Kanban with MRP

Hi,
We are operating on Kanban for in house manufactured items.We run monthly MRP by which all our production requirements are getting planned.
For In house manufactured kanban materials we use replenishment strategy 0005 by which a planned order is generated and then it is converted to production order with external number ( We don't want to use internal no. production order which is possible to get by using repl. strategy 0006).
Our concern is there are some oplanned orders that are getting generated through MRP for the same material which is on Kanban,which triggers planning of its raw materials.(we do not want to use consumption based planning for raw materials).
We do not want to generate the planned orders for kanban materials through MRP but at the same time the raw material should get planned.
Since there are 2 sources of planned order generation(MRP and Kanban) the scheduler can not differentiate Kanban planned orders which are to be converted to production orders.
Pl. suggest some method to handle this scenario,
Thanks & Regards
Sandeep Shenoy

Hi,
You can avoid generating Planned orders by MRP for Kanban materials by following setting in the material master of Kanban material:
Go to Material Master-> MRP-4 View->Select Plant & Storage Location then you will find one more Tab in MRP-4 --->Storage Location MRP Tab
Under this tab , in SLoc MRP indicator field select
1 Storage location stock excluded from MRP
Then save the settings.
Your problem will be resolved.
Revert if still any problem / doubt.
Award points if useful.
Regards,
Tejas

Similar Messages

Kanban With MRP and with External vendors

We are implementing SAP 4.7 for one of clients and here is the requirement:
They want to use Kanban with external vendors where once KANBAN is empty, it should create a schedule line for the defined scheduling agreement. Problem is , we have to exclude the material from MRP in order to work with "External Purchase Orders" or "Scheduling Agreement" replenishryment category.
They do not want to exclude the KANBAN materials from MRP but want to use KANBAN for procurement with vendors.
Is this possible?
Because when we try replenishment strategy " Working with MRP" , SAP does not create any PO or Schedule line desite of maintaining all the data. Instead, SAP allows replenishment elements created in MRP run to flow thru and create PO/ Schedule lines.
Is it possible to include the material in plant MRP and still use external procurement kanban?

Hi Vikas
Ia m not familiar with asynchronous MRP. Can you elaborate on that? What specific settings we need to make for that?
Thanks for your help.
Regards.
Mankai

KANBAN w/ MRP Planned Orders

Hi fellow experts. I'm using Kanban with MRP for replenishment via production order.
The MRP run generates planned orders that should not be converted to production orders. Productions orders are generated by Kanban impuls 'empty' reducing planned orders from MRP.
Question: Why do the palnned orders have the conversion flag set. As they shall not be converted (e.g. by job) it would be easier if that PO's would not be set as convertable.
Tnx

Dear,
Which Replenishment Strategies are you using?
0005     Working with plnd orders / MRP
0006     Working with production orders /MRP
If you are using in-house kanban strategy (0005 - Working with planned orders/MRP) in control cycle
      1. Create a one time card using PK23.
      2. The status of th card would be EMPTY.
      3. Now change the status to FULL. The planned order would be consumed.
      4. Now go to PK31 and reverse the card from FULL to EMPTY. A new planned order would be created.
Else use Replenishment Strategy 006
Regards,
R.Brahamnkar

KANBAN External Supplier with MRP

We have a requirement to use KANBAN for external vendors and also do forecasting for same materials using MRP.
Does standard SAP support this?
We are using replenishment strategy 02 ( with SA's ) but it is not working.
Any ideas ??

Hi Prashanth,
It makes no sense to have both KANBAN and MRP for he same material in a plant. KANBAN is an alternative method to material requirements planning! That's why also SAP will not allow that.
The only exception is when the material is in-house manufactured, and you want to pass dependent requirements to it's sons in the BOM via MRP planning and explosion of BOM.
If you only need to pass to your supplier some info on future requirements, but still work operatively via KANBAN, you can try using LTP MRP for that (if planning is demand based), or just material forecast (without MRP) if planning is consumption based.
Regards,
Mario

KANBAN with Quota arrangement

Dear Guru,
Ist possible to use Quota arrangement in KANBAN external Procurement (Scheduling Agreement)?
If so, please advice me how to do it... i am new to KANBAN.
Regards,
Senthil

Hi Kumara,
As per my knowledge Quota Arrangement is not possible to use in KANBAN with Schedulling Agreement.
However pls find below the process steps for KANBAN WITH SCHEDULING AGREEMENT:
You can carry out KANBAN with Replenishment Strategy- External Procurement in following two ways :
1.     External procurement from Vendor to Main Stores:
Basic rules and Prerequisites:
u2022     MRP type should be u2018NDu2019 in MRP1 view of material master.
u2022     Availability check should be u201CKPu201D in MRP3 view of material master.
u2022     Material received from vendor is directly posted to unrestricted stock. Inspection at vendors place or vendoru2019s process control to ensure rejection free material. Inspection set up in Material master should be inactive.
u2022     Backflush is not required and Material is issued against a Pick List for Production Order.
Process steps:
1.     Create supply area for Main stores. TC: PK05
2.     If required, extend the material to main storage location. TC: MMSC
3.     Make the necessary changes in the material master as explained above.
4.     Create scheduling agreement. Put kanban indicator (X) in the additional data of item.
5.     Create Kanban control cycle. TC:PKMC
6.     Print the barcode. TC:PK17
7.     Set the kanban status to EMPTY by scanning the barcode. TC: PKBC. A Schedule line will be generated for the supply of material to main stores.
8.     View the demand source view. TC: PK13n
9.     When the material is received at Gate, perform goods receipt into blocked stock (movement type 103). TC: MIGO
10.     Once the material reaches Main stores scan the barcode to FULL. TC: PKBC (At the background GR with 105 movement will happen).
2.     External procurement from Vendor directly to shop:
Basic rules and Prerequisites:
u2022     MRP type should be u2018NDu2019 in MRP1 view of material master.
u2022     Availability check should be u201CKPu201D in MRP3 view of material master.
u2022     Backflush indicator is must. It can be defined in the routing or in the material master itself. If Backflush indicator is set in the material master, then the material will be backflushed through out the plant (Material issue not required against production order). However if you want the material to be backflushed only when it is used for certain products, then Backflush indicator should be set in the routing ( in the component allocation against operations).
u2022     Confirmation should be done for each operation in the production order either individually (CO11n) or collectively (CO15). Confirmation posts goods issue of components (relevant to confirmed operation/s) to production order
u2022     Maintain KN01 storage location in the field - production storage location of MRP2 view in the material master. Back flushing will take place from this location. Field - Storage location for external procurement should be KN01 in the material master.
u2022     Material received from vendor is directly posted to unrestricted stock. Inspection at vendors place or vendoru2019s process control to ensure rejection free material. Inspection set up in Material master should be inactive.
Process steps:
1.     Create supply area for kanban stores (KN01). TC: PK05
2.     Extend the material to Kanban storage location. TC: MMSC
3.     Make the necessary changes in the material master as explained above.
4.     Create scheduling agreement. Put kanban indicator (X) in the additional data of item.
5.     Create Kanban control cycle. TC:PKMC
6.     Print the barcode. TC:PK17
7.     Set the kanban status to EMPTY by scanning the barcode. TC: PKBC. A Schedule line will be generated for the supply of material to kanban store.
8.     View the demand source view. TC: PK13n
9.     When the material is received at Gate, perform goods receipt into blocked stock (movement type 103). TC: MIGO
10.     Once the material reaches shop, scan the barcode to FULL. TC: PKBC (At the background GR with 105 movement will happen).
Hope this helps.
Revert if any doubt and reward points if useful.
Regards,
Tejas

Purchase Order is generated after MRP for Material with MRP Type ND

Hi Everyone,
Material type := HAWA
My material procurement type = F i.e. External Procurement.
MRP Type = ND in Production server , and VB in Quality
Lot Size = EX
Material Status :- 15 Pre-release both for Quality and production server
The Material is bulk material and bulk material indicator is set.
Purchasing View is also maintained for the same.
Planning Strat = Z5 Company specific
Special procurement key:- Z7 Company specific
I am running MD02 with following parameters.
Create Pur Req =1, PR
Create MRP List = 1, MRP List
Delivery Schedule = 3, Schedule Lines
Planning Mode = 2 Re- Explode BOM & Routing
Scheduling = 1
Issue:
After MRP run, system is generating PR, Though with MRP type ND purchase requisition should not be generated.
Observation:- Looks like there is inconsistency of material date in Quality and production server.
When I tried to run the planning , The Error message was generated"Material status is set to pre- release.
After changing the material status to 20 (Active ) , when we run the MRP , The error message is generated "Material is not planned automatically "
We havent been able to locate the root cause so far
Please guide us
Thanks in Advance,
Ayaz
Edited by: Ayaz Alam Khan on Feb 16, 2011 2:41 PM

IF the material is ND, system won't Run MRP for the material
Observation:- Looks like there is inconsistency of material date in Quality and production server.
There is no link
When I tried to run the planning , The Error message was generated"Material status is set to pre- release.After changing the material status to 20 (Active ) , when we run the MRP , The error message is generated "Material is not planned automatically "
system will read the X plant material status or plant specific material status first and then only system will read MRP type

Creation of Purchase Requisition with MRP - MD02

Hello,
I have created a sales order using one material with MRP. When I run MRP-transaction MD02 for this material, a purchase requisition is created.
What we want is to block the creation of the purchase requisition when the sales order has delivery block (code 02). I have been trying to use this enhancements; setting break-points in all function modules, but when running MD02 is does not stop there:
MEREQ001      Customers' Own Data in Purchase Requisi
LMDR2001      User exits restr. profiles of opt. pur.ord.-based load bldg
LMDZU001      User exits in additional planning
M61X0001      User exits PP-MRP materials planning
M61X0002      User Exits PP-MRP Material Requirements Planning Evaluation
Do you know a way to do this or also change data in the purchase requisition created with MD02?
Thanks and regards.

Dear ,
Are you very particualr to process the Sales Order demand when there is a delivery block ?
To restrict that one you can do the following steps :
1.Goto Sales Order -VA02-Select the line item -Double Click -Select the Schedule line tab -Set Sechedule line item categoery as CN instead of CP.If it is CP then it will processed through MRP
2.Change the pricining date and make credit block for sales Order and do not release though VKM3 so it will not be tearted through MRP run to have PR geneartion
Hope this is clear
regards
JH

Problem With MRP

Hi Friends,
I am facing a problem with MRP. In my Implementation, my Client is a Automobile Gasket Manufacturer.
One major product line is Gaskets which is high volume and low price
We will use Make to stock with streategy 40.
Now the queries are as follows-
1) What should be the frequency of MRP Run for the plant (weekly , monthly of daily)
2) If after one MRP Run- some Planned Orders and some Purchase Req are converted to Production Orders and Purchase Orders. My Prod Orders- 100 Pieces and PO is 1000 Kgs.
Now subsequently , due to change in schedule,(PIR is maintained by Sales Department and it changes often) lets say, my PIR is Changed from 100 to 10 Pieces ,
How can a PPC person come to know of this and inform the Buyer to foreclose the PO or amend the PO and as well change the Prod order also.
Thanks in Advance
Waiting for your Reply,
Praveen

Hi Praveen
1) What should be the frequency of MRP Run for the plant (weekly , monthly of daily) : Daily Basis as your demand changes frequently.
2) PPC will understand from MD04 screen where all the result of MRP as Stock Requirement List available.U cant change Production Order while running MRP as your demand changes from 100 to 10 pecies because Prodction Orders are firmed recipept.In that case you can change quantiy , do the availablity check and scheduled again or set TECO so that it will not show up in the MD04 screen also.
Any changes to demand and subsequent effect can be viewed through the exception messeges column in MD04/MD05
Hope this will help you to figure it out.
Regards
Jia

APO DP with MRP How does it work.?

Hi Gurus,
             I just wanted to know how the process works with APO DP implementation with MRP?
Please let me know if you have documents available. It will be really great help
Thanks a lot
Regards,
Raj

Hi Raj,
   Demand Planning tool is basically meant for generation of Future demand at different planning level with the help of Characteristcis Value combination.
   For generation of future demand you need past sales history which you can take from R/3 with the help of BW functionality.
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So first you have to transfer demand which is unconstrained in to R/3 in MD61 with the help of transaction /SAPAPO/REL_TO_OLTP - Release from InfoProvider to ERP System but you need to take backup of your DP planning area & save data in to info cube.
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   But MRP having some restriction like MRP & Capacity planning will not run simulteniously etc. so generally we are prefer SNP tool for genetarion of these data with accuracy & optimized.
Hope this will help you.
Regards
Sujay

Purchase requisition with MRP controller

Hi everybody, I need support because I have to control during purchase requisition to block users with specific MRP controller.
I mean, user A only have permission to create purchase requisition with MRP controller Z and user B only have permission to create purchase requisition with MRP controller Y.
Thanks for all the ASAP cooperation.
Regards.

Hi Mitra,
You will find your answer here.
MRP controller for PR document type
Do let me know if it helped, as I might have to explore this option for an upcoming requirement.
Thanks
Shailesh

Kanban with purchase order : avoid manual change status to full

Dear guru ,
i use a kanban with purchase order.
When I enter status empty (using for example PK13N) the system create purchase order.
I want to avoid that the users enter status full using PK13N or PKBC .
The users execute goods receipts against purchase order using MIGO in order that the system trigger status full automatically.
How can I avoid that users change manual status to full using PK13N or PKBC ?
Thanks.

We have this scenario and to solve that we did a development. I heard in the past that even you can configure it on SPRO it doesn't work.
I made some tests recently but I didn't get any positive result. We did tests entering the kanban id into the inbound delivery and post through vl32n and migo but it doesn't work.
Regards
Eduardo Chagas

Costing affect with MRP at planned order level and after production order

Dear all,
How the costing affect with MRP at planned order level and after production order completion?
Edited by: Maulik on Jun 24, 2009 1:59 PM

Dear Maulik,
check Mr. Vinod's inputs abt costing
1. Maintain following master data:
MM01 Material Master with Costing and accounting view. Make sure all the cost Std, Moving avg etc is maintained along with valuation class in Accounting view 1. In costing tab pls make sure "with qty structure" and "Material Origin" are ticked.
CS01 BOM with components marked with costing relevance in Status/Long Text Tab. Also check all the qty are correct.
CR01 Work Center in Basic data tab maintain standard value key sau SAP1 and in costing tab maintain the workcenter, activity type and formulas (Usually standard formulas like for Machine Hours SAP006, Labour SAP007, Setup Activity SAP005 is used).
KL01 Cretae activity types, in basic data tab maintain ATyp Category AS "1" and cost element (as provided by your FI Guy).
KP26 Activity pricing, here with the combination of Activity type and the cost center you assign price to the activity.
2. SPRO Activity
Maintain Costing sheet IMGControllingProd cost controllingProd Cost PlanningBasic settingoverheadsdefine costing sheet.
OKKN Define costing variant, you define costing type (In the costing type, you define the purpose of a material cost estimate by specifying, for example, which field in the material master record the costing results can be transferred to like std price, moving avg etc), Valuation Variant (defines how the prices are prioratized), date control and transfer structure.
3. Costing Process Flow:
1. CK11N CREATE COSTING RUN
2. CK24 CREATE PRICE UPDATE (You Mark and release the prce to be updated)
4. COSTING VARIANT WRT PP
1. OPL1 DEFINE COSTING VARIANT WRT PP
2. OKK4 or OPN2 DEFINE VALUATION VARIANT
3. OKK1 or OPM1 DEFINE COSTING TYPE
4. OPL8 ORDERTYPE DEPENDENT PARAMETER (assign the above creted costing type for both planned and actual)
Hope this will throw some light on product costing.
Regards
kumar

Kanban with status sequence WAIT EMPTY FULL shows '-' neg. sign after GR

Hi PP
I am using one control cycle in kanban with replenishment strategy
stock transfer where in stock transfer using "stock transfer with
reservation".
I made one bin empty at the demand source using t code PK13N
But when i am doing transfer posting using migo against the
replenishment element created by emptying the kanban , i am getting
messge "NO KANBAN EXIST".
why system is behaving abnormal i mean trnasfer posting not happening.
system is not behaving normal.If i forcibly do the posting ignoring
warining message above mentioned it shows no change in bin status ,
then if i manually change status to green by PK13n it makes it green
but wth negative sign.This behavior is quite abnormal as i have
sufficient stock to get transfered too.
status sequence is with three statuses WAIT EMPTY FULL
Please help in this regard
Even if i use this status sequence for inhouse production also same problem is their

Hi,
Check the settings for replenishment strategy u have selected for the material.
OM11 - Production Relenishment strategy
OM12 - Procurement Replenishment strategy
as in ur case u are now procuring that element so, check order type in ur replenishment strategy
Regards
Samunder Singh

Subcontracting with MRP areas / Customer consigment

Dear all,
I'm currently looking for some information regarding subcontracting processes with MRP areas.
On the first hand I need a general overview how subcontracting purchase orders would be handled with MRP areas. In addition I'm really interested in the replenishment of the subcontractor stocks. On the other hand some facts about the customizing would be fine.
My second topic is consigment stocks at the customer. So I need similar information as for the MRP areas but regarding this customer consigment.
It would be really great if someone has some literature recommendations or official documentations about these issue.
Many thanks in advance!
Regards
Enrico

Hi Enrico,
Working with subcontracting and MRP area's gives you the option to plan the requirements for the subcontractor separately and you can then order the components separately. This functionality is used when working with scheduling agreements and direct deliveries to the subcontractor as there this is a requirement.
A second instance where one would use and MRP area with sucontracting is that when a material is used both by the subcontractor and it's also used directly in the plant production. The requirements for the subcontractor can be separately planned using an MRP area.
The following links may give you some more information regarding working with subcontracting and MRP area's
[MRP area|http://help.sap.com/saphelp_470/helpdata/en/c4/106956ae8a11d1a6720000e83235d4/content.htm]
[Planning for Components to be Provided in Subcontracting|http://help.sap.com/erp2005_ehp_04/helpdata/EN/c4/106956ae8a11d1a6720000e83235d4/frameset.htm]
Edited by: Peter Pallen on Jun 5, 2011 7:19 PM

ATP check together with MRP

Hi experts,
Can ATP check runs together with MRP requirements? If yes, how to solve the issue below?
Scenario: Finished product is required to transfer MRP requirements when creating sales orders. Meanwhile, ATP check runs.
Issue: Due to strategy group 52, Consumption mode 1 & Bwd consumption period 45 (MRP 3), dates in shipping tab in sales orders can NOT be proposed, such as MAD. Delivery can NOT be created due to no MAD. (No schedule lines due for delivery up to the selected date Message no. VL248)
If letting those three fields (strategy group, etc.) blank in MRP 3, dates in shipping tab in sales orders can be proposed. But MRP requirements cannot happen.

Hi Weihua,
We are facing the similar issue where we need to do ATP at storage location level. May I know how big is the enhancement you have done i.e: man day? and if possible, could you please point out to us where to enhance this?
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