When executing a production order, you must ensure that the material components are available in the required quantity at the scheduled time. Therefore, you perform material availability checks for your production orders.
Material Availability Check
When a production order is created, the system determines requirement quantities and requirement dates for the material components in the order: The requirement quantities are determined based on the selected bill of material and the planned production quantity of the order. The requirement dates result from the start dates of the operations to which the material components are assigned. Let's consider the following scenario as an example: We create a production order for the production of 100 bicycles. According to the bill of material, 200 wheels are required. The bicycles are to be assembled in the operation Wheel Assembly. Scheduling has determined that this operation should start on April 12 at 2:30 pm. The 200 wheels are therefore to be picked on this date.
You can use the material availability check to ensure that the required component quantities are available at the scheduled time. A material availability check is usually automatically triggered at order creation and/or at order release (see Customizing activity Define Checking Control). However, a production controller can also trigger an availability check manually at any time. A manual check can be triggered for an individual order (for example, in the Change Order application) or for several orders simultaneously using mass processing. The latter can be executed in the foreground (for example, in the Manage Production Orders app) or in the background.
When the material availability check is triggered, a scope of check is determined for each material component. The scope of the check is set in the Customizing activity Define Scope of Check. It defines, for example, the stocks and the receipts and issues to be taken into account by the availability check. You can define different scopes of checks to be executed at order creation and order release. For example, when a production order is created, the planned goods receipts of purchase orders and the on-stock quantity of a material component are to be taken into account, but when an order is released, only the on-stock quantity is to be considered. Alternatively, when a production order is created, you could also take the material in quality inspection stock into account, but at order release, you require that the components must be available in unrestricted-use stock.
As a result of a material availability check, committed quantities are recorded for the checked components and the order status is updated. If all components are completely available at the required time, the Material committed order status is set. If one or more components cannot be confirmed as requested, the MSPT Material shortage status is set, and the material shortage is recorded in a missing parts list and in the missing parts information system. Using the Customizing activity Define Checking Control, you can define whether orders cannot be opened and/or released in case of material shortage.
ATP Method: Example
The material availability check is performed according to the available to promise method (ATP). The system checks for every requirement whether the required quantities are available at the requested time and commits them if they are available. Let us discuss the ATP approach using the following simple example:
In this demonstration, you will see the following process steps:
- Execute and analyze an automatic material availability check.
- Execute and analyze a manual material availability check.
- Execute and analyze a material availability check with missing parts.
- Analyze a missing part situation in the order information system and in the availability overview.