1 Introduction to MRP with SAP S/4HANA

19

1.1 MRP Basics

19

1.2 MRP within the Supply Chain in SAP Systems

20

1.3 MRP with SAP S/4HANA

24

1.3.1 Classic MRP

24

1.3.2 MRP Live

24

1.3.3 MRP Cockpit

25

1.3.4 Demand-Driven MRP

27

1.3.5 Predictive Material and Resource Planning

28

1.4 Summary

28

2 MRP Basics

29

2.1 MRP Procedures

29

2.1.1 Material Requirements Planning

30

2.1.2 Master Production Scheduling

31

2.1.3 Consumption-Based Planning

33

2.1.4 Demand-Driven MRP

34

2.2 The MRP Planning Process

35

2.2.1 Reading the Planning File

36

2.2.2 Calculating the Net Requirements

37

2.2.3 Calculating the Procurement Quantity

39

2.2.4 Determining the Replenishment Proposal Type

41

2.2.5 Scheduling Replenishment Proposals

43

2.2.6 Exploding the BOM

50

2.2.7 Creating Exception Messages

52

2.3 Summary

53

3 Master Data and Basic Settings

55

3.1 Material Master

56

3.1.1 MRP Type

62

3.1.2 Lot-Sizing Procedures

76

3.1.3 Procurement Types and Special Procurement Types

85

3.1.4 Scheduling Parameters

87

3.1.5 Net Requirements Calculation

90

3.1.6 MRP Area

93

3.2 Procurement Master Data

95

3.2.1 Internal Procurement

97

3.2.2 External Procurement

112

3.2.3 Quota Arrangement

121

3.3 Planning File

126

3.4 Summary

128

4 Configuring MRP

131

4.1 Overall Plant Parameters

132

4.1.1 Maintain Environment

134

4.1.2 Maintain Master Data

136

4.1.3 Maintain Planned Orders

141

4.1.4 Maintain Planning Run

142

4.2 MRP Group

158

4.2.1 Consumption Mode/Adjustment Horizon

160

4.2.2 Horizons

160

4.2.3 Determine Production Storage Location

162

4.2.4 Convert Planned Order

163

4.2.5 Program Plan: Independent Requirements Split

163

4.2.6 Evaluation

164

4.2.7 Planning Run

164

4.2.8 External Procurement

169

4.2.9 Availability Check

170

4.3 MRP Type

170

4.4 Lot-Sizing Procedure

174

4.5 Availability Check

178

4.6 MRP Areas

180

4.7 Parallel Processing

185

4.8 Summary

187

5 Running MRP

189

5.1 MRP Live versus Classic MRP

189

5.2 Classic MRP

193

5.2.1 Control Parameters

194

5.2.2 Single-Item/Single-Level Planning

197

5.2.3 Single-Item/Multilevel Planning

199

5.2.4 Single-Item Interactive Planning

202

5.2.5 Multilevel Sales Order/Project Planning

204

5.2.6 Total Planning Run

206

5.2.7 Master Production Scheduling

209

5.3 MRP Live

211

5.3.1 MRP Dispatcher

211

5.3.2 MRP Live Control Parameters

212

5.3.3 Running MRP Live in SAP GUI

214

5.3.4 SAP Fiori

216

5.4 Planning PP/DS Materials in MRP Live (One MRP Run)

221

5.5 Summary

223

6 Evaluating the MRP Results

225

6.1 Exception Messages

225

6.2 Rescheduling Checks

230

6.3 The Stock/Requirements List

235

6.3.1 Individual Access

236

6.3.2 Collective Access

254

6.4 MRP List

260

6.5 Information and Settings for Materials in MRP on SAP HANA

263

6.6 Order Report

264

6.7 Pegged Requirements

268

6.8 Evaluation of the Planning Situation

270

6.9 MRP Cockpit

272

6.9.1 Shortage

273

6.9.2 Accessing SAP Fiori Applications for MRP

275

6.9.3 Monitor and Manage Material Coverage

277

6.9.4 Monitor and Manage Internal Requirements

282

6.9.5 Monitor and Manage External Requirements

284

6.9.6 Monitor and Manage Production or Process Orders

285

6.9.7 Display MRP Master Data Issues

289

6.9.8 Manage Change Requests

290

6.9.9 Detect MRP Situations

293

6.10 Summary

301

7 Managing Planned Orders

303

7.1 Planned Orders

303

7.2 Planned Order Availability Check

308

7.3 Planned Order Conversion

311

7.4 Additional Options for Mass Processing

317

7.5 Summary

321

8 Advanced MRP Features

323

8.1 Subcontracting Planning

323

8.2 Planning Calendar

329

8.3 BOM Explosion Number

333

8.4 Parts Interchangeability

336

8.4.1 Creating an MPN-MRP Set

336

8.4.2 Planning an MPN-MRP Set

339

8.5 Range of Coverage Profile (Dynamic Safety Stock)

341

8.6 Summary

346

9 Demand Management

347

9.1 What Is Demand Management?

348

9.2 Planning Strategies

352

9.2.1 Planning with Final Assembly (Strategy 40)

355

9.2.2 Net Requirements Planning (Strategy 10)

356

9.2.3 Gross Requirements Planning (Strategy 11)

358

9.2.4 Make-to-Order Production (Strategy 20)

359

9.2.5 Planning without Final Assembly (Strategies 50 and 52)

361

9.2.6 Planning with a Planning Material (Strategies 60 and 63)

363

9.2.7 Planning at Assembly Level (Strategies 70, 74, and 59)

365

9.2.8 Assembly-to-Order (Strategies 81 through 86)

367

9.3 Creating a Demand Plan

368

9.3.1 Splitting Independent Requirements

373

9.3.2 PIR Reorganization

373

9.4 Configuring Demand Management

374

9.5 Summary

377

10 Demand-Driven MRP

379

10.1 What Is DDMRP?

379

10.1.1 Buffer Calculation

381

10.1.2 The DDMRP Process

384

10.2 Setting Up DDMRP

386

10.2.1 Product Classification

386

10.2.2 Mass Maintenance of Products

394

10.2.3 Buffer Proposal Calculation

396

10.3 Running DDMRP

400

10.4 Integrating DDMRP with SAP IBP

409

10.5 Summary

410

11 Long-Term Planning

413

11.1 Creating a Long-Term Planning Scenario

414

11.2 Running Long-Term Planning

419

11.3 Processing Simulative Planned Orders

422

11.4 Evaluating the LTP Results

426

11.4.1 Evaluating Work Center Capacity

429

11.4.2 Transferring the LTP Results to the Logistics Information System

430

11.5 Cleaning Up the Long-Term Planning Scenario

435

11.6 Summary

438

12 Predictive Material and Resource Planning

441

12.1 Prerequisites to Run pMRP

442

12.2 Creating a pMRP Simulation

443

12.3 Processing pMRP Simulations

448

12.4 Releasing the pMRP Simulation

456

12.5 Summary

457

13 Administering MRP

459

13.1 Housekeeping MRP

459

13.1.1 Keeping the Planning File Consistent

460

13.1.2 Managing Background Jobs

461

13.1.3 Deleting Old MRP Lists

464

13.2 Troubleshooting MRP

464

13.2.1 Material Not Planned

465

13.2.2 Inconsistencies

467

13.2.3 MRP Live Support Functions

473

13.3 Improving MRP Performance

478

13.3.1 Classic MRP

478

13.3.2 MRP Live

482

13.3.3 Frequent Causes and Solutions

490

13.4 Summary

492

14 Enhancing MRP

493

14.1 Enhancing Classic MRP

494

14.2 Enhancing MRP Live

498

14.3 Enhancing the SAP Fiori Applications of the MRP Cockpit

501

14.4 Summary

504

15 Migrating to SAP S/4HANA

505

15.1 Performing Readiness Check

505

15.2 Assessing Simplifications in MRP

507

15.2.1 Planning File

507

15.2.2 Storage Location Planning

509

15.2.3 Subcontracting

511

15.2.4 Production Versions

511

15.2.5 External Procurement

512

15.2.6 Total Requirements Cleanup

513

15.3 Reviewing Custom Code

515

15.4 Evaluating New MRP Features

516

15.4.1 MRP Live

516

15.4.2 Demand-Driven MRP

517

15.4.3 Predictive Material and Resource Planning

517

15.4.4 SAP Fiori and the MRP Cockpit

518

15.5 Summary

519

Appendices

521

A Roadmap for MRP in SAP S/4HANA

521

B The Author

525