MRP Documents in SAP
MRP Documents in SAP
MRP
DOCUMENTS
IN SAP
SAP MRP
Material Requirement Planning (SAP MRP) is a tool which helps in planning the
requirement quantities and schedules of a given material. It not only ensures
availability of the material for which MRP is carried out, but also ensures
availability of the components (of all the BOM levels) below in the BOM
structure.
Apart from assuring material availability, MRP also carries out scheduling
of the procurement proposals using the lead times for the
materials/components. When the material is an internally manufactured
material, it will use the lead times or operation lead times from the
routings/recipes and when the material is an external procured material, it
will fetch the lead times or delivery times for the material defined at an
appropriate place in the tool/system. Scheduling of the procurement
proposals not only derives the capacity loading of the orders on the
workcenter but it also calculates the delivery dates of the components that
would be requried for manufacturing (delivery date = start date of
processing).
While the Material Requirement Planning in SAP ECC (SAP MRP), derives a plan
for the materials and helps the planners and supervisors to purchase, produce
or sell. It offers all the possible planning methods available in the market like
the reorder point planning for the consumption based planned materials, lot
for lot MRP planning for the demand based planning materials, forecast based
planning methods which uses the past historical figures to extrapolate the
future requirements (again a consumption based planning material).
SAP material requirement planning or SAP MRP, uses the following factors
in its planing run:
b) planning types - type of the MRP run, i.e., consumption based planning methods
or demand based planning methods and net requirement planing or gross
requirement planning
On the other hand, you could also have the demand coming in from sales orders
and the production is initiated thereafter, such scenarios are typical make-to-
order. Manfuacturing after an Order is booked is carried out for products of high
value or for products whose design is supplied by the customer or as
specified/requested by a customer. For Example, Manufacturing of Jewelry,
Aircrafts, Special Purpose Pumps.
Note that Made-to-Order can also be initiated for a typical Made-to-Stock Product,
in
is cases where a special customer places a huge order and the manufacturing
triggered seperately for them.
All the above cases are typical make-to-order and such demands come in
through sales orders.
SAP came across as the very first few companies which evolved the
concept of MRP II in to ERP and earning for themselves a growing
business by selling this new concept. Companies and businesses across
the world made use of this ERP tool and the standard processes offered
to profit themselves.
The SAP R/3 or ECC has a MRP system that plans for material and capacity
(schedules) without considering any constraint and by assuming availability
of infinite capacity for the work centers. This gap of SAP ECC was later-on
removed with the help of an add-on or a plug-in introduced by SAP for the
advanced planning of requirements; it was called SCM - APO (Supply Chain
Management - Advanced Planning Optimizer). This tool worked on much
complex and much supreme heuristics with the capability of planning based
on finite capacity and constraints. The SCM - APO had modules such as
Demand planning which was a superlative version of Sales and Operation
Planning (SAP - SOP) in SAP ECC, Supply Network Planning which allowed
planning across plants and across geographical locations and allowing
businesses to place orders for production or procurement across the global
based on time and cost contraints and the PPDS module (Production
planning and detail scheduling) which was a detailed version of SAP ECC
plant level MRP based Production planning with more brainy heuristics
codes which could consider multiple contraints and finite based planning
situations in one planning run.
Made-to-stock Scenario:
3 view or materials which are marked with collective requirements in the MRP 4
screen, the system calculates the material requirements through the use of a
pretty simple algorithm; where it takes into account the stock in the storage
locations, the receipts expected for the materials through purchase or
production and the incoming demands.
In a made-to-stock scenario, the incoming customer requests are fulfilled from the
inventory. The made-to-stock products are normally the consumer products or
products which have a monopoly market and are sold out of the existing inventory.
Such products are developed and produced continuously over the years till the
product comes to the end of its life cycle.
In such scenarios, the shop floor or the production team never knows, for whom
the product is being produced. The customer demands and the market situations
can only be forecasted and used as a basis for future production. In SAP the
forecasted quantity is evidently used in a form of planned-independent-
requirement.
Made-to-order Scenario:
In cases where the material is defined as made-to-order, i.e., materials
which are marked with a made-to-order strategy in the MRP 3 view of the
SAP material master and marked with individual requirements in MRP 4
view, the system calculates the material requirements through the use of an
algorithm which takes in to consideration the receipts expected for the
material through purchase or production and the incoming sales order
demands. Here the system does not take into account the storage location
stock of the material (since the stock in the storage location for the material
is always tagged for a customer order and cannot be used anywhere else).
In such a scenario, the tracking of the sales order from its creation to
planning to production to inventorying to delivery can be easily tracked
unlike in made-to-stock scenarios, where the incoming sales orders are not
tracked in the plant, but are fulfilled by the existing stocks.
Materials planning is one of the key of good inventory control systems. The
objective of materials planning is to monitor stocks to ensure material
availability.
As a leader in ERP software, SAP R/3 also has a special materials planning
function that works like and even better than other inventory control
software. With materials planning in SAP, we can determine automatically
which material is required, the quantity required and when it is required. By
doing so, we can prevent lacking of materials when we need it.
An example of how SAP materials planning and other SAP functionalities can
help company to excel its business.
Sales and Distribution (SD) module of SAP receives demand from customer.
Sales department will create a sales order (SO) or sales forecast which
contain the information of what, how many, and when Finished Goods are
needed by the customer. The SO or sales forecast will be considered as an
independent requirement in SAP. This requirement will trigger materials
planning process for finished goods.
SAP will compare the requirements with finished goods current stock. If the
requirement fulfillment will result in shortage of stocks (according to
certain calculation of materials planning procedure for the finished goods),
materials planning will automatically create procurement proposal, such as
planned order. Planned order can be converted into production order (if
finished goods are produced internally) or purchase requisition (if finished
goods are procured externally). In addition, materials planning can also
create purchase requisition directly as a procurement proposal (no planned
order).
You should read previous post about materials planning overview before
reading this post. In this article we will explain in detail about materials
planning procedure in SAP R/3. Its basic concept is similar with other
inventory control software, but SAP R/3 has its own unique procedures for
materials planning. Basically, there are two types of standard materials
planning procedures in SAP, which are:
There are three procedures in Consumption Based Planning (CBP), which are:
The following values are important for defining the safety stock:
b.Forecast-based planning
In forecast-based planning, historical data is used in the material forecast
to estimate future requirements. These requirements are known as
forecast requirements and are immediately available in planning.
The forecast, which calculates future requirements using historical data, is
carried out at regular intervals. This offers the advantage that
requirements, which are automatically determined, are continually
adapted to suit current consumption needs.
We will write another post about how to configure MRP in SAP R/3 System.
Please come back later.
Materials planning is one of the key of good inventory control systems. The
objective of materials planning is to monitor stocks to ensure material
availability. As a leader in ERP software, SAP R/3 also has a special
materials planning function that works like and even better than other
inventory control software. With materials planning in SAP, we can
determine automatically which material is required, the quantity required
and when it is required. By doing so, we can prevent lacking of materials
when we need it.
MRP is especially useful for the planning of finished products and important
assemblies and com
There are three procedures in Consumption Based Planning (CBP), which are:
In reorder point planning, SAP checks whether the available stocks are below
the reorder point t will create procurement proposal.
The following values are important for defining the safety stock:
In standard SAP R/3 system, besides “VB – Manual Reorder Point” and “VM –
Automatic Reor Types that have reorder point as its basis to calculate
requirement with additional procedure whi manual reservation) as a
requirement. The MRP Type are: “V1-Manual reorder point with exter with
external requirements”.
b.Forecast-based planning
In forecast-based planning, historical data is used in the material forecast to
estimate future requ requirements and are immediately available in planning.
Besides all procedures that have been explained above, in SAP R/3 system we
can create other p through configuration with SPRO T-code.
We will write another post about how to configure MRP in SAP R/3 System.
MRP
MRP is the planning tool in SAP which will look at all aspects of a material and
is highly based upon the master data of the material. MRP looks at current
inventory, current requirements, and open purchase requisition/orders and so
on. So if a material is required to satisfy a sales order and there is no inventory,
MRP will create a planned order if the item is to be produced in house. This
planned order can then be converted to a production order by the master
scheduler.
▪ PlanningProcedure
▪ MRP at Plant or MRP Area Level
▪ Reorder Point Planning