SAP MRP Made Easy.pdf
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R/3 System
MRP Strategies
Made Easy
Guidebook to Materials
Requirements Planning
SAP Labs, Inc.
R/3 Simplification Group
MRP Strategies Made Easy
Copyright
Copyright
Ó
1998 including screenshots by SAP Labs, Inc. All rights reserved.
Neither this documentation nor any part of it may be copied or reproduced in any form or by any means or
translated into another language, without the prior consent of SAP Labs, Inc.
SAP Labs, Inc. makes no warranties or representations with respect to the content hereof and specifically
disclaims any implied warranties of merchantability or fitness for any particular purpose. SAP Labs, Inc.
assumes no responsibility for any errors that may appear in this document. The information contained in
this document is subject to change without notice. SAP Labs, Inc. reserves the right to make any such
changes without obligation to notify any person of such revision or changes. SAP Labs, Inc. makes no
commitment to keep the information contained herein up to date.
Trademarks
ABAP/4 is a registered trademark of SAP AG.
SAP, R/2, R/3, SAPoffice, SAPscript, SAP EarlyWatch, and SAP Business Workflow are registered
trademark of SAP AG.
All other products mentioned in this documentation are registered or unregistered trademarks of their
respective companies.
MRP Strategies Made Easy
ii
©
1998 SAP Labs, Inc.
MRP Strategies Made Easy
Contents
Contents
Terminology..................................................................................................................................................................................................... vii
Typeface Styles...............................................................................................................................................................................................viii
Special Icons .................................................................................................................................................................................................... ix
Chapter 1: Introduction.............................................................................................................................................. 1–1
Overview .......................................................................................................................................................................................................1–1
Questions ..............................................................................................................................................................................................1–2
Planning Level .......................................................................................................................................................................................1–2
Production Level....................................................................................................................................................................................1–3
Procuring Components..........................................................................................................................................................................1–3
Responsibility for Production .................................................................................................................................................................1–3
Influence of Stock ..................................................................................................................................................................................1–3
Consumption Strategies and Logic ...............................................................................................................................................................1–4
Purpose .................................................................................................................................................................................................1–4
Prerequisites..........................................................................................................................................................................................1–4
Determining the Requirements Type.............................................................................................................................................................1–5
Activities ................................................................................................................................................................................................1–5
Table of Planning Strategy Assignments...............................................................................................................................................1–7
Cross-Plant Planning...................................................................................................................................................................................1–10
Purpose ...............................................................................................................................................................................................1–10
Prerequisites........................................................................................................................................................................................1–10
Process Flow .......................................................................................................................................................................................1–10
Chapter 2: Strategies for Make-to-Stock Production .............................................................................................. 2–1
Purpose .........................................................................................................................................................................................................2–3
Prerequisites..........................................................................................................................................................................................2–3
Process Flow .........................................................................................................................................................................................2–3
Planning with Final Assembly (40) ................................................................................................................................................................2–4
Purpose .................................................................................................................................................................................................2–4
Prerequisites..........................................................................................................................................................................................2–4
Process Flow .........................................................................................................................................................................................2–5
Key Properties of Strategy 40................................................................................................................................................................2–5
Other Areas ...........................................................................................................................................................................................2–6
Sample Scenario: Strategy 40...............................................................................................................................................................2–6
Coping with Insufficient Coverage of Components..............................................................................................................................2–12
Production by Lot Size (30) .........................................................................................................................................................................2–14
Purpose ...............................................................................................................................................................................................2–14
Prerequisites........................................................................................................................................................................................2–14
Process Flow .......................................................................................................................................................................................2–14
Key Properties of Strategy 30..............................................................................................................................................................2–15
Other Areas .........................................................................................................................................................................................2–15
Sample Scenario: Strategy 30.............................................................................................................................................................2–16
Net Requirements Planning (10) .................................................................................................................................................................2–18
Purpose ...............................................................................................................................................................................................2–18
Prerequisites........................................................................................................................................................................................2–19
Process Flow .......................................................................................................................................................................................2–19
Key Properties of Strategy 10..............................................................................................................................................................2–19
Other Areas .........................................................................................................................................................................................2–20
Sample Scenario: Strategy 10.............................................................................................................................................................2–20
Comparing Strategies 10 and 40.........................................................................................................................................................2–24
Combining Strategies 10 and 30 .........................................................................................................................................................2–26
©
1998 SAP Labs, Inc.
iii
MRP Strategies Made Easy
Contents
Gross Requirements Planning (11) .............................................................................................................................................................2–27
Purpose ...............................................................................................................................................................................................2–27
Prerequisites .......................................................................................................................................................................................2–27
Process Flow.......................................................................................................................................................................................2–27
Other Areas .........................................................................................................................................................................................2–28
Sample Scenario: Strategy 11.............................................................................................................................................................2–28
Planning Without Final Assembly and Without MTO (52) ...........................................................................................................................2–32
Purpose ...............................................................................................................................................................................................2–32
Prerequisites .......................................................................................................................................................................................2–33
Process Flow.......................................................................................................................................................................................2–33
Key Properties of Strategy 52 .............................................................................................................................................................2–33
Other Areas .........................................................................................................................................................................................2–34
Sample Scenario: Strategy 52.............................................................................................................................................................2–34
Planning with a Planning Material and Without MTO (63)...........................................................................................................................2–40
Purpose ...............................................................................................................................................................................................2–40
Prerequisites .......................................................................................................................................................................................2–40
Process Flow.......................................................................................................................................................................................2–42
Key Properties of Strategy 63 .............................................................................................................................................................2–42
Other Areas .........................................................................................................................................................................................2–42
Sample Scenario: Strategy 63.............................................................................................................................................................2–43
Chapter 3: Strategies for Planning Components .................................................................................................... 3–1
Overview .......................................................................................................................................................................................................3–2
Prerequisites .........................................................................................................................................................................................3–2
Process Flow.........................................................................................................................................................................................3–2
Planning at Assembly Level (70)...................................................................................................................................................................3–3
Purpose .................................................................................................................................................................................................3–3
Prerequisites .........................................................................................................................................................................................3–3
Process Flow.........................................................................................................................................................................................3–4
Key Properties of Strategy 70 ...............................................................................................................................................................3–4
Sample Scenario: Strategy 70...............................................................................................................................................................3–5
Planning at Phantom Assembly Level (59) ...................................................................................................................................................3–9
Purpose .................................................................................................................................................................................................3–9
Prerequisites .........................................................................................................................................................................................3–9
Process Flow.......................................................................................................................................................................................3–10
Key Properties of Strategy 59 .............................................................................................................................................................3–10
Sample Scenario: Strategy 59.............................................................................................................................................................3–11
Strategies for Multi-Use Materials ...............................................................................................................................................................3–14
Definition .............................................................................................................................................................................................3–14
Use ......................................................................................................................................................................................................3–15
Combining Sales Order and Production Requirements ......................................................................................................................3–15
Planning Requirements Separately.....................................................................................................................................................3–17
Stock-keeping at Different BOM Levels ......................................................................................................................................................3–20
Stocking Level—Two Levels Below the Finished Product ..................................................................................................................3–21
Stocking Level—One Level Below the Finished Product ....................................................................................................................3–21
No Components Stored on Level Below the Finished Product ...........................................................................................................3–21
Replenishment Lead Time ..........................................................................................................................................................................3–22
Definition .............................................................................................................................................................................................3–22
Use ......................................................................................................................................................................................................3–22
Integration ...........................................................................................................................................................................................3–22
Chapter 4: Strategies for Make-to-Order (MTO) Production .................................................................................. 4–1
Overview .......................................................................................................................................................................................................4–2
Prerequisites .........................................................................................................................................................................................4–2
Process Flow.........................................................................................................................................................................................4–2
iv
©
1998 SAP Labs, Inc.
MRP Strategies Made Easy
Contents
Planning Without Final Assembly (50) ..........................................................................................................................................................4–3
Purpose .................................................................................................................................................................................................4–3
Prerequisites..........................................................................................................................................................................................4–3
Process Flow .........................................................................................................................................................................................4–4
Key Properties of Strategy 50................................................................................................................................................................4–4
Other Areas ...........................................................................................................................................................................................4–5
Sample Scenario: Strategy 50...............................................................................................................................................................4–5
Planning with a Planning Material (60)..........................................................................................................................................................4–8
Purpose .................................................................................................................................................................................................4–8
Prerequisites..........................................................................................................................................................................................4–9
Process Flow .......................................................................................................................................................................................4–10
Sample Scenario: Strategy 60.............................................................................................................................................................4–10
Make-to-Order Production (20) ...................................................................................................................................................................4–13
Purpose ...............................................................................................................................................................................................4–13
Prerequisites........................................................................................................................................................................................4–13
Process Flow .......................................................................................................................................................................................4–14
Key Properties of Strategy 20..............................................................................................................................................................4–14
Other Areas .........................................................................................................................................................................................4–14
Sample Scenario: Strategy 20.............................................................................................................................................................4–14
Chapter 5: Production with Variant Configuration .................................................................................................. 5–1
Overview .......................................................................................................................................................................................................5–2
Strategies for Variants...................................................................................................................................................................................5–3
Variants and Variant Determination.......................................................................................................................................................5–3
Make-to-Stock Production for Variants..................................................................................................................................................5–5
Make-to-Order Production for Variants..................................................................................................................................................5–6
Planning Variants (54)...................................................................................................................................................................................5–9
Master Data Setup...............................................................................................................................................................................5–11
Process Flow .......................................................................................................................................................................................5–13
Other Areas/FAQs ...............................................................................................................................................................................5–15
Characteristics Planning..............................................................................................................................................................................5–16
Overview..............................................................................................................................................................................................5–16
Creating Planned Independent Requirements for Characteristics Planning .......................................................................................5–17
Integrating Logistics Information System (LIS)....................................................................................................................................5–22
Characteristics Planning with Dependent Requirements (56) .............................................................................................................5–23
Assembly Processing with Characteristics Planning (89)....................................................................................................................5–26
Make-to-Order Production with Configurable Materials (25) .......................................................................................................................5–32
Strategy Focus ....................................................................................................................................................................................5–32
Master Data Settings ...........................................................................................................................................................................5–32
Process Flow .......................................................................................................................................................................................5–32
Chapter 6: Assembly Orders..................................................................................................................................... 6–1
Overview .......................................................................................................................................................................................................6–2
Assembly Processing—Procedure ........................................................................................................................................................6–2
Custom Strategies.........................................................................................................................................................................................6–3
Copy the Proper Requirements Classes into your Custom Requirements Class..................................................................................6–4
Create a Requirements type and Include the Newly Created Requirements Class ..............................................................................6–5
Create a Planning Strategy ...................................................................................................................................................................6–6
Create a Strategy Group and Include the Newly Created Planning Strategy........................................................................................6–8
Assembly Processing with Production Orders (82) .......................................................................................................................................6–9
Creating a Production Order Directly or Through a Planned Order.....................................................................................................6–10
Special Settings for Production Orders ...............................................................................................................................................6–10
Sample Scenario: Strategy 82.............................................................................................................................................................6–11
Assembly Processing with Planned Orders (81) .........................................................................................................................................6–13
Special Settings for Planned Orders ...................................................................................................................................................6–14
©
1998 SAP Labs, Inc.
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