Applicable Process Steps
Anonymous Forecast and MRP
|Create Planned Independent Requirements||Planned Independent Requirements (PIRs) are used to perform demand management functions. A planned independent requirement contains one planned quantity and one date, or a number of planned independent requirements schedule lines, that is, splitting one planned quantity according to dates.|
Instead of creating a single requirement, sometimes a requirement plan that includes one or more planned independent requirements can be maintained for mass processing. In this case, the requirements are grouped and maintained under a requirement plan number.
|Material Requirements Planning||The aim of material requirements planning is to tailor available capacities and receipts on time to suit requirements quantities. You can use MRP or consumption-based planning for this purpose.|
|Adjust Planning in Planning Table||This step describes how to plan the production of materials on the production lines.|
Classic Kanban: External Procurement with Requirements Planning
Kanban board is one of the tools that can be used to change the container status, which can provide both demand source (consumer) and supply source (supplier, producer) with a detailed overview of Kanban circulation. In addition, Material Replenishment could be quickly triggered by setting Kanban container status.
You can perform the automatic Kanban calculation. The system calculates on the basis of existing requirements and your specified calculation parameters, either the number of Kanban containers (cards) that are to circulate in a control cycle or the quantity of material to be procured per Kanban container.
With the number of Kanban containers and the quantity of material per container, the material circulation and the stock of material in the control cycle are defined. To ensure the lowest possible stock of material while simultaneously achieving a secure material supply, the setting of these two values must be optimized. Because the requirement situation often fluctuates considerably in many industries, it is necessary to check and adjust these values with the automatic Kanban calculation on a regular basis.
|Check Dependent Requirement of Material||In this step, you check whether dependent requirements for the material exist.|
|Release Scheduling Agreement||This process step shows you how to release scheduling agreement delivery schedule with forecast schedule.|
|Set Available Kanban to EMPTY||In this step, you set an available Kanban to EMPTY to trigger the external procurement of the material.|
Posting the Goods Receipt for External Procurement
You can post goods receipt for external procurement either by changing the Kanban container to FULL or by posting goods receipt for Just-in-time (JIT) call.
|Option A: Change the Kanban to FULL||In this step, you change the status of the Kanban you processed in previous step to FULL for the material.|
|Option B: Goods Receipt for JIT Call||This process step shows you how to post goods receipt for JIT call. It is useful especially when you want to post partial quantities of individual items of a summarized JIT call, or for more containers at once.|
|Precalculation of Kanbans for Future Requirements||In this step, you precalculate the Kanbans you need for the next period (month).|
|Release Proposal of Kanbans Required for Future Period||In this step, you check the proposal for future Kanban requirements before you release the proposal.|
|Unlock New Kanbans||If Kanbans are created during Kanban calculation release, their statuses are locked. When they are really needed, they have to be unlocked.|
|Alert for Delayed Replenishments - Creation of Replenishment Elements / JIT Calls (Optional)||In this step, you set more than the maximum allowed number of Kanbans to EMPTY to force the creation of alerting, which causes delayed replenishments.|
|Alert for Delayed Replenishments - Evaluation of Replenishment Elements / JIT Calls (Optional)||In this step, you check the alerts caused by previous step.|
Event-driven Kanban: External Processing and PDF Print of Kanban Card
In event-driven Kanban, material provision is not based on a predefined number of Kanbans or a predefined Kanban quantity. Instead, it is based on actual material consumption. The material is not continually provided and replenished at a supply area. It is only replenished when specifically requested. In this case, the material is procured externally with purchase orders.
|Create Event-Driven Kanban||In this step, you create a Kanban for the material.|
|Variant 1: Set Kanban to FULL||In this step, you set a Kanban to full for the material.|
The Kanban status is changed to FULL, which automatically results in a goods receipt in the storage location.
|Variant 2: Goods Receipt||In this step, you set a Kanban to full for the material.|
The goods receipt to a purchase order with Kanban indicator automatically results in a status change of the Kanban to Full. This corresponds to the purchase order.
|Print the Kanban Card||In this step, you print the Kanban Card.|
|Set Available Kanban to EMPTY||In this step, you set an available Kanban to Empty. The status change to empty results in an event-driven Kanban process in the deletion of the Kanban.|
|Check the Status of the Printing and Review the PDF (Optional)||In this step, the printed Kanban card is validated for testing purposes.|
If you want to print the Kanban card in reality, SAP Cloud Print Manager has to be installed. For more information, see SAP Note 2099739.
|Repetitive Manufacturing Backflush||This step executes multiple activities in a single step, such as finished product goods receipt, backflush of component materials, posting of costs to cost collector, and creation of material and journal entries.|
Errors can occur in backflushing. For example, there may not be sufficient warehouse stock available or important data, such as the issue storage location may be missing. You then have the following options:
|Post Processing List of Error Records||To post-process backlogs from backflushing, you can use this function to create a list of components that have to be post-processed.|
|Review Manufacturing Object Pages||This process step shows you how to review different object pages available for different roles in the Manufacturing area.|