MPS and MRP are two planning processes used to ensure material availability. MPS focuses on critical items and plans them separately before a detailed MRP run. MRP then explodes BOMs, adjusts for inventory, and offsets requirements to generate time-phased material needs. MRP runs generate planned orders, purchase requisitions, and production orders.
MPS and MRP are two planning processes used to ensure material availability. MPS focuses on critical items and plans them separately before a detailed MRP run. MRP then explodes BOMs, adjusts for inventory, and offsets requirements to generate time-phased material needs. MRP runs generate planned orders, purchase requisitions, and production orders.
MPS and MRP are two planning processes used to ensure material availability. MPS focuses on critical items and plans them separately before a detailed MRP run. MRP then explodes BOMs, adjusts for inventory, and offsets requirements to generate time-phased material needs. MRP runs generate planned orders, purchase requisitions, and production orders.
The purpose of MPS (Master Prod. Sched) and MRP (Material Req.
Planning) is to guarantee material availability on a 2 step planning process
SOP Sales & Operation Planning Material Product Group Cost Center Activity Types Routing Work Center Demand Management (Admin of Ind Req.) MPS MRP Material Requirements Planning Planned Orders Purchase Requisition Production Order Items Items Items Goods Receipt Sales Info Syst CO-PA OP OP Items Goods Issue C.O.T Costs debited to Prod.Order MATERIAL PLANNING Product Group Forecast Manual Disaggregation and transfer to Sales Order (Created in SD) Header +Items Mvt 101 Variances settled FI CO FI CO MM E (inhouse production) F (Externally procured) Release Not normally part of MRP because MRP doesnt consider capacities unless scheduling parameter is set in MRP. Areas of responsibilities Assembly painting engineering Who does the work? Stock Final Good 3000 Plant Activity 3000 Raw Consum 3000 Stock Raw 3000 Controlling Profitable Analisys Use to derive a future demand program from the demand figures in the past SOP: planning and forecasting module with the logistic area. It provides a method for : Sales plan: (data from the SIS, data from CO-PA, from past sales to forecast future sales, from another P.group, or manually) Is a Product family. It groups together products with similar plann. charact. Product Group 1 Prod. Group A Prod. Group B Mat. A1 Mat. A2 Mat. B1 Mat. B2 P.Groups require a proportion factor. A higher level is disaggregated to a lower level Production plan (based on sales plan) can be created several ways: = to sales plan, target stock level, days supply, inventory to zero, manually) Feasibility estimates To create a Sales or Prod. Plan at one level we must disaggregate. For ex. disaggregate the sales plans of all the product groups down to the materials, and develop production plans at that level. The plan that is sent to demand manag. is used to manage the Ind. Req. D i s a g g r e g a t i o n Forcasting =Warehouse Req. =Planned Ind. Req. =Customer Ind. Req. MAKE TO STOCK PROD: Plan consump. are forecast, then procur. and prod. takes place without Sales Orders. Requirements covered by warehouse stock (=>shorter delivery time). SUBASSEMBLY PLANNING: M.to.Stock Prod for assemblies. The finished products are not produced to stock, rather the necessary assemblies are procured. MAKE TO ORDER PROD: products are procured and produce once a Sales Order arrives. PLANNING STRATEGY controlls the diff. mode of action of Planned Ind. Req. STRATEGY 40 Planning with Final Asembly =>fast reaction to customer demand Proc. and Prod. of all comp. and assemblies is triggered by Plnnd. Ind. Req. in Demand Mgt before a Sales Order arrives. Incoming Sales Orders consume these Plnnd. Ind. Req. If Sales Ord. exceed Pl. Ind. Req, a new Plnnd Order for the unplanned quantity is trigger for the next MRP run (thus Sales Ord. affect requirements). M1. BACKWARD CONS: the Sales Ord. consumes Pln. Ind. Req. that lie before this sale. M3. FORWARD CONS: the Sales Ord. consumes Pln. Ind. Req. that lie after this sale. M2. BACK/FORW CONS: uses both. By default Backwards consumption. The mode and the periods can be defined in the Material master or in each MRP group. CONSUMPTION Determines the direction on the time axis in which the arriving sales orders are to consume the Plnnd. Ind. Req. (MPS) - Master production scheduling is a form of MRP that concentrates planning on the parts or products that have the great influence on company profits or which dominate the entire production process by taking critical resources. These items are marked as A parts (MPS items) and are planned with extra attention. These items are selected for a separate MPS run that takes place before the MRP run. The MPS run is conducted without a BOM explosion so that the MRP controller can ensure that the Master schedule items (MSI) are correctly planned before the detailed MRP run takes place. MPS operates within only one level of the BOM, While MRP can be utilized throughout all levels of a materials BOM. MRP is set of techniques that uses BOM data, inventory data, and the MPS to calculate requir. for materials. Time-phased MRP begins with the items listed on the MPS and determines 1. The quantity of all components and mat. required to fabricate those items and 2. the date that the components and material are required. Time-phased MRP is accomplished by exploding the BOM, adjusting for inventory quant, and offsetting the net requirements MRP TYPES (how materials should be planned) MRP NO PLANING CONSUMPTION BASED: _Based on historical rates of consumption (past cons) _Appropriate for low value mat (b,c parts) _No ref. to master plan (not triggered by ind. req) _Net req. cons. is triggered when: *stock levels fall below a reorder point (safety stock) or *by forecast req. (frompast cons. data). _Appropriate for mat. with demand consistent _Ind-Dep. Req and sales order dont affect them. Purchase Order Schedule Lines Planned Orders Stock +fixed receipts that exists (PR, PO,Pln.O, PrO) VS Safety Stock +Requirements (Pln Ind. Req, Sales O) =quantity available for planning. BOM Bill Of Material Multilevel Backward Scheduling The systemcalculates the start dates based on a end date. MRP RUN Planning run can be done in 2 levels: 1. Total planning (planning of all materials of one or several plants.(online or in the background). 2. Single-item planning: 2.1. Multilevel. Planning of all BOMs materials 2.2 Single-level. Planning of a specific material 2.2 Interactive. Interactive single-level planning Scope of the Planning Run Processing key field specify the type of planning: NEUPL: Regenerative planning (plann of all MRP relevant materials). (first time, errors) NETCH: Net change for total horizon (plann all mat. we made changes). NETPL: Net change for planning horizon Control parameters for MRP Processing key Create Purchase Requisit (mat. procured ext.) Create Schedules lines (bis) Create MRP list (always, never, only except. Planning mode (if existing data simply be adjusted, whether BOM and routings should be re-exploded or whether the plann. Should be started fromthe beginning again. MD04: Stock/Req.list: info current status of stocks MRP list: info latest plann run Only in the opening period 1 1 1 2 2 2 MRP Net Requirements calculation Is executed in the planning run to determine if there is a shortage for a certain material. Item Category: Stock Non Stock Variable size Documents Text Class Intra material Material type: Raw materials Operating supplies Semi-finished products Finished products controls: Business process . Views (Screens) Department-specific data Material # assignment Procurement types GL- general ledger accounts MRP Control Parameters (required for planning run) 1. Processing key 2. Create Purchase Req. 3. Schedule lines 4. Create MRP list 5. Planning mode contain the list the sequence of steps for producing a material: Operations, Operation Sequences Usage Time elements Work Centers. Component allocations www.sap-terp10.com.ar SOP Sales & Operation Planning Material Product Group Cost Center Activity Types Routing Work Center Demand Management (Admin of Ind Req.) MPS MRP Material Requirements Planning Planned Orders Purchase Requisition Production Order Items Items Items Goods Receipt Sales Info Syst CO-PA OP OP Items Goods Issue C.O.T Costs debited to Prod.Order MANUFACTURING EXECUTION Product Group Forecast Manual ` Disaggregation and transfer to Sales Order (Created in SD) Header + Items Mvt 101 Variances settled FI CO FI CO MM E (inhouse production) F (Externally procured) Release Areas of responsibilities Assembly painting engineering Who does the work? Controlling Profitable Analisys Forcasting =Warehouse Req. =Planned Ind. Req. =Customer Ind. Req. Purchase Order Schedule Lines Planned Orders BOM MD04: Stock/Req.list: info current status of stocks MRP list: info latest plann run Only in the opening period Raw Consumption Raw Stock Finished Goods stock Plant Activity 5000 5000 10000 10000 Cost Elem ent Elements of a Prod. Order: Order Header Settlement rule Costs Operations Operation sequences Material components PRTs Trigger points Documents links Order Creation Options: Without BOM Routing With BOM Routing With Routing With Planned Order Availability Check: Checks for: (from Rout+BOM or manually) -Material components -Capacities -PRTs contain the list the sequence of steps for producing a material, that is: Operations, Operation Sequences Usage Time elements Work Centers. Component allocations If a BOM is changed after a Pln Order is created but before is converted into a Prod. Order: BOM is not re-read and the Prod. Order uses the old BOM Releasing orders: levels _Individual operation _Whole order _Several orders together Production Order: GI - Goods Issue Posting: Is executed for a consumption of a material component for a prod. order. MM - Material document: describe the g. movt. from the MM (stock) point of view. FI - Accounting document: describes the goods movt. from the FI point of view. CO - Cost accounting document: serve various cost analysis purposes _ Account affected: .Consumption is debited .Raw material Stock is credited . NON Finished goods stock, Plant activity Q + $ (value) in Material master data is updated Reservations is Reduced (for planned withdrawal) Determination of actual costs (evaluation) and update of order When you display the material document, you can branch to the other documents GI doc. can be printed. The GI posting is controlled via a movement type 261. List the application modules that integrate with Manufacturing Execution: Inventory Management Quality Management FI - Financial Accounting CO -Controlling SD - Sales and Distribution Order PS -Project Systems HCM -Human Capital Management Production Order: GR - Goods Receipt Posting Realizes the stock receipt of a product produced using a production order. MM - Material document: FI - Accounting document: CO - Cost accounting document: serve various cost analysis purposes _ Account affected: .Finished good stock is debited .Plant activity is credited . NON consump, raw mat. When you display the material document, you can branch to the other doc. GR doc. can be printed Delivery quantity in an order is Updated lant activity is Updated Evaluation of the receipt Credit to order The GR posting is controlled via a movement type 101. Basic data Default values Cost center Capacities Scheduling HR assignment Cost Object Controlling (COC): Order settlement: _Debits the stock account _Credits the order Order related .flexible production environment .flexible product range .Cost mgt of ind. production lots .if controlling is required for each order .High setup costs .Manufacture o co-products Product related Status Prod. Order: CRTD 1 1 1 2 2 2 www.sap-terp10.com.ar Vendor Info record Material Conditio n Output Account group Material type Industry sector Condition types Output types Manually by the Dep. Respons. Automatically by MRP Is an Internal document 20 10 Stock item Non-stock item Item Category Purchase order Source of supply Info record Quotation Contract Source list Goods Receipt MM Doc Movement type: determines the kind of goods movements. What happens to the items, how they are handledkey to differentiate between goods movements (ex: GR, GI or transfer postings). (Inv. Mgt) Determines which stock or consumption accounts are updated (posted) in Financial Accounting. Determines the structure of the screen when entering documents and updating quantity fields. 1 Storage location F - Unrestricted Q Quality Insp. X Blocked Stock Goods receipt area 105 103 101 Invoice/ Billing 2 Pay 3 FI Doc Consumption Raw Stock Raw Bank GR / IR Reconciliation Vendor Subledger Vendor P / L - Balance sheet G / L: 300 3000 3300 1 1 3300 3300 3300 3300 3300 3300 1 3 2 2 3 2 3 Cost element PROCUREMENT PROCESS Purchase Requisition 20 10 Consumable Material: Are materials or services that are procured specifically for an account assignment object. (EX: office supplies; computer systems) Value is recorded in the cost element or asset accounts. When a material is procured directly for consumption, no material master record is necessary. In the case of consumable material with a master record: o Not subject to inventory management (on either quantity or value basis) o Subject to inventory management on a quantity, but not a value basis Account Assign. Objects A Asset C Cost Center P Project P Prod. Order S Sales Order with / without reference Item category: defines the process used to procure a material or service. S Standard: material procured externally S Stock transport order: mat. is transf. from 1 plant to another S Subcontracting: vendor manufacture a component C Consignment: Liability only when mat. is withdrawn from consg. stock, no when the stock is placed in the consg. store T Third-party order: material order from a vendor with the instruction to deliver the goods directly to a 3er party (customer) Header Data: Doc. # Date Vendor Terms of payment Currency Item: Material # Delivery date Q, $, Text Posting a Goods Receipt by referencing to a Purchase Order has a 3 advantages: The goods receiving department can check whether the goods delivered are what was actually ordered. Data from PO is copied automatically to the GR transaction. PO history is updated upon GR creation. When goods receipt to the warehouse is posted: A MM doc. is created: with info such as material delivered and quantity delivered; storage location and associated plant. An FI doc. is created: which record the effects the material movement has on the value of the stock. Goods movements: A transaction that causes a stock change. Include both external and internal movements. You can distinguish between: Goods receipt (GR): is a goods movement in which the receipt of goods from both an external vendor and from production is posted. A GR leads to an increase of warehouse stock. Goods issue (GI): is a goods movement in which a material withdrawal, goods issue, material consumption, or goods shipment is posted to a customer. A GI leads to a decrease of warehouse stock. Stock trasfer: is removal of materials from particular storage location and placement into another storage location. Stock transfers can take place both within the same plant and between two plants. Transer posting: changes the stock identification or qualification of a material regardless of its a physical movement or not. (EX: release of the stock for quality inspection). Stock type you enter goods receipt against production and purchase orders Effects of Goods Receipt: MM - Material document is created (quantity) FI - Accounting document is created (value) CO Cost Accounting document cost analysis purpose Material master is updated (here not in the inv. verif) _ Account affected: .Stock raw (+ Consumption Raw) is debited .Provision in the GR/IR is credited . NON Bank, Reconc. Vendor, Subdledger Vendor PO History for a PO items is updated (when a GR is entered with reference to this item) Quality Management (Inspection lot is created) Warehouse Management (Transfer Requir. is created) Output may be generated (GR slip) Material Mgt, manages the procurement process until Invoice verif. Other Dpt (account) manage the payment and evaluation of invoices. Therefore, Inv. Verif. creates a link between Mat. Mgt and external (FI) or Internal account. (CO) Invoice Verification and Vendor Payment If there are variances between the PO or GR vs INVOICE, the system warns the user and blocks the invoice for payment. Posting the invoice completes the process of Invoice Verification. Types of Invoice Verification: Invoice items can be posted with reference to: Goods receipt based Invoice verification: invoices for quantities greater than the goods receipt cannot be posted. Purchase order based Invoice verification: you can settle all items, irrespective of whether there have been partial deliveries. The postings are automatically made to the corresponding G/L accounts. When an Invoice is posted, an open item is credited on the vendor account. Logistics: Invoice Verification: Effects FI - Accounting document is created PO History is updated Open Itemis created in the vendors account If invoice $ differs from the PO $, the stock value and the current moving price is recalculated and updated in the material master, for a material valuated with mov. aver. $. _ Account affected: .Provision in the GR/IR clearing account are reversed - debited .Reconc. Vendor is credited .Subledger Vendor is credited . NON Stock raw-consum. raw, Bank Material Management Integration: (FI) Financial Accounting: Purchasing and FI maintains data on the VENDOR master data (is a creditor account in FI) that contains account.+ procur. info (SD) Sales and Distribution: requirements that arrives to Sales can be passed on to Purchasing. when a P.Req. is created, it can be directly assigned to a Sales Order. Production Planning: and MM are linked through inventory needs. Inv. Mgt is responsible for assuring all components required for production. Plant Maintenance and MM are linked by BOM. Its possible to post a GR with ref to an equipment BOM and to withdraw part for maintenance orders too. Integration in Logistics: the Inv. Mgt system (manages Stock (Q) quantity + ($) value) can be extended by the WMS which manages storage (also Storage Bins) Process of GR with Transfer Order GR posting is subject to WMS: checks for each PO item and generates: MM + FI docs for goods movt.: _MM doc.: Header + Item (q, descrip, stor.loc., plant), is identified by material document number and year. _FI doc.: Header + Item (G/L acc. #, $) records the effects of material movements on the accounts. Is identified by CC (of the plant); acc doc. #, fiscal year. Transfer requirement doc Incoming quantity of materials into the goods receiving area An Interim storage area in the receiving warehouse number A transfer order is used to move the items from the receiving area (in a put away process) the destination storage type, the storage section, storage bin are determined Org. level needed for a PO Plant Purch. Org. Vendor Storage loc not nec. until good are not received. Account Posting Good Receipt : Debit Stock, Credit GR/IR Invoice Receipt: Debit GR/IR, Credit Vendor (Recon.+Subledger) (=> acc. payable) Pay Vendor: Debit Vendor (Recon.+Subledger), Credit Bank/Cash FI Doc MM Doc MM Doc FI Doc CO Doc Documents generated Account payable Vendor (Recon.+Subledger) are debited, Bank/Cash is credited www.sap-terp10.com.ar Inquiry Quote Sales Order Delivery/ Shipping 10 Warehouse Goods Issue Invoice / Billing Receive Payment Revenue Inventory Change Bank Customer Receiv/ Reconciliation Customer Sub-Ledger 1 2 3 1 4000 Inventory/Stock 4000 10000 10000 10000 10000 10000 10000 1 2 2 3 3 2 3 Auto MM Doc FI Doc CO Doc Documents generated TO Pick Quantity Confirm Pick Quantity Transfer Request Transfer Order MM Doc FI Doc CO- PA Doc FI Doc Customer Info record Material Condition Output Material type Industry sector Condition types Output types SALES ORDER MANAGEMENT Pre sales activities: establishing and maintaining customer relationships Creating and tracking customer contacts Mailing campaigns Answering customer ques. received by email, fax etc Inquiries Quotations Sales order processing: Contains all info.(Inquiries and quotations docs) to process the customers request during sales order processing. Sales process data from master records. 1 quotation can = multiple sales orders. Multiple quotation can = 1 sales orders. A Sales document is created in a sales area. It references from Inquiry + Quote Sales documents structure: is grouped into 3 levels: header customer related data) items data about the material / quantities ordered, $, conditions schedule lines delivery q. + dates. schedule line =1 item, expect for partial deliveries => multiple schedule lines. Backward scheduling: The customers requested delivery date is used to calculate the pick/pack time and the transportation lead time. The delivery must be created on the earliest of the two dates (selection date for the outbound delivery). Incompletion log: Each SD document contains data required for the documents and for further processing. The system determines which fields are displayed in the incompletion log when the user does not fill them during sales order processing. The incompletion log will be displayed: Automatically when you save your entries. Or by choosing edit-incompletion log In customizing you can decide which fields should be part of the incompl. log The incompl. log functions are available in the sales order and in the delivery. Transfer of requirements: Communication between SD and Procurement is carried out via requirements. The material for the order can come from in-house production or external procurement. If there is insufficient material available, purchase orders can be made via material planning. Availability check in the sales order: Can be required via customizing Can be required via the material master record The system can check other plants for a material Backward scheduling is used to determine whether a material will be available Shipping processing in SD begins when you create the delivery document (Header and item)(copying information from the sales order, such as the materials and quant). The deliv. doc. controls, supports and monitors numerous sub processes for shipping processing such as: (Optional) picking and confirming (transfer req. orders) (Optional) Packing (Optional) Planning and monitoring of transport (shipment docs) Posting the goods issue GI (goods issue documents). Creating a transfer order includes copying data from the delivery document to the transfer order for processing within the warehouse. The transfer order is essential for controlling the movement of goods within the warehouse. The transfer order is based on a simple principle: where you are taking goods from and to, within your warehouse. There is a source location and a destination location for every transfer order. Creating outbound delivery: You can create an outbound delivery in a shipping point for orders that are due for delivery. The relevant data is copied from the order to the outbound delivery. 1 Sales Order can = 1 or several outbound deliveries Several Sales Orders can = 1 outbound delivery. The orders must all have the same characteristics that are essential for the shipping process: Shipping point Due date Ship-to address Picking: You create transfer order for an outbound delivery A transfer order is generated for a warehouse number. The system copies the relevant data from the delivery. Picking in shipping processing: You can control an item in an outbound delivery so that picking is required. Picking is carried out by creating transfer requests with which you trigger and survey warehouse movements. Packing: When packing you can combine delivery items and pack them in different shipping units. GI - goods issue posting: effects MM - Material doc: describe the g. movt. from the MM (stock) point of view. FI - Accounting doc: describes the goods movt. from the FI point of view. CO - Cost accounting document: serve various cost analysis purposes _ Account affected: .Inventory/stock is credited .Inventory change (cost of goods) is debited . NON Banked, Revenue, Customer. Q in Inventory Mgt and the Delivery req. in material planning are updated. Further documents for FI are created. (document flow updated) Billing due list is generated. The status in all relevant sales doc is updated Customer requirement deleted Billing: Billing supports: Creating invoices for products and services Creating credit and debit memos Cancelling previously posted billing documents Automatically transferring billing document data to accounting When you create a billing document, data is copied from the sales order and the delivery docs to the billing document. Functions: It is SD document that helps you to generate invoices. The billing document serves as a data source for FI to help you monitor and process customer payments. When you create a billing doc., the G/L accounts will normally be updated automatically. During this process, the system carries out: o Customer Receivables account is debited (bis) o Revenue account is credited (bis) Creating a billing document: You can create an invoice for a delivery or sales order. You can group invoices using selection criteria, such as customer, billing date and destination country. The SAP system can combine deliveries into a billing document, provided these deliveries share some essential characteristics: Payer Billing date Destination country Billing document structure: two levels: Header (Payer, Billing date) Item (Details about the material,Billing quant, items Net value) Billing document posting: effects Customer credit account is updated Status in all related sales, delivery and billing documents, is updated Sales statistics in the SIS are updated _ Account affected: Customer Receivables account is debited Customer Subledger account is debited Revenue account is credited Further documents for accounting can be automatically generated by the system, for example: For the components controlling (CO) accounting Profitability analysis (CO-PA) posted Market segment analysis (CO-PA) Consolidation (FI-LC) Payment: process part of the application module FI Payment supports: Posting payments against invoices Reviewing differences Incoming payment posting: effects Cash/Bank account is debited Customer Receivables account is credited Customer Subledger account is credited Document flow in the SAP system: docs in sales process are linked to each other using the doc. flow. This let you access the history and current status of your sales process at any time 1.Standard order 2.Delivery 3.WMS transfer order 4.GI- goods issue 5.Invoice 6.Accounting document Sales and distribution integration: Integrates with Materials Management for availability checking Integrates with Production Planning for make to order product Integrate with Project Systems for delivery and billing processing Integrate with Warehouse Management module, where the product is picked and print shipping document Integrate with Materials Management, Financial Accounting and Controlling when posting a goods issue Integrates with Profitability Analysis for sales order Integrates with Sales Information System We know that payment has been received from the customer for a particular invoice, because the overall processing status of the accounting documents changes to cleared. ORDER TO CASH PROCESS Pre-sales activities -> Sales order processing -> Inventory sourcing -> Shipping-> Billing ->Payment receipt and posting Account Posting 1. Goods Issue : Credit Inventory, Debit Cost of goods sold (Inv. Change) 2. Billing a customer : Credit Revenue, Debit customer (Reconc+Subdledger) 3. incoming Payment: Credit Customer(Reconc+Subdledger), Debit bank account Open item posted on cust.s account www.sap-terp10.com.ar PROCUREMENT MATERIAL PLANNING MANUFACTURI NG EXECUTION SALES ORDER FI CO INVENTORY AND WAREHOUSE MGT Client Client Client Client CC Controlling Area Client Client CC CC CC CC Plant Operating Concern CC CC Plant Plant Plant Sales Area (Sales Org - Dist. Ch- Profit Centers CC Transport. Pln. Point Plant Subdiv. Of CC Storage Location Storage Location Storage Location Plant Credit Control Area Business Area Plant Maintenance Plant Default values Purch. Org. Storage Location Plant Shipping Point Location Selection for reporting Purch. Group Shipping Point Purch. Org. Storage Location Maintenance Work Center Authoriz. Checks Sales Org. Warehouse Number Maintenance Planning Plant Wage structures, Work schedules Maintenance Planner Groups Country groupings Legal person Time management Payscales Public holiday calendar Active employees Retirees Contractors Deffault values Reporting Authorization Trainee Hourly Salaried Payroll Area Organizational Unit Position (specific) Job (general) Person (ass.to position) Material Material Material Customer GL Account Vendor BOM BOM Infor Record Vendor Info Record Routing Work Center Material Customber Conditions Task Lists (routings,etc) Output Credit Mgt PRTs Condition MASTER DATA Personnel Area Personnel Subarea ORG. LEVELS General Location- Based Planning- Based Organizationa l ENTERPRISE ASSEST MGT/CUST. SERVICE Employee Group Employee Subgroup Enterprise Personnel HR MANAGEMENT CC Client