Configuring Replenishment Strategies

In the configuration activity, Define In-House Production Strategies, you define Kanban replenishment strategies for in-house production.

The SAP preconfigured replenishment strategies start with PD. It is therefore recommended that you avoid using this naming pattern when you create your own replenishment strategies.

Each strategy is defined by the following data:

• Control Type:

  The control type determines which replenishment and control elements are used for controlling the procedure and the costs of the replenishment. You can select one of the following options:

  • Working with Kanbans and cost collector
  • Working with planned orders and cost collector
  • Working with production orders
  • Replenishment using containers / MRP
  • Working with planned orders / MRP
  • Working with production orders / MRP
• Order Type:

  Production order type for replenishment using production orders.

• Goods Receipt:

  Movement type is used to post the automatic goods receipt for materials produced in-house. In Kanban, if you do not enter a movement type, the standard movement type 101 is used.

• Use Packing Instruction:

  This setting controls the use of a packing instruction for Kanban container creation in the Kanban control cycle.

• Signal Lock in Minutes:

  This check box defines a lock time that is activated once you have triggered the Kanban signal. In this time, if you go over the bar code a second time by mistake, for example, the system does not change the status.

• Consider Capacity:

  You can set the Consider Capacity check box to specify that the system is to take account of the available capacity of the work center in the Kanban calculation and calculate a trigger point for assigned materials to improve capacity utilization.

  In the Kanban calculation, the system performs the following additional steps:

  • The system calculates the capacity requirements for all control cycles that consume the available capacity of the same work center.
  • The system checks whether the available capacity is sufficient to manufacture the planned production quantity.
  • The system calculates trigger points for individual control cycles or for certain groups of control cycles with the aim of reducing setup times.

  It is possible to consider capacities in all in-house production strategies that use planned or production orders as replenishment elements and that use one of the following control types:

  • Working with planned orders and cost collector
  • Working with production orders
  • Working with planned orders / MRP
  • Working with production orders / MRP
• Consumption to Cost Center:
  • Usage:

    This setting determines that a material is consumed to the cost center.

    Materials that are not backflushed can thus be procured via Kanban. The bulk material check box must be set for the corresponding material in the material master.

    The system posts the material first of all to the demand source storage location when you set the container status to Full. When you set the status to Empty it posts the consumed quantity to the cost center.

  • Movement Type:

    Determines the movement type with which the system posts the material from the storage location to the cost center. If you do not enter a movement type, the system standard movement type 201 is used.

• Print Kanban:

  In the print Kanban, Form Template defines the content and layout of the Kanban card.

• Print Control Cycle:

  In the print control cycle, Form Template defines the content and layout of the printed Kanban control cycle.

In the configuration activity, Define External Procurement Strategies, you define Kanban replenishment strategies for external procurement.

The delivery can either be made directly to the production line (ship-to-line) or via a central goods receiving area.

The SAP preconfigured replenishment strategies start with PD. It is therefore recommended that you avoid using this naming pattern when you create your own replenishment strategies.

The strategies are set up using the following data:

• Control Type:

  The control type defines the procurement elements used to control replenishment. You can select one of the following options:

  • Working with purchase orders
  • Working with scheduling agreements
  • Working with stock transfer order
  • Working via source list
  • Replenishment using containers / MRP
  • Working with summerized JIT calls
• Order Type:

  Purchase order type for replenishment using purchase orders.

• Goods Receipt:

  Movement type used to post the goods receipt of the material. In Kanban, if you do not enter a movement type, the standard movement type 101 is used.

• Sub-Day Scheduling:

  This check box determines that the planned delivery date and time for event-driven containers is calculated according to the supply planning shift sequence defined in the calculation profile. This setting has no effect if the user enters an explicit planned delivery date and time.

• Scheduling According to Calculation Profile:

  You select this check box to calculate the planned delivery date and time for all external replenishment strategies, according to the supply working times defined in the calculation profile. This setting has no effect if the user enters an explicit planned delivery date and time.

• Use Packing Instructions:

  This setting controls the use of a packing instruction for Kanban container creation in the Kanban control cycle.

• Signal Lock in Minutes:

  This check box defines a lock time that is activated once you have triggered the Kanban signal. In this time, if you go over the bar code a second time by mistake, for example, the system does not change the status.

• Consumption to Cost Center:
  • Usage:

    This setting determines that a material is consumed to the cost center.

    Materials that are not backflushed can thus be procured via Kanban. The bulk material check box must be set for the corresponding material in the material master.

    You have two possibilities for posting consumption to the cost center:

    • Post procurement to cost center:

      Here you consume the material directly to the cost center. The system posts the material immediately to the cost center when you set the Kanban container status to Full.

    • Post withdrawal to cost center:

      Here, the system posts the material first of all to the demand source storage location when you set the container status to Full. When you set the status to Empty it posts the consumed quantity to the cost center.

  • Movement Type:

    Determines the movement type with which the system posts the material from the storage location to the cost center. If you do not enter a movement type, the system standard movement type 201 is used.

  • Account Assignment Category:

    This check box specifies which account assignment category is to be used when creating a purchase order.

    You use this field if you set procurement for the cost center in the Consumption at Cost Center field and if you work with the replenishment strategy Process with Purchase Orders or Process with Stock Transport Orders and you have not entered any contract in the control cycle.

    The account assignment category you enter here is then used when creating the purchase order. If you do not enter any account assignment category, the account assignment category K is used.

    This check box is not used for any other replenishment strategy. For example, the account assignment category from the contract is used for creating the purchase order if you have entered one in the control cycle.

• Print Kanban:

  The Form Template of print Kanban defines the content and layout of the Kanban card.

• Print Control Cycle:

  The Form Template of print control cycle defines the content and layout of the printed Kanban control cycle.

In the configuration activity, Define Stock Transfer Strategies, you define Kanban replenishment strategies for stock transfer.

In a stock transfer procedure, materials or goods are transported from one storage location to another storage location, usually in the same plant.

The strategies for stock transfer are defined by the following data:

• Control Type:

  The control type defines the procurement elements used to control replenishment. You can select one of the following options:

  • Stock transfer with reservation
  • Direct stock transfer
  • Stock transfer with reservation / MRP
  • Direct transfer posting / MRP
  • Container control without reservation or stock transfer / MRP
  • Stock transfer with warehouse task

  For reservations, the Kanban signal creates a reservation for the material. The person in the storage location fills the container with the information in the reservation list and carries out a manual transfer posting. Then the container is moved to the shop floor.

  For direct posting, the Kanban signal triggers the printing of a goods receipt/issue slip with which the material is withdrawn and packed into the empty containers. With the status change Set container to empty the system automatically posts the goods receipt.

• Cross-Plant:

  This check box determines that the supply source that delivers replenishment for the corresponding control cycle is in a separate plant.

  If you assign a replenishment strategy containing this check box to a control cycle, you must also maintain the supplying plant in the supply source data.

• Movement Type
• Stock Determination Rule:

  The stock determination rule and the stock determination group assigned to the material define the stock determination strategy.

• Search Procedure Batch Determination:

  The search procedure determines the sequence of the strategy types for which the system tries to determine strategy records within the framework of batch determination.

• Sub-Day Scheduling:

  This check box determines that the planned delivery date and time for event-driven containers is calculated automatically, according to the supply planning shift sequence defined in the calculation profile. This setting has no effect if the user enters an explicit planned delivery date and time.

• Use Packing Instructions:

  This setting controls the use of a packing instruction for Kanban container creation in the Kanban control cycle.

• Signal Lock in Minutes:

  This check box defines a lock time that is activated once you have triggered the Kanban signal. In this time, if you go over the bar code a second time by mistake, for example, the system does not change the status.

• Consumption to Cost Center:
  • Usage:

    This setting determines that a material is consumed to the cost center.

    Materials that are not backflushed can thus be procured via Kanban. The bulk material check box must be set for the corresponding material in the material master.

    You have two possibilities for posting consumption to the cost center:

    • Post procurement to cost center:

      Here you consume the material directly to the cost center. The system posts the material immediately to the cost center when you set the Kanban container status to Full.

    • Post withdrawal to cost center:

      Here, the system posts the material first of all to the demand source storage location when you set the container status to Full. When you set the status to Empty it posts the consumed quantity to the cost center.

  • Movement Type:

    Determines the movement type with which the system posts the material from the storage location to the cost center. If you do not enter a movement type, the system standard movement type 201 is used.

• Print Kanban:

  The Form Template of the print Kanban defines the content and layout of the Kanban card.

• Print Control Cycle:

  The Form Template of the print control cycle defines the content and layout of the printed Kanban control cycle.