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SAP MRP Strategies Made Easy
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MRP Strategies Made Easy
Contents
© 1998 SAP Labs, Inc. iii
Contents
Terminology..................................................................................................................................................................................................... vii
Typeface Styles...............................................................................................................................................................................................viii
Special Icons....................................................................................................................................................................................................ix
Chapter 1: Introduction..............................................................................................................................................1–1
Overview .......................................................................................................................................................................................................1–1
Questions ..............................................................................................................................................................................................1–2
Planning Level.......................................................................................................................................................................................1–2
Production Level....................................................................................................................................................................................1–3
Procuring Components..........................................................................................................................................................................1–3
Responsibility for Production.................................................................................................................................................................1–3
Influence of Stock..................................................................................................................................................................................1–3
Consumption Strategies and Logic ...............................................................................................................................................................1–4
Purpose.................................................................................................................................................................................................1–4
Prerequisites..........................................................................................................................................................................................1–4
Determining the Requirements Type.............................................................................................................................................................1–5
Activities ................................................................................................................................................................................................1–5
Table of Planning Strategy Assignments...............................................................................................................................................1–7
Cross-Plant Planning...................................................................................................................................................................................1–10
Purpose...............................................................................................................................................................................................1–10
Prerequisites........................................................................................................................................................................................1–10
Process Flow.......................................................................................................................................................................................1–10
Chapter 2: Strategies for Make-to-Stock Production..............................................................................................2–1
Purpose.........................................................................................................................................................................................................2–3
Prerequisites..........................................................................................................................................................................................2–3
Process Flow.........................................................................................................................................................................................2–3
Planning with Final Assembly (40) ................................................................................................................................................................2–4
Purpose.................................................................................................................................................................................................2–4
Prerequisites..........................................................................................................................................................................................2–4
Process Flow.........................................................................................................................................................................................2–5
Key Properties of Strategy 40................................................................................................................................................................2–5
Other Areas...........................................................................................................................................................................................2–6
Sample Scenario: Strategy 40...............................................................................................................................................................2–6
Coping with Insufficient Coverage of Components..............................................................................................................................2–12
Production by Lot Size (30).........................................................................................................................................................................2–14
Purpose...............................................................................................................................................................................................2–14
Prerequisites........................................................................................................................................................................................2–14
Process Flow.......................................................................................................................................................................................2–14
Key Properties of Strategy 30..............................................................................................................................................................2–15
Other Areas.........................................................................................................................................................................................2–15
Sample Scenario: Strategy 30.............................................................................................................................................................2–16
Net Requirements Planning (10).................................................................................................................................................................2–18
Purpose...............................................................................................................................................................................................2–18
Prerequisites........................................................................................................................................................................................2–19
Process Flow.......................................................................................................................................................................................2–19
Key Properties of Strategy 10..............................................................................................................................................................2–19
Other Areas.........................................................................................................................................................................................2–20
Sample Scenario: Strategy 10.............................................................................................................................................................2–20
Comparing Strategies 10 and 40.........................................................................................................................................................2–24
Combining Strategies 10 and 30.........................................................................................................................................................2–26
MRP Strategies Made Easy
Contents
iv
© 1998 SAP Labs, Inc.
Gross Requirements Planning (11).............................................................................................................................................................2–27
Purpose...............................................................................................................................................................................................2–27
Prerequisites .......................................................................................................................................................................................2–27
Process Flow.......................................................................................................................................................................................2–27
Other Areas.........................................................................................................................................................................................2–28
Sample Scenario: Strategy 11.............................................................................................................................................................2–28
Planning Without Final Assembly and Without MTO (52) ...........................................................................................................................2–32
Purpose...............................................................................................................................................................................................2–32
Prerequisites .......................................................................................................................................................................................2–33
Process Flow.......................................................................................................................................................................................2–33
Key Properties of Strategy 52 .............................................................................................................................................................2–33
Other Areas.........................................................................................................................................................................................2–34
Sample Scenario: Strategy 52.............................................................................................................................................................2–34
Planning with a Planning Material and Without MTO (63)...........................................................................................................................2–40
Purpose...............................................................................................................................................................................................2–40
Prerequisites .......................................................................................................................................................................................2–40
Process Flow.......................................................................................................................................................................................2–42
Key Properties of Strategy 63 .............................................................................................................................................................2–42
Other Areas.........................................................................................................................................................................................2–42
Sample Scenario: Strategy 63.............................................................................................................................................................2–43
Chapter 3: Strategies for Planning Components.................................................................................................... 3–1
Overview .......................................................................................................................................................................................................3–2
Prerequisites .........................................................................................................................................................................................3–2
Process Flow.........................................................................................................................................................................................3–2
Planning at Assembly Level (70)...................................................................................................................................................................3–3
Purpose.................................................................................................................................................................................................3–3
Prerequisites .........................................................................................................................................................................................3–3
Process Flow.........................................................................................................................................................................................3–4
Key Properties of Strategy 70 ...............................................................................................................................................................3–4
Sample Scenario: Strategy 70...............................................................................................................................................................3–5
Planning at Phantom Assembly Level (59) ...................................................................................................................................................3–9
Purpose.................................................................................................................................................................................................3–9
Prerequisites .........................................................................................................................................................................................3–9
Process Flow.......................................................................................................................................................................................3–10
Key Properties of Strategy 59 .............................................................................................................................................................3–10
Sample Scenario: Strategy 59.............................................................................................................................................................3–11
Strategies for Multi-Use Materials...............................................................................................................................................................3–14
Definition .............................................................................................................................................................................................3–14
Use......................................................................................................................................................................................................3–15
Combining Sales Order and Production Requirements ......................................................................................................................3–15
Planning Requirements Separately.....................................................................................................................................................3–17
Stock-keeping at Different BOM Levels ......................................................................................................................................................3–20
Stocking Level—Two Levels Below the Finished Product ..................................................................................................................3–21
Stocking Level—One Level Below the Finished Product ....................................................................................................................3–21
No Components Stored on Level Below the Finished Product ...........................................................................................................3–21
Replenishment Lead Time ..........................................................................................................................................................................3–22
Definition .............................................................................................................................................................................................3–22
Use......................................................................................................................................................................................................3–22
Integration ...........................................................................................................................................................................................3–22
Chapter 4: Strategies for Make-to-Order (MTO) Production .................................................................................. 4–1
Overview .......................................................................................................................................................................................................4–2
Prerequisites .........................................................................................................................................................................................4–2
Process Flow.........................................................................................................................................................................................4–2
MRP Strategies Made Easy
Contents
© 1998 SAP Labs, Inc. v
Planning Without Final Assembly (50) ..........................................................................................................................................................4–3
Purpose.................................................................................................................................................................................................4–3
Prerequisites..........................................................................................................................................................................................4–3
Process Flow.........................................................................................................................................................................................4–4
Key Properties of Strategy 50................................................................................................................................................................4–4
Other Areas...........................................................................................................................................................................................4–5
Sample Scenario: Strategy 50...............................................................................................................................................................4–5
Planning with a Planning Material (60)..........................................................................................................................................................4–8
Purpose.................................................................................................................................................................................................4–8
Prerequisites..........................................................................................................................................................................................4–9
Process Flow.......................................................................................................................................................................................4–10
Sample Scenario: Strategy 60.............................................................................................................................................................4–10
Make-to-Order Production (20) ...................................................................................................................................................................4–13
Purpose...............................................................................................................................................................................................4–13
Prerequisites........................................................................................................................................................................................4–13
Process Flow.......................................................................................................................................................................................4–14
Key Properties of Strategy 20..............................................................................................................................................................4–14
Other Areas.........................................................................................................................................................................................4–14
Sample Scenario: Strategy 20.............................................................................................................................................................4–14
Chapter 5: Production with Variant Configuration..................................................................................................5–1
Overview .......................................................................................................................................................................................................5–2
Strategies for Variants...................................................................................................................................................................................5–3
Variants and Variant Determination.......................................................................................................................................................5–3
Make-to-Stock Production for Variants..................................................................................................................................................5–5
Make-to-Order Production for Variants..................................................................................................................................................5–6
Planning Variants (54)...................................................................................................................................................................................5–9
Master Data Setup...............................................................................................................................................................................5–11
Process Flow.......................................................................................................................................................................................5–13
Other Areas/FAQs...............................................................................................................................................................................5–15
Characteristics Planning..............................................................................................................................................................................5–16
Overview..............................................................................................................................................................................................5–16
Creating Planned Independent Requirements for Characteristics Planning .......................................................................................5–17
Integrating Logistics Information System (LIS)....................................................................................................................................5–22
Characteristics Planning with Dependent Requirements (56).............................................................................................................5–23
Assembly Processing with Characteristics Planning (89)....................................................................................................................5–26
Make-to-Order Production with Configurable Materials (25).......................................................................................................................5–32
Strategy Focus ....................................................................................................................................................................................5–32
Master Data Settings...........................................................................................................................................................................5–32
Process Flow.......................................................................................................................................................................................5–32
Chapter 6: Assembly Orders.....................................................................................................................................6–1
Overview .......................................................................................................................................................................................................6–2
Assembly Processing—Procedure........................................................................................................................................................6–2
Custom Strategies.........................................................................................................................................................................................6–3
Copy the Proper Requirements Classes into your Custom Requirements Class..................................................................................6–4
Create a Requirements type and Include the Newly Created Requirements Class..............................................................................6–5
Create a Planning Strategy ...................................................................................................................................................................6–6
Create a Strategy Group and Include the Newly Created Planning Strategy........................................................................................6–8
Assembly Processing with Production Orders (82).......................................................................................................................................6–9
Creating a Production Order Directly or Through a Planned Order.....................................................................................................6–10
Special Settings for Production Orders ...............................................................................................................................................6–10
Sample Scenario: Strategy 82.............................................................................................................................................................6–11
Assembly Processing with Planned Orders (81).........................................................................................................................................6–13
Special Settings for Planned Orders ...................................................................................................................................................6–14
MRP Strategies Made Easy
Contents
vi
© 1998 SAP Labs, Inc.
Assembly Processing with Repetitive Manufacturing..........................................................................................................................6–14
Special Settings for Repetitive Manufacturing.....................................................................................................................................6–15
Sample Scenario: Strategy 81.............................................................................................................................................................6–16
Assembly Processing with Characteristics Planning (89) ...........................................................................................................................6–18
Index.........................................................................................................................................................................................................................1
MRP Strategies Made Easy
Terminology
© 1998 SAP Labs, Inc. vii
Terminology
The following sections explain the terminology used throughout this guide.
Click
When you see the word “click,” use the mouse to point and click to perform the action. “Click” is always
used for on-screen buttons. For example:
The following phrases ask you to use
your left mouse button to click the on-
screen button:
1. Click Authorizations.
2. Click Back.
3. Click possible entries.
Number callouts on the screenshot
help clarify the activity.
Choose
The word “choose” always appears
with menu paths. Use your mouse to
select the menu item from the top of
your window. In some cases, a menu
path might lead you through several
screens.
Menu paths appear as follows:
1. Choose Activity group → Transport.
1
1
3
2
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