or 4).

You can define the consumption mode and the consumption periods either in the material master or for each MRP group. If no values for either consumption mode or consumption period have been entered, then the system uses the default setting with backward consumption for 999 days (Note: If a consumption mode has been entered and the consumption period is left blank, only requirements on the same day are consumed).

ÂŠ SAP AG

TERP10

5-29

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The purpose of Master Production Scheduling (MPS) and Material Requirements Planning (MRP) is to guarantee material availability on a two step planning process.

MPS is an optional step in the planning process.

Master scheduled items (MPS items) are usually materials that greatly influence company profits or dominate the production procedure. The general idea is to schedule these products first resolving any capacity, etc. problems and then execute MRP for the remaining product levels.

SAP provides a variety of functions to support master production scheduling, including a graphical planning table and a whole series of evaluation reports.

The MPS run results in planned orders for the master schedule items and dependent requirements for the level directly below the MPS items.

ÂŠ SAP AG

TERP10

5-30

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ďŁŠ SAP AG 2006

The basic planning type is defined per material using the MRP type, that is entered in the MRP 1 view of the material master. Planning of a material can be MRP or consumption-based. A material can also be excluded from MRP using the corresponding MRP type.

Material requirements planning takes current and future sales as its reference point and is executed for the whole BOM structure. The planned requirements quantity (in the form of planned independent requirements or sales orders) triggers requirements calculation.

Consumption-based planning is based on consumption values in the past and uses forecast or statistical procedures to determine future requirements. Consumption-based planning is characterized by its simplicity and is mainly used for "B and C parts", or in other words, those with low values.

ÂŠ SAP AG

TERP10

5-31

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ďŁŠ SAP AG 2004

Manual reorder point planning is a typical process in consumption-based planning. It is characterized by its simplicity.

Consumption-based planning procedures use past consumption data (historical data) to calculate future requirements with the help of the material forecast or static planning procedures. Consumption-based planning procedures have no reference to the master plan. This means that the net requirements calculation is not triggered by an independent or a dependent requirement. Instead, the net requirements calculation is triggered when stock levels fall below a reorder point or by forecast requirements calculated from past consumption data.

You control the planning using a manually entered reorder point (for example, 50 pieces). During the planning run, the system checks only whether stock has fallen below this reorder point or not (that is, whether there are less than 50 pieces in stock). If that is the case, the system triggers procurement to the amount of the lot size (a fixed lot size of 500 pieces for example).

If schedule lines are created directly by the planning run, for example, for materials procured externally, the administrative work for this sort of planning is minimal.

Reorder point planning is appropriate only for materials with demand that stays relatively consistent. Real-time inventory management is also necessary.

ÂŠ SAP AG

TERP10

5-32

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ďŁŠ SAP AG 2004

If MRP discovers shortage quantities, procurement proposals are generated: purchase requisitions and planned orders are internal planning elements which can be changed, rescheduled or deleted at any time.

In the case of in-house production, the system creates planned orders for the planning of production quantities. When planning is complete, plannned orders can be converted into production orders.

In the case of external procurement, the system creates either a planned order, or directly creates a purchase requisition, or a schedule line for a pre-existing scheduling agreement for planning the external purchase order quantity. When planning is complete, planned orders can be converted into purchase requisitions and, at a later date, the purchase requisitions can be converted into purchase orders.

You control whether the system immediately creates purchase requisitions or firstly creates planned orders for externally procured materials in the initial screen of the planning run using the "creation" indicator for purchase requisitions.

If a scheduling agreement exists for a material and is relevant to MRP in the source list, then you can also create schedule lines directly in MRP. You control this using the creation indicator for schedule lines in the initial screen of the planning run.

ÂŠ SAP AG

TERP10

5-33

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MRP can be executed as total planning for all materials or as individual planning.

The task of individual planning is to plan a material separately (for example, interactively), whereas multilevel individual planning takes place over all BOM levels of this material. In single-level planning it is only the header material that is planned. In multilevel planning, dependent requirements are thus also planned.

Secondary requirements that arise from the planning of a finished product’s BOM components, are set via secondary requirements, that arise from the explosion of a material’s BOM. Dependent requirements depend on respective planned orders. Materials (assemblies) are needed to realize these planned orders.

If a planned order is converted into a production order, the dependent requirements are transferred to order reservations.

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5-34

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ďŁŠ SAP AG 2004

In MRP, a net requirements calculation is also executed in the planning run to determine whether a material shortage exists for a certain material. In addition, stock and fixed receipts that currently exist (purchase orders, production orders, fixed purchase requisitions and planned orders...) are compared with the safety stock and requirements. The result of this comparison is the quantity available for planning.

If the quantity available for planning is lower than zero, a material shortage exists. MRP reacts to material shortages by creating new procurement proposals, that is, by creating purchase requisitions or planned orders, independently of their procurement type. The suggested procurement quantity results from the lot-sizing procedure, that is set in the material master.

ÂŠ SAP AG

TERP10

5-35

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ďŁŠ SAP AG 2004

MRP uses backward scheduling - the system calculates the necessary start dates based on a predefined end date.

MRP reacts to the requirements needed for the finished product (a sales order, for example) Procurement proposals are created for the finished product and dependent requirements for the components are calculated via the BOM explosion. The dependent requirements date arises from the start date of the planned order that caused the requirements.

Assuming the dependent requirements date is the availability date, the system determines the basic order dates of the components by means of backward scheduling using in-house production time or planned delivery time.

ÂŠ SAP AG

TERP10

5-36

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You can carry out the planning run on two levels: as total planning for a plant or for an individual material. It is thus possible to execute a total planning run for several plants and/or MRP areas.

You can execute a single-item planning run either for a specific material only (single level) or for all BOM levels (multi level). Interactive planning of a material is also possible.

A total planning run can be executed online or as a background job.

Total planning for a plant encompasses all materials relevant to MRP for this plant and includes the BOM explosion for materials with BOMs.

From the MRP menu, you can execute total planning "Online" or "As background job". In order to execute the total planning run as a background job, you select a report variant limiting it to the corresponding plant and plan the job.

A user exit enables you to limit the total planning run specifically to those materials which fulfill freely definable criteria. You can use this, for example, to select all the materials belonging to a particular MRP controller.

ÂŠ SAP AG

TERP10

5-37

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ďŁŠ SAP AG 2004

During regenerative planning, the system plans all materials of a plant. This is practical when carrying out the planning run for the first time and on rare occasions when, due to technical errors, the consistency of the data cannot be guaranteed.

In a working plant, it usually makes sense (especially when you are using many materials) to only carry out MRP for those materials that have undergone MRP-relevant changes (through goods issues, new sales orders, changes to the BOM struscture, for example). Due to its short run-time, net change planning - which is used to plan these materials only - enables you to carry out the planning run in short time intervals, so that you can always work with the current planning result.

During net change planning in the planning horizon, the system only takes changes within the planning horizon into account. The system plans only those materials that have been subject to an MRP-change within the planning horizon. The materials are planned within this horizon only.

You set the planning horizon in Customizing for MRP as a plant or MRP group parameter. The planning horizon should at least span the time period in which sales orders are received, and, furthermore, contain the delivery and total lead times for the material.

You specify the type of planning run via the "processing key" field in the initial screen for planning. In single-item planning, you are only able to differentiate whether "net change planning" (NETCH) or "net change planning in the planning horizon" (NETPL) is to be performed. In total planning, you also have the option of using the key NEUPL, with which all materials in the planning file are planned.

ÂŠ SAP AG

TERP10

5-38

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ďŁŠ SAP AG 2006

The following control parameters for MRP are required for the planning run:

Processing key: You define the planning type as regenerative planning or net change planning over the whole period or restricted to the planning horizon.

The indicators "Create purchase requisition" and "Schedule lines" are only relevant for materals that are procured externally. You can determine whether or in which period purchase requisitions and schedule lines are required as the result of the planning run.

You can determine further whether the planning run is to generate MRP lists. It is also possible to have the system generate MRP lists only when certain exception messages have appeared for a material (the exception messages that should trigger an MRP list to be generated can be defined in the Customizing IMG activity "Define and group exception messages").

The planning mode defines whether the existing planning data should simply be adjusted, whether BOMs and routings should also be re-exploded or whether the planning should be started from the very beginning again.

You can also set the creation indicator for purchase requisitions, schedule lines and MRP lists in the MRP group. The materials that are assigned to this MRP group are then planned accordingly in the total planning run.

ÂŠ SAP AG

TERP10

5-39

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The current stock / requirements list contains up-to-date information on the current status of stocks, requirements and receipts. You are able to view any changes immediately. This can be done as soon as the current stock / requirements list is called up or, upon displaying the current stock / requirements list, the elements are re-read from the database using the "Refresh" function.

The MRP list depicts the result of the latest planning run and is therefore static: Changes that are made after the planning run cannot be seen. You can control whether or not an MRP list is generated during the planning run.

The basic structure of both lists is the same: # Links are in the form of a tree for the worklist of the MRP controller. # Above the list is the header with the material number. You can display additional data in the header details. # The list itself contains the individual MRP elements and the corresponding available quantities.

User-specific settings enable you to adapt the lists to personal requirements - these apply to both lists (see the corresponding Customizing documentation in the evaluations for MRP "Configure MRP list / stock/requirements list"). You can display additional data, which can then be accessed using a function key, over a customer exit (see Customizing, "Customer-Exit: Program additional columns")

ÂŠ SAP AG

TERP10

5-40

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Planned orders are used to plan the in-house production of a material. Planned orders already contain the basic dates within which production should take place. Moreover, they contain, in the form of dependent requirements, the component requirements for the components that are needed for production. Capacity Requirements Planning can be executed based on planned orders.

For the ultimate execution of production, the planned order is converted into a production order, that is, a production order (PP) or a process order (PP-PI).

ÂŠ SAP AG

TERP10

5-41

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For externally procured materials, planning of procurement can take place by means of planned orders or purchase requisitions. If planned orders are created at first, they have to be converted into purchase requisitions. Planning is also directly possible with scheduling agreement releases.

In purchasing, purchase requisitions are converted into purchase orders. No later than this step should a source of supply (a supplier) assigned to purchase orders .

ÂŠ SAP AG

TERP10

5-42

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ďŁŠ SAP AG 2004

Each step in the production planning process corresponds to a different material planning level. Each planning level provides input to the next level.

ÂŠ SAP AG

TERP10

5-43

!"#$%&"'()'"**&*+,(-./&0(1233"%4

D.2("%$(*.<(":'$(#., ! 56/'"&*(#7$(&3/.%#"*0$(.8(/'"**&*+(9#%"#$+&$9(.*( :29&*$99(/%.0$99$9 ! 56/'"&*(#7$(;&88$%$*0$(:$#<$$*(!"#$%&"'9( =$>2&%$3$*#9()'"**&*+("*;(?.*923/#&.*( @"9$;()'"**&*+(/%.0$;2%$9( ! A$90%&:$("*;(/$%8.%3(#7$(9#$/9(&*(#7$(!"#$%&"'( )'"**&*+(/%.0$99 ! B;$*#&84(#7$(&*#$+%"#&.*(/.&*#9(<&#7(!"#$%&"'9( !"*"+$3$*#("*;(1"'$9(C%;$%(!"*"+$3$*#(

 SAP AG 2004

TERP10

5-44

!"#$%&"'()'"**&*+,(-*&#(./00"%1

E+4).,#)$+;).50#)%+F ! !"#$%&'()%*#)+,-.$&/.%&+$.0)0#1#02).$")3.2%#,)".%.) 42#)5()3.%#,&.0)60.$$&$-7) ! 8960.&$)%*#)"&''#,#$:#)5#%;##$)<.%#,&.0) =#>4&,#3#$%2)?0.$$&$-).$")@+$2436%&+$) A.2#")?0.$$&$! !"#$%&'()%*#)B#()&$%#-,.%&+$)6+&$%2);&%*)+%*#,) 3(CD? 8=?)6,+:#22#2

 SAP AG 2006

TERP10

5-45

TERP10

5-46

!"#$%&'($(! )*'+,!-.+$%'./!0/.**'*1! 234'&,!-.(+$%!5.+.! At the conclusion of this exercise, you will be able to: • Describe the organizational levels and views of the material master • Display the material master • Display a single-level bill of material • Display a multi-level bill of material Pumps with the material number R-F1## are produced in Plant 1000. You want to view the material master record and the bill of material to familiarize yourself with the production planning process. 1-1

Display the material master for pump 6789::. To do this, use the transaction for displaying material masters. You can call this transaction from the production master data menu. 1-1-1 When you call the transaction, enter material number 6789::. In the dialog box, select !"#$%&'"("&). Fill in the table below with the values you see on the !"#$%&'"("&)&view. Description Base unit of measure Net weight Unit of weight 1-1-2 What is the material type? __________

TERP10

5-47

1-2

Display other views of !"#$%%. Choose !"#"$%&'(")*+, then select -./&01&2345& !$6"78#(9:1&;$$389%(9:&< in the dialog box. 1-2-1 The system asks you to enter organizational level data before proceeding. This screen did not appear when you only wanted to see basic data. Why does it appear now? ______________________________________________________ Enter Plant 1000. 1-2-2 MRP 2 view. What value is assigned to the procurement type field? __________________ Access field level help for the procurement type field. What is the meaning of procurement type? ______________________________________________________ Close the help window. What are the possible entries for procurement type? __________ 1-2-3 Work Scheduling view. What value is assigned to the production scheduler field? __________ What is the total lot size dependent in-house processing time? __________(days) per __________(PC) 1-2-4 Accounting 1 view. What value is assigned to the price control field? __________ What is the moving price? __________ What is the standard price? __________ What is the currency of these prices? __________ Exit the material master record.

1-3

ÂŠ SAP AG

TERP10

5-48

1-4

Display the material BOM for !"#$%% in Plant $&&&, BOM usage $'(production). You can find the corresponding transaction in the Master Data under Production. When you call the transaction, enter the material, the plant $&&&, and usage $. Choosing !"#$% takes you to the item overview. 1-4-1 What is the component number of item 0010? ________________________________________________ 1-4-2 What is the component quantity and unit of measure? __________ 1-4-3 Is this component a stock item? __________ 1-4-4 Will this component be valid in the bill on January 1, 2007? __________ 1-4-5 Does a bill of material exist for this component? __________

1-5

Display the material BOM for component !"($%%. 1-5-1 What is the valid from date of this bill of material? __________ 1-5-2 What is the base quantity and unit of measure of this bill of material? ______________________________________________________ 1-5-3 Exit the BOM.

1-6

Display a multi-level BOM explosion report for pump !"#$%%, plant $&&&. Use BOM application ))&$. Write the component numbers, component quantities and units of measure of the multi-level pump bill of material in the boxes below. This will be useful as a reference in future exercises. 1-6-1 How many single level BOMs are in this structure? __________ *+,+-'

ÂŠ SAP AG

./01/2+23'

TERP10

45623738'

9273'/:' ;+6<5=+'

5-49

TERP10

5-50

!"#$%&'($)*#(+&,+(""#"-& ./0#1%&'($)*#(+&,+(""#"-&,*/1)22& At the conclusion of this exercise, you will be able to: • Create a product group • Create a sales plan • Create a production plan • Perform a single-item, multi-level MRP run for our pump. • Review the results of the plan • Enter a customer order for our pump. • Confirm that consumption process takes place Marketing has supplied you with their updated six month sales forecast for the redesigned pump. You will create a product group that includes the redesigned pump, as well another popular pump. You will use the Sales and Operations Planning module to enter the forecast. Then you will create a production plan for RF1##. In this scenario you will do planning using the make-to-stock strategy Planning with Final Assembly. In this planning strategy sales orders entered consume the forecast. After transferring the planned independent requirements to Demand Management, you will then run MRP. MRP creates the manufacturing plan. To determine if sales orders consume the forecast, you will enter a customer order, for the pump. You will then re-run MRP to see if it adjusts the plan. 2-1

The pumps are planned using sales and operations planning. Management plans all pumps overall as one product group. The product group will consist of products R-F1## and R-F2##. 2-1-1 Create the product group GR## for the pumps. Enter the following data on the initial screen

3#)+4&

5($(&)"$*6&

Product Group

GR##

Description

Group ## Pumps

Plant

1000

Base Unit

Members

Select the “Materials” radio button. TERP10

5-51

!"#$%! On the Create Product Group: Maintain Members (Materials) screen, enter the material numbers R-F1## and R-F2## in the !"#$"%&'(#$"% field, and plant number 1000 in the )*+', field. Assign a proportion factor of 60% to R-F1## and 40% to R-F2##. &'($) ! 2-2

Create a sales and production plan for Product Group Gr##. 2-2-1 On the -%"+,"&)*+'.&/'0,0+*&12%""', enter product group GR## and plant 1000, then choose the enter icon. 2-2-2 In the dialog box that appears that results, enter 7## in the version number and â&#x20AC;&#x153;Version 7##â&#x20AC;? in the version description, and then select the enter icon to get to the -%"+,"&34(567-(,&)*+'&82%""'. 2-2-3 Create a sales plan. Starting with the second month into the future (i.e., if this is September, the second month into the future is November), enter the following information into the sales row of the planning table: "#$%&!

'()*+!,()-*!

Month + 2

200

Month + 3

150

Month + 4

100

Month + 5

150

Month + 6

200

Month +7

175

2-2-4 Due to uncertainty of market demand, management wants to maintain a service level of 3 days inventory supply. To indicate this in your plan, enter 3 into the 9+%5",&:+;8<&8(==*; field for each month of the plan beginning with the second month in the future. !"#$%! 2-2-5 Create the production plan for product group GR## based on the sales plan and desired target inventory level. &'($) !

ÂŠ SAP AG

TERP10

5-52

2-3

Disaggregate the production plan for the product group and transfer the product plans for R-F1## and R-F2## to Demand Management for use in detailed production planning. 2-3-1 Enter the following data on the Transfer Planning Data to Demand Management screen: !"#$%&

'($)#&

Product Group

GR##

Plant

1000

Version

7##

Prod. Plan for mat. or PG members as a proportion of PG

Selected

From Date

Todayâ&#x20AC;&#x2122;s date

Invisible Transfer

Not selected

Active Indicator

Selected

& 2-3-2 Execute the transfer by clicking on the Transfer Now button. 2-3-3 By deselecting the Invisible Transfer indicator the disaggregation results are presented on another screen allowing the planner to modify the results before saving them manually to demand management. Review the results for R-F1## and then Save. The results for R-F2## are displayed. Save the results for R-F2##. 2-3-4 Display the Stock Requirements list for *+!,--, plant ,.... Examine the results. Are the planned independent requirements covered by planned orders?

ÂŠ SAP AG

TERP10

5-53

2-4

Run MRP for the complete bill of material for pump !"#$%% in plant $&&&. Use the following data:

2-5

Processing key

'()*+

Create purchase req.

Delivery Schedules

Create MRP list

Planning mode

Scheduling

Also Plan Unchanged Components

./0/1/23

Display results before they are saved

./0/1/23

Display material list

./0/1/23

Simulation mode4

./0/1/23

Display the MRP list for !"#$%%, plant $&&&. Examine the results. 2-5-1 Are all the independent requirements covered by planned orders? __________ 2-5-2 What is the number of the first planned order? 2-5-3 Select the !"#$%&'()$&)*'&)+$,-. icon to see further planning information for this material.

2-6

Compare the stock / requirements list to the MRP list. 2-6-1 Do differences exist between the two lists? __________ 2-6-2 Why? ________________________________________

2-7

Display the stock / requirements list for !"5$%%, plant $&&&. What planned order created the first dependent requirement in the list? Is it the same planned order from exercise 2-5-2? _______________________________

ÂŠ SAP AG

TERP10

5-54

2-8

You want to determine if sales orders consume demand, therefore, enter a sales order for your pump, !"#$%%. On the Create Sales Order: Initial Screen, use the following data: Order type

&!'

Sales organization

$(((

Distribution channel

Division

((

On the Create Standard Order: Overview screen, enter the order information: Sold-to party

$(((

Ship-to party

$(((

PO number

)&"%%'

Req. deliv. date

*+,'$-'./'0.12345

Material

!"#$%%

Order quantity

What is the sales order number? __________ 2-9

Display the MRP 3 view of the material master for !"#$%% in plant $(((. 2-9-1 What consumption mode is assigned to this item? __________ 2-9-2 What is the backward consumption period? __________ 2-9-3 What is the forward consumption period? __________

2-10

Display the stock / requirements list for !"#$%%'in plant $(((. Did consumption take place correctly? __________

2-11

Run MRP again, for the complete bill of material for pump !"#$%% in plant $(((. Use the same parameters from exercise 2-4.

2-12

Compare the MRP list (or the stock / requirements list) of !"#$%% in plant $((( to the values you recorded in exercise 2-10. 2-12-1 Has the plan changed? __________ 2-12-2 How? ________________________________________________

ÂŠ SAP AG

TERP10

5-55

TERP10

5-56

!"#$%&'#()! *('&+!,-&./'-$!0$-(('(1!! 2#3'4+!,-)&./!5-&-! 1-1

!"#$%&$'%(!()*"+,'&$"-(!(./%&0*(1/&/(!(./&0*$/2(./%&0*(!(./&0*$/2(!( 1$%32/4(!(1$%32/4(5,**0-&((;,,<=>!

1-1-1 When you call the transaction, enter material number 6789::. In the dialog box, select !"#$%&'"("&). Fill in the table below with the values you see on the !"#$%&'"("&)&view. Description

),63(

Base unit of measure

)5(73$0'07%88(

Net weight

9:;(

Unit of weight

<=(

1-1-2 What is the material type? >$-$%?0+()*"+,'&! @?0(6/&0*$/2(&430($%(+$%32/40+($-(&?0(@$&20(A/*("-(&?0(%'*00-! B020'&(&?0(A/'C($'"-(&"(#"(D/'C(&"(&?0(E-$&$/2(%'*00-F( ! 1-2

Display other views of 6789::. Choose *+,+%(&-$+./#0 then select 123&45&6789& *%:+;<,$=>5&?%%7<=($=>&) in the dialog box. 1-2-1 The system asks you to enter organizational level data before proceeding. This screen did not appear when you only wanted to see basic data. Why does it appear now? @?0%0(G$0H%(/*0()2/-&(%30'$I$'J(&?0*0I"*0K(4",(6,%&(0-&0*(/()2/-&F((! Enter plant 1000. 1-2-2 MRP 2 view. What value is assigned to the procurement type field? L(7E-M?",%0(3*"+,'&$"-8! Access field level help for the procurement type field. What is the meaning of procurement type?

ÂŠ SAP AG

TERP10

5-57

!"#$%&'()%*()+')%,-.*/0%'1%#$/%,)'*()/2/1#%#&,/%3"/-04%.**/++%3"/-0%-/5/-% $/-,%6789:! ;$/%"10"*.#')%#$.#%0/3"1/+%$'<%#$/%2.#/)".-%"+%,)'*()/0:! Close the help window. What are the possible entries for procurement type? !"#$%&'()%*()+')%,-.*/0%'1%#$/%,)'*()/2/1#%#&,/%3"/-04%.**/++%,'++"=-/% /1#)"/+%67>9:! ?4%74%=-.1@4%A:%%! 1-2-3 Work Scheduling view. What value is assigned to the production scheduler field? BCC%%! What is the total lot size dependent in-house processing time? D/#(,%#"2/%%

%%%%:BE%0.&+%!

F)'*/++"1G%#"2/% %

HB:H>%0.&+!

I1#/)',/).#"'1%

%J:E%0.&!

K.+/%L(.1#"#&%%

8BB%,*!

;'#.-% %

H>:HJ%0.&+%,/)%8BB%,*!

MM)/+(-#+%2.&%5.)&! 1-2-4 Accounting 1 view. What value is assigned to the price control field? D%6D#.10.)0%,)"*/9 What is the moving price? "#$%&'(!)*$!&+#,-.&!/01230!-&$!4!-%&5&! What is the standard price? "#$%&'(!)*$!&+#,-.&!/64276!-&$!4!-%&5&! What is the currency of these prices? ?NO! ?P"#%#$/%2.#/)".-%2.+#/)% !

ÂŠ SAP AG

TERP10

5-58

1-3

For pumps R-F1## and R-F2##, it is important to be able to deliver sales orders quickly. Since production of the pumps takes a certain amount of time, it must be planned in advance. This means that production of the pumps should take place before any sales orders are received. Production of the pumps, should be planned using planning with final assembly. Therefore change the strategy group, in the MRP3 view, of R-F1## and R-F2##, to strategy group 40-Planning with final assembly. !"#$%&$'%(!()*"+,'&$"-(!(./%&0*(1/&/(!(./&0*$/2(./%&0*(!(./&0*$/2(!( 34/-#0!(5660+$/&027(!""#$%& Material '()*++. Choose !"#"$%&'(")*+, then select -./&0 in the dialog box. Enter plant 1000. In the strategy group field maintain a value of 40 (planning with final assembly). Save the material master record.

1-4

Display the material BOM for '()*++ in Plant *###, BOM usage *&(production). You can find the corresponding transaction in the Master Data under Production. When you call the transaction, enter the material, the plant *###, and usage *. Choosing 12%"3 takes you to the item overview. • (

!"#$%&$'%(!()*"+,'&$"-(!(./%&0*(1/&/(!(8$22%("9(./&0*$/2!(8$22("9( ./&0*$/2!(./&0*$/2(8:.((!(1$%;2/7(!,-#.%&

1-4-1 What is the component number of item 0010? <=8>??& 1-4-2 What is the component quantity and unit of measure? >()3& 1-4-3 Is this component a stock item? @0%(=(53&(A5&06('/&0#"*7B(C/2,0($%(!(A%&"'D($&06B& 1-4-4 Will this component be valid in the bill on January 1, 2007? @0%(AE/2$+(,-&$2(10'06F0*(G>H(IIIIB& 1-4-5 Does a bill of material exist for this component? @0%(=(J%6(AJ%%06F27B($-+$'/&"*($%('40'D0+( & 1-5

Display the material BOM for component '(/*++. • (

!"#$%&$'%(!()*"+,'&$"-(!(./%&0*(1/&/(!(8$22%("9(./&0*$/2!(8$22("9( ./&0*$/2!(./&0*$/2(8:.((!(1$%;2/7(!,-#.%&

:*(7",('",2+(+",F20='2$'D("-(&40(/%%06F27($-+$'/&"*('40'D(6/*D("-(&40(6/&0*$/2( $&06("C0*C$0K(%'*00-("9(<=L>??(/-+(%020'&(,0123145M(34""%0(657859&$'"-M& 1-5-1 What is the valid from date of this bill of material? NGONPOQNNQ& 1-5-2 What is the base quantity and unit of measure of this bill of material? >()3& >=R=G( ST$&(&40(8:.M © SAP AG

TERP10

5-59

1-6

Display a multi-level BOM explosion report for pump !"#$%%, plant $&&&. Use BOM application ''&$. â&#x20AC;˘ (

!"#$%&$'%(!()*"+,'&$"-(!(./%&0*(1/&/(!(2$33%("4(./&0*$/3(!(506"*&$-#(!( 27.(8963"%$"-(!(./&0*$/3(27.(!(.,3&$30:03(27.(()*$+,-

On the initial screen enter the following data: #./01-

2343-/5467-

Material

R-F1##

Plant

1000

BOM Application

PP01

;030'&(890',&0<( ( Write the component numbers, component quantities and units of measure of the multi-level pump bill of material in the boxes below. This will be useful as a reference in future exercises.

8/9/0-

):;<:5/54-

=>354.47-

?5.4-:@A/3B>6/-

1-6-1 How many single level BOMs are in this structure? =$:0!

>"&0?((@"A6"-0-&(5B=CDD(15E(FFF(FF(*040*0-'0+("-(30:03(C($%(/( +"',A0-&(GH@&(IH&0A(@/&0#"*J(K(1L(-"&(/(A/&0*$/3<((89$&(&M0(*06"*&<-

ÂŠ SAP AG

TERP10

5-60

!"#$%&'($)*#(+&,+(""#"-&& ./0#1%&'($)*#(+&,+(""#"-&,*/1)22& 2-1

(

!"#$%&$'%(!(()*"+,'&$"-(!((./)(!()*"+,'&(0*",1(!((2*34&3( 3'4567&

Enter the following data on the Create Product Group: Initial screen: 8#)+9&

:($(&)"$*;&

Product Group

GR##

Description

Group ## Pumps

Plant

1000

Base Unit

Members

Select the “Materials” radio button.

5-&3*& On the !"#$%#&'"()*+%&,"(*-.&/$01%$01&/#23#"4&5/$%#"0$647 screen, enter the material numbers R-F1## and R-F2## in the /#23#"&1*23#" field, and plant number 1000 in the '61% field. Assign a proportion factor of 60% to R-F1## and 40% to R-F2##. .463( & 2-2

Create a sales and production plan for Product Group Gr##. • (

!"#$%&$'%(!()*"+,'&$"-(!(./)(!()74--$-#(!(8"*()*"+,'&(0*",1(!(2*34&3( 3'45<7&

2-2-1 On the !"#$%#&'6$1.&810%0$6&9+"##1, enter product group GR## and plant 1000, then choose the enter icon. 2-2-2 In the dialog box that appears, enter 7## in the version number and “Version 7##” in the version description, and then select the enter icon to get to the !"#$%#&:(*;<=!*%&'6$1&screen. 2-2-3 Create a sales plan. Starting with the second month into the future (i.e., if this is September, the second month into the future is November), enter the following information into the sales row of the planning table:

TERP10

5-61

!"#$%&

'()*+&,()-*&

Month + 2

200

Month + 3

150

Month + 4

100

Month + 5

150

Month + 6

200

Month + 7

175

2-2-5 Due to uncertainty of market demand, management wants to maintain a service level of 3 days inventory supply. To indicate this in your plan, enter 3 into the !"#$%&'(")*+'*,--.) field for each month of the plan beginning with the second month in the future. !"#$%& 2-2-5 Create the production plan for product group GR## based on the sales plan and desired target inventory level. •

!&'#(!()%$*#$(+%,&-.#"(+/*"(!&0*%1$#(&*234(3-++/2&

5*6$( & 2-3

Disaggregate the production plan for the product group and transfer the product plans for R-F1## and R-F2## to Demand Management for use in detailed production planning. • (

7,1'3#'.3(!(8%,&-.#',"(!(598(!(:'3*11%$1*#',"(!(0%*"3;$%(8%,&-.#( <%,-+(#,(8/*""'"1(.!/012&

2-3-1 Enter the following data on the Transfer Planning Data to Demand Management screen: 34*)5&

6()-*&

Product Group

GR##

Plant

1000

Version

7##

Prod. Plan for mat. or PG members as a proportion of PG

Selected

From Date

Today’s date

Invisible Transfer

Not selected

Active Indicator

Selected

& 2-3-2 Execute the transfer by clicking on the Transfer Now button. =,-(>'//(1$#(*(>*%"'"1(?$33*1$(@8/*""'"1(A$%3',"(#,(B$(0%*"3;$%%$&('3( ",#(#C$(*.#'6$(6$%3',"D(5$/$.#($"#$%(#,(./$*%(#C$(>*%"'"1(?$33*1$(*"&( +%,.$$&(>'#C(#C$(&*#*(&'3*11%$1*#',"(*"&(#%*"3;$%E& © SAP AG

TERP10

5-62

2-3-3 By deselecting the Invisible Transfer indicator the disaggregation results are presented on another screen allowing the planner to modify the results before saving them manually to demand management. Review the results for R-F1## and then Save. The results for R-F2## are displayed. Save the results for R-F2##. !"#$%&'%('")#*+%#$%,-.*#/0#*+%#*$1",0%$#2/-#('..#"/*'3%#*+%#456#/0#*+%# 7$/8-3*#)$/-7,#7$/8-3*'/"#7.1"#+1,#9%%"#1,,')"%8#*/#7$/8-3*#:;<=>>#1"8# ?56#*/#:;<@>>A! 2-3-4 Display the Stock Requirements List for "#$%&&, plant %'''. Examine the results. • #

B/)',*'3,#!#C$/8-3*'/"#!#D:C#!#E&1.-1*'/",#!#F*/3GH# :%I-'$%J%"*,#B',*##()*'+,!

Are the planned independent requirements covered by planned orders? K/#L#9%31-,%#D:C#+1,#"/*#9%%"#$-"A# 2-4

Run MRP for the complete bill of material for pump "#$%&& in plant %'''. • B/)',*'3,#!#C$/8-3*'/"#!#D:C#!#C.1""'")#!F'").%;!*%JM#D-.*';B%&%.# # ()*'-,! Use the following data: Processing key

./012

Create purchase req.

Delivery schedules

Create MRP list

Planning mode

Scheduling

Also Plan Unchanged Components

*4546478

Display results before they are saved

*4546478

Display material list

*4546478

Simulation mode!

*4546478

Choose E"*%$!and confirm your input parameters, then choose E"*%$ again to start MRP. When MRP is finished, a results screen should appear. EN'*#*+%#$%,-.*,# ! 2-5

Display the MRP list for "#$%&&, plant %'''. Examine the results. •

B/)',*'3,#!#C$/8-3*'/"#!#D:C#!#E&1.-1*'/",#!#D:C#.',*#()*'9,!

2-5-1 Are all the independent requirements covered by planned orders? O%,! 2-5-2 What is the number of the first planned order? P1$'%,#0/$#%N1J7.%#Q=QR?! 2-5-3 Select the EN71"8#+%18%$#8%*1'., icon to the left of the material in the header to view further planning information for this material. © SAP AG

TERP10

5-63

2-6

Compare the stock / requirements list to the MRP list. •

!"#$%&'(%)*+%,-.&%.(,(/&%0#&#%!%1&#/23"(45-"($(6&.%,-.&%/#$78"-.#6%!

2-6-1 Do differences exist between the two lists? 9#%%! 2-6-2 Why? 9#%7,866-6:%#"%(;(/5&-#6%8/&-<-&=%'8.%&82(6%7,8/(%#6%&'-.%$8&("-8,%.-6/(% &'(%)*+%"56>%%! ?;-&%&'(%)*+%,-.&% ! 2-7

Display the stock / requirements list for "#$%&&, plant %'''. What planned order created the first dependent requirement in the list? • @#:-.&-/.%!%+"#A5/&-#6%!%)*+%!%?<8,58&-#6.%!% 1&#/23*(45-"($(6&.%@-.&%()*'+,! On the left hand side of the first dependent requirement, select the Details%#B% (,($(6&%icon. C(.D%-&%-.%&'(%.8$(%7,866(A%#"A("%B"#$%(;("/-.(%EFGFE>%%% !

2-8

You want to determine if sales orders consume demand, therefore, enter a sales order for your pump, "#-%&&. •

@#:-.&-/.%!%18,(.%86A%H-.&"-I5&-#6%!%18,(.%!%J"A("%!%K"(8&(>%(./'%,%!

On the Create Sales Order: Initial Screen, use the following data: Order type

0"!

Sales organization

%'''

Distribution channel

Division

?6&("%%! On the Create Standard Order: Overview screen, enter the order information: Sold-to party

%'''

Ship-to party

%'''

PO number

10#&&!

Req. deliv. date

*23!%4!56!)5789:;

Material

"#-%&&

Order quantity

?6&("!

TERP10

5-64

If an information message appears concerning the invoice date choose !"#$%&to acknowledge it. If the Standard Order: Availability Control screen appears, select the '()!*#+,-.#$ indicator and then select the /0123$#$&-345 button. 6.4$5&&! What is the sales order number? 7.%($89&:0%&$).123$&;;;<= >00?&.#&#@$&A0##01&0:&#@$&8B%$$"&:0%&#@$&8.3$8&0%-$%&"C1A$%5! !)(#&#@$&8B%$$"5& ! 2-9

Display the MRP 3 view of the material master for "#$%&& in plant %'''. >0D(8#(B8&!&E%0-CB#(0"&!&F.8#$%&G.#.&!&F.#$%(.3&F.8#$%&!&F.#$%(.3&!& G(823.+&!&G(823.+&/C%%$"#&&())'*+! 2-9-1 What consumption mode is assigned to this item? H&IJ.B?K.%-&,&:0%K.%-&B0"8C12#(0"L! 2-9-2 What is the backward consumption period? MN!IK0%?-.+8L! 2-9-3 What is the forward consumption period? MN!IK0%?-.+8L! !)(#&#@$&1.#$%(.3&1.8#$%&%$B0%-5& !

2-10

Display the stock / requirements list for "#$%&&!in plant %'''. â&#x20AC;˘ &

>0D(8#(B8&!&E%0-CB#(0"&!&FOE&!&!4.3C.#(0"8&!&6#0B?,&O$*C(%$1$"#8&>(8#& (),'-+!

Did consumption take place correctly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

ÂŠ SAP AG

Run MRP again, for the complete bill of material for pump "#$%&& in plant %'''. Use the same parameters from exercise 2-4.

TERP10

5-65

2-12

Compare the MRP list (or the stock / requirements list) of !"#$%% in plant $&&& to the values you recorded in exercise 2-10. 2-12-1 Has the plan changed? !"#' 2-12-2 How? $%"&'()#*&+,-.."/&0)/")1#&23-.*(*45&'0)&60.*%&7&85&9-#&)"/3:"/&;4&<=&*0& :0>")&*%"&+,-.."/&(./"+"./".*&)"23()"6".*?&&@&."9&+,-.."/&0)/")5&9(*%&-& 23-.*(*4&0'&<=5&9-#&:)"-*"/&*0&:0>")&*%"&#-,"#&0)/")?&'

ÂŠ SAP AG

TERP10

5-66

!"#$%!&'()!*+',-#./#! 1.

Fill in the blanks to complete the sentence. A product group helps in the planning process by grouping products with

Determine whether this statement is true or false. All bills of material are created and maintained as single-level bills.

What happens when MRP determines that shortage quanitites exist for a material? _________________________________________________________

Determine whether this statement is true or false. Basic data in the material master is applicable to the entire company and is stored at the plant level.

What are the options for executing a MRP run? _________________________________________________________

Determine whether this statement is true or false. During a MRP run, the quantity of a planned order is determined by the cost of the material.

What is the difference between a regenerative MRP run and a net change MRP run? _________________________________________________________

ÂŠ SAP AG

TERP10

5-67

TERP10

5-68

!"#$%&'$! 1.

Fill in the blanks to complete the sentence. A product group helps in the planning process by grouping products with . "#$%&'(!)*+##,#-!./+'+.0&',$0,.$! The consumption-based planning procedures are generally only based on the previous consumptions of the material "#$%&'(!1'2&! As opposed to MRP, consumption-based planning procedures are only based on material consumption. External requirements such as sales orders, planned independent requirements, and reservations, are generally not relevant to planning.

Determine whether this statement is true or false. All bills of material are created and maintained as single-level bills. "#$%&'(!1'2&! !

What happens when MRP determines that shortage quanitites exist for a material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

Determine whether this statement is true or false. Basic data in the material master is applicable to the entire company and is stored at the plant level. "#$%&'(!B+*$&! Basic data in the material master is applicable to the entire company, but is stored at the client level. Basic data includes the material number, the material group, the unit of measure, and conversion factors for alternative units of measure.

ÂŠ SAP AG

TERP10

5-69

What are the options for executing a MRP run? !"#$%&'()*"+,%-*.%/(0,1""*"+(2#*"+,%-,%3%,4(/5,.*-,%3%,4(6&(*".%&17.*3%8( (

(((((((((96.1,(0,1""*"+(6",*"%(

(

(((((((((96.1,(0,1""*"+(*"(.:%(;17<+&65"=(

( 6.

Determine whether this statement is true or false. During a MRP run, the quantity of a planned order is determined by the cost of the material. !"#$%&'(>1,#%( 9:%(?51".*.@(6A(1(0,1""%=(6&=%&(*#(=%.%&/*"%=(;@(.:%(,6.(#*B%(<%@(=%A*"%=(*"(.:%( /1.%&*1,(/1#.%&(&%76&=C(

What is the difference between a regenerative MRP run and a net change MRP run?

(

!"#$%&'((D"(1(&%+%"%&1.*3%(0,1""*"+(&5"4(1,,(/1.%&*1,#(1&%(0,1""%=4($:%&%1#(*"( 1("%.(7:1"+%(0,1""*"+(&5"4(6",@(.:6#%(/1.%&*1,#(.:1.(:13%(5"=%&+6"%(1(7:1"+%( &%,%31".(.6(EFG(1&%(0,1""%=C(

ÂŠ SAP AG

TERP10

5-70

!"#$%&%'$()*+*(,*-*.$/$-+

01-+$-+34 ! 01/21-$-+3(1#(!"#$%&%'$()*+*(,*-*.$/$-+

 SAP AG 2006

TERP10

6-1

!"#$%&%'$()*+*(,*-*.$/$-+0(1-"+(234$%+"5$6

;2(2).(/*'/$97&*'(*-(2)&7(9'&2E(0*9(+&$$(8.(%8$.(2*F ! !"#$%&'()*+(,&-./0/$.(1%2%(3%'%4.5.'2( &'2.46%2.7(+&2)(2).(897&'.77(#6*/.77.7(+&2)&'( 2).(50:;< !=<(7*$92&*' ! >%&'(%(8%7&/(9'?.672%'?&'4(*-(2).(1*/95.'2( 3%'%4.5.'2(:072.5 ! 1.7/6&8.(2).(-9'/2&*'7(*-(2).(@$%77&-&/%2&*'(7072.5 ! !"#$%&'(A%6&%'2(@*'-&496%2&*' ! !"#$%&'(2).(#96#*7.(*-(<6*?9/2(:269/296.(B6*+7.6( %'?(!'4&'..6&'4(C*6D8.'/) ! !"#$%&'(2).(!'4&'..6&'4(@)%'4.(3%'%4.5.'2( <6*/.77

 SAP AG 2006

TERP10

6-2