Mapping Spare part kit planning in SAP

Question

Hi,
We have below requirement in Spare part Kitting process
1)
Client  makes compressors, which obviously have a lot of components, where one of the prime part is valve.
2)
Valve Kit is a finished product having components which are used in regular unit production also, where MRP Type can be VV or PD.
3)
This valve kit sold as a spare part.Customers buy these kits and typical assembly time is 1 day.
4)
This kit is not kept in stock and is assembled after receiving an order.
5)
To be ready for customer orders, client forecasts these kits (about 10000) and drives the demand for lower level components.
6)
When customer places an order, legacy system promises the dates based on availability of components. Date is promised to the customer based on the availability of the components. Also the requirement is passed on to the floor to assemble and shipped the same day.
7)
To meet above requirement, we proposed to use Forecast based planning, where system will create planned order for Kit assembly & component can be planned.Knowing there is a back drop i.e. planned order created thru forecast can be converted into production order.
8)
Then demonstrated “ATO – Assemble to Order” functionality in SAP. This uses strategy group 81 for the kit material XX-XXXX-XX. When a sales order is created for a material with strategy group 81, system immediately creates a planned order and as per component availability, proposes the next available date of the assembly.
9)
Since ATO is an MTO process, Planned order is tied to Sales Order and when production order goods receipt is done, stock is received into Sales Order stock. Hence Sales Orders do not consume the forecast.
10)
Question here is how to consume the forecast? When sales order is shipped system is not updating consumption data? This is important as today they use the consumption values to execute the forecast.
If any one has come across similar requirement, please give other options keeping below points in view
1. We should be able to plan valve kits may be thru forecasting or PIR's. This to start procuring components.
2. When sales order is created, system should do availability check at component level.
3. Consumption data should be updated if we use forecasting to plan kit or if we use PIR's, sales order should consume the demand. Consumption of forecasting requirement is also required.
Thanks in advance.
Hari

Answer 1

Hi ,
Looks like problem is due to
- Need to do ATP at componnent level  which is only possible with Planning  strategy 81,82. You cannot use planning strategy 40( 40 considers forecast , sales order & consumption)
- 81 ,82 planning strategy doesn't consume forecast for End item(Sales order entry material)
You could use Sales order BOM function. It is provided for selling Kits. BOM is exploded in sales order & kit items are put as seperate sales order items ( 20... 30... 40 ) Here are steps.
-  Create BOM with usage 5- Sales order relevancy of bom components is Ticked
- Create Sales order with item which is BOM header. System will explode BOM & all items will be part of sales order as item.
- You can configure Sale Price at End FG level, Inventory management( DO issue) at item /components level .
- Forecast will be consumed at end item level.Need configuration
- ATP check can be performed at componenet level
Only thing is you will not have Plan order for doing assembly & there is no cost captured for assembly . Kitting donot involve much labor time.
Hope it helps
Jatin