Configuring Make-to-Order Production – Finished Goods Sales and Final Assembly (BJE)

You use this configuration item to define the rescheduling periods and the relevant receipt elements. The rescheduling period represents the period in which the system checks whether the existing dates of the receipt elements, which are no longer allowed to be changed automatically, still suit the requirements situation.

If the dates of these elements are no longer suitable, the system creates the following exception messages for the Monitor Stock / Requirements List app and for the Material Planning Data - Read API (API_MRP_MATERIALS_SRV_01) depending on the requirements situation:

• Bring operation forward, if the date of the requirement lies before the date of the receipt element.
• Postpone operation, if the date of the requirement lies after the date of the receipt element.
• Reverse operation, if the requirement no longer exists.

When determining the rescheduling period, take the period in which a precise planning run is to be carried out into account. You define the rescheduling period per plant or per MRP group.

You use the tolerance values to determine whether a tolerance period exists in which no exception messages are created.

The following receipt elements are not changed in the planning run:

• Firmed planned orders
• Firmed purchase requisitions
• Purchase orders
• Production orders
• QM inspection lots

You can define which of the above-mentioned receipt elements are to be provided with a rescheduling proposal for rescheduling in. Rescheduling proposals for rescheduling out are always created for all receipt elements. You can also determine a time tolerance for the rescheduling proposal, that is, a tolerance by which the requirements date is allowed to deviate from the order finish date or the delivery date. Only when this tolerance value is exceeded, will the system create a rescheduling proposal.

Note

• If you maintain no rescheduling period, the system will not carry out a rescheduling check. This means, the system does not create an exception message for firm order proposals. For every newly planned requirement, the system will create an appropriate receipt element without first checking the firmed receipts that already exist, although their dates are unsuitable.
• The system calculates the rescheduling horizon from the end of the replenishment lead time in reorder point planning.

In joint production it is not possible to reschedule receipt elements at will, because the goods receipt depends on the planning run for another material. For this reason, it is best to use a very small rescheduling horizon.

1. Define the rescheduling period for the plants.
2. Decide which receipt elements are to be included in the rescheduling check.
3. Define the tolerances for the plants within which you want no rescheduling proposals.

You use this configuration item to assign material types to task list types to enable the creation of routings for materials of this type.

SAP recommends using the assignments contained in the standard SAP system. Only make new assignments if the standard assignments do not cover all of your needs. For task list type Q (inspection plan), only the standard material types FERT, HALB, ROH, and HAWA are available.

Check the assignments of material types to task list types. If needed, assign new material types to the task list types.

You use this configuration item to define several selection priorities for every selection ID. You assign the selection criteria to every priority. The system automatically selects a task list that matches the selection criteria.

Selection criteria are, for example:

• Task list type
• Task list usage
• Task list status

If no alternative task list can be found, the system continues the search using the selection criteria assigned the next lowest priority.

Note

In shop floor control, the selection ID is defined for each order type in the order-dependent parameters.

Define the following for every selection ID:

• Selection priority
• Task list type
• Task list usage
• Task list status

You use this configuration item to assign orders to order types. You have to assign every order to an order type. The order category (= 40, process order) is a fixed setting and cannot be changed. The order categories are predefined in the SAP System and characterize the technical properties of the orders. The order category defines, for example, the transactions you can use to process an order.

The order type defines the following:

• Order residence time

  You define how long completed orders remain in the SAP System before they are archived.

• Status management

  An order can run through several statuses*. The status controls which business-related operations* are permitted with an order.

• Number assignment

  You have to assign a number range to each order type. If you create a new order type by copying an existing one, you can either keep the number range assignment or choose a different one.

Note

In addition to the general order parameters at client level, there are also parameters at plant level, which you can process in the configuration step under Shop Floor Control → Master Data for Process Manufacturing → Define Order-Type-Dependent Parameters.

Order types are preset in the standard delivery of the SAP System.

1. Classify the orders with regard to their defining characteristics (for example, order category or number range).
2. For each order category, define whether you want to use status management.
3. If necessary, define your own order types. To do so, copy an existing order type and adjust the data as necessary.

You use this configuration item to define the parameters that are valid for each order type and plant.

The parameters are split up as follows:

Here, you define the data that influences master data selection or order master data maintenance. The screen contains the following indicators:

• The production version defines if the production version is selected automatically or manually.
• The recipe selection ID defines the priorities according to which the recipe is selected.
• You can activate the entry tool for operations to help you when you create operations.

• General
  • Substitute MRP controller/substitute production supervisor. These are proposed when you create process orders if an MRP controller or production supervisor are not specified in the material master, or if there is no reference to material.
  • Reservation/Purch.Req. specifies whether certain order objects (operations, components) are relevant to MRP.
  • Collective requisition enables collective purchase requisition per order for externally processed operations or non-stock items.
• Bill of Material
  • Application defines how the BOM alternatives are selected
  • Batch determination
  • Search procedure defines how batch determination is to take place
• Quality Inspection

  Inspection type defines how a quality inspection is to be carried out

• Status Change Documents
  • Here, you define whether you want change documents to be written if a status change occurs. You also define the level at which the change documents are written:
  • A status change document documents the following:
    • Which status has been changed
    • Who changed the status
    • Whether the status has been activated or deactivated
    • In which transaction the status change has been carried out
  • In the process order*, you can define the status at the following levels:
    • Order header
    • Operation
    • Material component
• Status change documents can thus be defined independently of each other, at each of these four levels.
  Note

  If you have defined these parameters such that status change documents are written for a particular order level, the SAP system only writes a status change document for a status change from this point in time if the order (or operation/component) has been created since the status change documents have been activated.
• Documentation of Goods Movements

  You can specify that goods movements are to be documented with reference to an order.

• Cost Accounting

  Here, you define the parameters relevant for cost accounting, such as costing variants for planned and actual costs and a results analysis key.

• Distribution Role

  Default (distribution) role defines an automatically generated distribution role for CO settlement.

You use this configuration item to create production scheduling profiles for specific plants.

In a production scheduling profile, you can:

• Specify that certain business transactions or processes are to be carried out in parallel in a production or process order
  • Order release at the time the order is created
  • Generation of document link from the material master when the order is created
  • Generation of document link from a BOM when the order is created
  • Scheduling upon order release
  • Generation of document link from the material master upon order release
  • Generation of document link from a BOM upon order release
• Specify whether only partial quantities are to be confirmed at the time of an availability check
• Specify that an automatic goods receipt is to take place
• Specify that in the case of the confirmation:
  • No short quantities are to be updated
  • No excess quantities are to be updated
  • Neither short nor excess quantities are to be updated
  • An adjustment of the operation and component quantities to the actual values is to take place
• Make various specifications in the area of batch management:
  • Automatic batch creation when an order is opened
  • Branching to batch classification when a batch is changed
  • Extended batch classification via Customer Function Call
  • Generation of a batch split record in the production order for each batch that is found
• Specify settings regarding transport:
  • Specify that only transport requirements are to be created if transport requirements can be generated for all the components of the operation
  • Specify that either the committed quantities or the required quantities are to be taken into account when transport requirements are generated
  • Specify that the creation of transport requirements is to take place automatically
• Specify which order type is to be suggested depending on the business process
• You can assign a production scheduling profile to a:
  • Material (Work Scheduling screen in material master)
  • Production supervisor

Note

• The assignment to a material takes higher priority.
• The production scheduling profile is adopted in the production or process order at the time the order is opened.

1. Create the necessary production scheduling profiles.

2. Assign the profiles to the appropriate materials or production supervisors.

You use this configuration item to define the production supervisors for your plants. In addition, you can assign a control profile to each production supervisor. By assigning production supervisors to materials within the application, you can define responsibilities for a material within production activity control.

1. Create your production supervisors.

2. If necessary, assign profiles to your production supervisors.

You use this configuration item to define the floats for determining the basic dates of the planned orders. The floats are assigned to the material by means of the scheduling margin key in the material master record. The scheduling margin key is an indicator in the material master record that refers to a group of time intervals that are relevant to material requirements planning.

• Opening period

  The opening period represents the number of workdays that are subtracted from the order start date to determine the order opening date. This time is used as a 'buffer' for the MRP controller for converting planned orders into either purchase requisitions or production orders.

  Note

  The following floats are not relevant for materials that are procured externally:
• Float before production

  The float before production represents the number of workdays planned as a between the order start date (planned start date) and the target start date. This float is used to make sure that delays in staging materials do not lead to delays in production. The production dates could also be brought forward by the float before production in capacity bottlenecks.

• Float after production

  The float after production is used as a buffer time for instances where the manufacturing process has been disrupted so that the planned finish date can be kept to. The float after production is planned between the order finish date (planned finish date) and the target finish date. The float after production is also maintained in workdays.

• Release period

  The release period represents the number of workdays that are subtracted from the order start date to determine the date that the production order should be released. The release period is only relevant for maintaining production orders.

The opening period should represent the processing time that the MRP requires to convert planned orders into purchase requisitions or production orders. The opening period should at least be as long as the interval between two planning runs so that all planned order can be taken into account in the conversion.

Define the floats.

You use this configuration item to define the explosion date for the BOM, which is used in the planning run and for calculating dependent requirements.

You define the following plant-specific parameters:

• Explosion date for BOM
• Whether the planning run is to create dependent requirements for bulk material in the appropriate plant

Note

The explosion date determines which BOM is to be used for explosion in the planning run and, therefore, for the calculation of the dependent requirements. This means, the system selects the BOM that is valid for the explosion date and creates dependent requirements for the components contained in it.

The following possibilities are available for the explosion date:

• Only the order start date is valid as explosion date
• Only the order finish date is valid as explosion date

Note

If you select the Exclude Bulk Material checkbox, no dependent requirements are created in the planning run for BOM items that are flagged as bulk materials. This reduces the system load.

Note

If the checkbox is not selected, the system creates dependent requirements for bulk materials that can only be displayed in the planned order for information purposes but that are not included in the net requirements calculation. They are not planned in the planning run and they are not displayed in the stock and requirements list.

Set the parameters.

You use this configuration item to specify the priority with which BOM usage is selected. In this step, you specify the priority with which BOM usage is selected during the planning run. Here, a sequence is usually determined, which is used to select a valid BOM using the Usage criterion. The BOM usage is a tool that allows you to enter BOMs. It is an important selection criterion in the BOM application, which controls the automatic explosion of BOMs.

Define the selection ID for the BOM.

In this configuration item, you can define task list usages to assign routing to various work areas. You can create several task lists with various usages for the production of a material. In work orders, you can assign order types* to usages. The system uses the usage in an order for automatic task list selection.

You can specify that a routing is to be used only for Plant Maintenance or for goods receipt.

Define task list usages.

You use this configuration item to define a collection of default values for task list headers and operations.

You can minimize the maintenance of task list data as follows:

• Data from the material master is proposed
• Data from the work center can be referenced or copied
• Data from the profile is proposed

You can enter a profile in routing maintenance. The values from this profile are proposed when you create a new routing or routing object, such as a header or an operation. This data can either be saved or overwritten.

The profile contains default values for the status or for the operation increment.

Note

The values you maintained in the material master or the work center will be proposed before any values from the profile.

1. Determine the default values that can reduce the amount of maintenance work in your company.
2. If necessary, define several profiles.
3. Maintain the default values for routing maintenance.

You use this configuration item to define MRP types to assign and set parameters for them. You use the MRP type to control which procedure is to be used to plan a material and which MRP parameters can be entered when maintaining a material master record. You enter the MRP type in the material master record.

The following parameters of the MRP type are relevant for the planning run:

• MRP Procedure

  The MRP procedure determines which of the following MRP types is to be used:

  • Material Requirements Planning (MRP)
  • Master Production Scheduling (MPS)
  • Consumption-Based Planning (Reorder Point)
  • Demand-Driven Replenishment (DD)
• Firming Type

  The firming type determines how order proposals are firmed and scheduled if you work with a planning time fence in the planning run. The following firming types exist:

  • Firming Type 0: Order proposals are not firmed automatically. With this firming type, no actual firming takes place. The materials only receive the indicator for MPS so that they can be planned using the special planning run for master production scheduling. This firming type only makes sense in combination with the MRP procedure MPS.
  • Firming Type 1: Order proposals are not firmed automatically. With this firming type, no actual firming takes place. The materials only receive the indicator for MPS so that they can be planned using the special planning run for master production scheduling. This firming type only makes sense in combination with the MRP procedure MPS.
  • Firming Type 2: An order proposal that lies within the planning time fence is automatically firmed as soon as its date lies at least one day before the end of the planning time fence. The system does not create any new order proposals within the planning time fence. The shortage situation is not adjusted within the planning time fence.
  • Firming Type 3: Order proposals that lie within the planning time fence are not firmed automatically. The order proposals required to cover the requirements are moved to the end of the planning time fence.
  • Firming Type 4: Within the planning time fence, the system creates no order proposals automatically. The shortage situation is not adjusted within the planning time fence.
• Planning Time Fence

  Using the planning time fence, you can exclude a certain period from the automatic planning run. In this period, only manual changes are made, depending on the firming type. The system will not create any order proposals within this period.

• External Requirements
  • This indicator is only relevant for reorder point planning. You use it to instruct the system to include customer requirements and manual reservations in the MRP calculation for materials that are planned by reorder point. If a material is planned with this type of reorder point planning, an entry is created in the planning file when creating or changing a sales order or manual reservation.
  • If you want to include requirements in the MRP calculation in addition to the customer requirements and manual reservations, select the following fields:
    • Requirements for materials to be provided in subcontracting
    • Dependent order reservations on the basis of production orders
    • Dependent order reservations on the basis of maintenance orders or networks
    • Release orders
    • Purchase requisition releases
    • Forecast delivery schedules
    • Note: The Incl. external reqmts indicator is only displayed if you select MRP procedure Reorder Point Planning.
• Forecast Indicator

  You use this indicator to determine whether or not the forecast is to be carried out.

• Forecast Consumption Indicator

  You use this indicator to determine which consumption values are to be used in the material forecast.

• Calculate Safety Stock Automatically

  You use this indicator to determine whether the safety stock is to be calculated automatically. The safety stock can be calculated automatically for materials planned with one of the consumption-based planning procedures if the service level has been maintained in the material master record, if historical data exists and if the forecast has been carried out for the material.

• Calculate Reorder Point Automatically

  You use this indicator to determine whether the reorder point is to be calculated automatically. The reorder point is calculated for materials planned in this way if automatic reorder point planning has been selected, if historical data exists, and if the forecast has been carried out for the material.

• Stock/Requirements List - Extended Header

  The Screen Sequence field controls which screens are displayed in the extended header and the order in which they are displayed.

In the standard system, the following MRP types are determined, for example;

• ND => No MRP
• PD => MRP
• VB => Manual reorder point planning
• D1 => Demand-driven replenishment

1. If necessary, change the parameters set in the standard system.
2. Add new MRP types to suit your own requirements.

You use this configuration item to define supply and demand profiles for the material shortage profile. You can group supply and demand elements for the various supply and demand matching evaluations. The grouping of the supply and demand elements is relevant for the evaluation of material shortages. The supply and demand profiles that you create here are assigned to the material shortage profile that you create in a second configuration step.

The standard system comes with predefined versions of the supply and demand profiles that typically need not be changed. The recommendation is that you check that the standard profiles meet your requirements and use them.

Note

You cannot make any changes to the SAP standard profiles.

1. Definition of the Supply Profile

   In this activity, you group the supply elements. The evaluation of shortages distinguishes between four supply groups (stock, execution supplies, ordered supplies, and planned supplies) to which you can assign appropriate supply elements.

2. Definition of the Demand Profile

   In this activity, you group the demand elements. The evaluation of shortages distinguishes between five different demand groups (negative stock, execution demands, ordered demands, planned demands, and forecast demands) to which you can assign appropriate demand elements.

In addition, when creating the demand profile, you can define a category importance and a sales demands importance to prioritize your sales demand elements. This priority information is used in the uncovered demand calculation as an overall sorting criterion. That is, for example, it determines which demand element has the highest delivery priority, the next highest, and so on.

Note

• If you want to create a new profile, you have to use the namespaces X*, Y*, or Z*.
• If you want to change a profile, you have to copy one of the predefined profiles and adapt them to your business needs. You also have to use the namespaces X*, Y*, or Z* for your copied profiles.
• If you don't need a supply or demand element in your supply or demand profile, you can assign the supply group or demand group option Blank - No Supply or Blank - No Demand. Otherwise, the MRP element category * All other supply elements or * All other demand elements collects all the MRP element categories that you have not assigned to any supply or demand group.

You use this configuration item to define the material shortage definitions that are displayed in the SAP Fiori apps for material requirements planning and in the SAP Fiori apps for demand-driven replenishment. You can create material shortage profiles. One material shortage profile can contain several material shortage definitions that each provide a set of rules the system uses, for example, when calculating material shortages and uncovered demand. These rules define the scope of the shortage calculation meaning the supply and demand elements to be considered as well as the conditions that have to be met to be a relevant shortage.

The material shortage definitions are displayed in the SAP Fiori apps for material requirements planning such as Monitor External Requirements or Monitor Material Coverage. They appear in the Shortage Definitions drop-down list and provide different views on the calculation of material shortages.

In the SAP Fiori apps for demand-driven replenishment such as Replenishment Planning and Replenishment Execution, the calculated material shortage appears on the Replenishment Details page displaying the shortage alerts.

The standard system comes with predefined material shortage profiles with material shortage definitions. Check whether these standard settings are sufficient for your business needs. If not, copy the SAP standard material shortage profiles and make any necessary changes.

Note

You cannot make any changes to the SAP standard profiles.

1. Create the material shortage profile and assign supply and demand profiles

   You copy the SAP standard material shortage profile and assign the appropriate supply and demand profiles.

2. Maintain material shortage definition
   • You define exactly which supply and demand groups are to be considered for each material shortage definition. This determines which supply and demand elements are to be considered for supply and demand matching.
   • You also specify here the material shortage definitions available in apps for demand-driven replenishment by selecting the Demand-Driven checkbox.
   • In addition, you define the evaluation horizon in workdays here and by selecting the Calculate Uncovered Demand checkbox, you can define that uncovered demands are to be calculated in addition to material shortages.
3. Maintain the material shortage threshold type
   • If you have created a material shortage definition to calculate material shortages only (that is, you have not selected the Calculate Uncovered Demand checkbox), then you also have to define the material shortage threshold type. This specifies when a planning situation is to be considered as a relevant shortage to be displayed in the material list.
   • If you have created a material shortage definition and have selected the Calculate Uncovered Demands checkbox so that uncovered demands are also calculated, you cannot maintain the threshold type manually. In this case, the system automatically sets the threshold type to Available Quantity Below Zero and determines a material shortage when the available stock quantity falls below zero.

You have created a material shortage profile with the following four material shortage definitions:

• Stock Days' Supply
  • Supply Groups: Stock
  • Demand Groups: All Demands
  • Definition Type: Material Shortage Calculation (Calculate Uncovered Demands checkbox is not selected)
• All Supplies vs. All Demands (MRP Standard Logic)
  • Supply Groups: All Supplies
  • Demand Groups: All Demands
  • Definition Type: Material Shortage Calculation
• Planned Supplies vs. Ordered Demands
  • Supply Groups: Planned Supplies
  • Demand Groups: Ordered Demands
  • Definition Type: Material Shortage Calculation + Uncovered Demands Calculation (Calculate Uncovered Demands checkbox is selected)
• Ordered Supplies vs. Planned Demands
  • Supply Groups: Ordered Supplies
  • Demand Groups: Planned Demands
  • Definition Type: Material Shortage Calculation + Maximum Coverage Calculation (MaxCovCalc checkbox is selected)

As a result, all four shortage definitions would be available in the SAP Fiori apps Monitor Material Coverage and Monitor Production Orders or Process Orders. However, only shortage definition 3 would be available in the apps Monitor External Requirements and Monitor Internal Requirements.

You use this configuration item to assign material shortage profiles to users. The assigned material shortage profile controls which material shortage definitions the user can choose from in the SAP Fiori apps for Material Requirements Planning.

In the standard system, this table is empty and the system automatically uses the SAP standard profile SAP000000001 for all users. If necessary, you can change this standard behavior.

• If you do not make any changes in this table, the system automatically uses the SAP standard profile SAP000000001 as the default value.
• If you want to assign the SAP standard profile (or an alternative profile that you have already created) to the majority of your users but want to assign a different profile to certain users, you can enter * in the User field and assign the appropriate material shortage profile.
• You can then enter other individual users to whom you want to assign different profiles and assign the appropriate material shortage profile.
• To enter the individual users, you can use the input help, which provides you with the list of business users that are maintained in the Maintain Business Users app.