Configuring Make-to-Stock Production – Repetitive Manufacturing (BJH)

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 once 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 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 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.

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 the parameters for scheduling planned orders for each plant, order type, and production scheduler. This comprises the following settings: detailed scheduling for date adjustment when deadlines are exceeded, scheduling control for detailed scheduling, and reduction.

• In Detailed Scheduling, you define the following:
  • How production dates are determined
  • Whether capacity requirement are generated
• In Adjust Scheduling, you specify the following:

  Whether and how basic dates are adjusted to production dates, for example, when exceeding dates, and what the dates for dependent requirements should be

• In Scheduling Control for Detailed Scheduling, in addition to specifying the control parameters for detailed scheduling, you specify the following:
  • Scheduling Type

    You specify the scheduling direction. You can also specify that a scheduling run should only be used to generate capacity requirements.

  • Start Date in the Past

    You specify how many days an order may lie in the past before today's scheduling is automatically triggered.

  • Automatically Calculate Dates

    You specify whether scheduling is automatically carried out when saving.

  • Display log automatically

    You specify whether the log is automatically displayed after scheduling.

  • Required Date of Material

    You specify where the required date for a component should be with respect to the operation.

  • Schedule Exact to the Break

    You specify that the break times should be taken into account exactly.

• In Reduction, you specify the following:
  • Whether in the order or in the collective order all the operations are reduced or only those on the critical path. Reduction along the critical path is only possible for production orders and planned orders with parallel sequences and for collective orders that contain production orders or planned orders.
  • Up to which maximum reduction level the reduction is to take place
  • To what percentage the floats before and after production in every reduction level should be reduced.

Define the scheduling parameters for planned orders.

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.