Tag Archive for 'MRP'

MD04 – Export planning to Excel

Sometimes a planner wishes to share the planning status of a particular material with colleagues or partners that are not SAP users. In this case it is useful to export the planning overview to Excel and perhaps pimp the lay-out with some colorful headers.To do this -from within MD04 or MD07- go to Menu > List > Variable Print.

MD04 Print variant

MD04 – Variable Print

Immediately a new overview opens up that may look less attractive than the overview you are used to. On the screen ‘Print list – variable’ you can change the lay-out and save it as a variant like you are used to in standard SAP reporting.

MD04 printlist lay-out

MD04 printlist lay-out

To get the best Excel results export the report directly to an Excel table, as opposed to first store it as a local file and then open it in Excel. This way the lay-out is optimized for direct filtering and sorting.

This is all there is to it. Sometimes SAP life is that easy.

What is a planned independent requirement?

Independent requirements and dependent requirements are the two main types of requirements you encounter when configuring SAP planning. This is what they are:

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MRP vendor selection

It is possible to let MRP propose the preferred (or fixed) vendor for your external procurement. This is especially useful in a scenario where a central purchasing department is dictating vendor selection, but where the actual procurement decisions (quantity and timing) is done elsewhere (e.g. production dept for procurement of raw materials). This post will give you the step-by-step:

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Lot-size for continuous production and process industry

A suitable lot-size for continuous production can be hard to come up with. Picture the situation of a mineral oils manufacturer that refines crude oil to 3 co-products. The planner wishes to control the process flow to align the production with demand (i.e. the refinery is not continuously refining at the same speed as it would in make-to-stock). Another requirement for ATP is that the production quantities are issued on a daily basis. Hence we want MRP to come up with weekly planned orders that are distributed on a daily basis. In abundance: 1 planned/process order per week, with equal quantities released per day.

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Consumption-based planning and MRP

MRP and Consumption-based planning are two fundamental SAP planning types that can be used to determine a product’s requirements. To avoid any confusion on the subject: I am not talking about the MRP run that is executed through MD01 and MD02. I’m talking about planning types that are set in the Material Master’s MRP1 tab. The MRP type is used in the MRP run to determine HOW procurement and/or production quantities are calculated.

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MRP processing keys

NETCH, NETPL and NEUPL are three fundamentally different ways to schedule your MRP run:

  • NETCH – Net Change Planning
  • NETPL – Net Change Planning within Planning Horizon
  • NEUPL – Regenerative Planning
MRP Processing Keys

MRP Processing Keys

I will elaborate on these three options and their workings:

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Different planning views

End-users can get confused about the difference between MD04 – Stock/requirement List and MD05 – MRP List. This post will give you the answer on when to use what report and why:

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Replenishment to Maximum Stock Level

Replenishment to maximum stock level

Replenishment to maximum stock level

It is not uncommon that the use of the field Maximum Stock Level in the MRP1 tab in the Material Master leads to misinterpretations. This field can only be properly used together with lot-sizing procedure HB: Replenishment up to maximum stock level. This is commonly used for tanker planning where storage is limited to the tank capacity. This lot sizing can be used in conjunction with re-order point planning or MRP. It cannot be properly used independent of lot sizing HB as a procurement ceiling (see my suggestion at the end of this post for a way to address this).

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Firming types in MRP

In a production environment it may not be preferable that new requirements on the short term can influence production quantities. The length of the term can be determined by the planning time fence. How MRP treats new requirements in this period can be determined using the firming type in customizing for MRP type:

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ATP on semi-finished materials

Today we learned from SAP Support that it is not possible to distribute dependent requirements through time for Available to Promise.

What does that mean? Well in our case (process industry) it means the following:

We have a material B1 that is made from A1. We sell both items A1 and B1. Since this is process industry we want weekly process orders to become available on a daily basis. Enter distribution function. When we release a process order for B1, SAP neatly distributes the total process order quantity over 7 days of the week. At the same time dependent requirements are created for material A1. When we check the stock/requirement list (MD04) for materials B1 and A1, in both cases SAP distributes the required quantities during the week.

When we do an ATP check (CO09) for material B1 we can see that every day some quantity becomes available. However, for material A1 the dependent requirements from MD04 are not visible anymore The dependent requirement is taken on the first day of production for the full quantity. This seriously disturbs ATP. This leads to a shortage at the beginning of the week that isn’t there in real time.

How on earth is this not supported by standard SAP R/3, since this seems a standard requirement for any material that is both a sales item AND a component?

SAP Notes: 574800, 572347, 77895