Max order quantity to preserve service levels

Dear Sales Gurus,
Here is an interesting challenge. I have seen a lot of topics around this issue, but no clear explanation on the background and probably for that reason no clear solution.
==============
Heading 1:The business case
Products that are sold can be characterized by being high or low volume, and frequently or not frequently ordered. This particular scenario is in the context of low-volume and not frequently ordered products. To assure service levels and working capital optimization you have defined a safety stock that corresponds to the frequence of the orders, average quantity ordered and standard deviation of ordered quantity. As practical example: Product AAA is sold every 2 months by 3 orders with average quantity of 15 and standard deviation of 5. The safey stock has been set to 60 units.
One of your sales offices/persons spots a one off-opportunity to sell 60 units of that product AAA and places a sales order for it. Consuming the inventory completely would result in most of the other regular customers being unsatisfied and service levels being broken.
==============
Objective
Assume partial deliveries are not accepted. The system should not propose a date, which is based on the available inventory. It should take into account the assumption that the quantity should be produced in order not to completely exhaust the safety stock and damage the service level for other regular customers.
One way to achieve that is to introduce a maximum order quantity, which can be statistically estimated to fit in certain constrains and factors.
==============
System Behaviour
Lets say a max quantity can be defined somehow and used in SO processing. When the ATP is run, it should check the max quantity and if the order exceeds that quantity, it should be satisfied by planning a new production. For example if the max quantity is set to 30 (mean + 3st.deviations), any order for up to 30 would be sourced from inventory, provided there is stock available, any order above this limit will immediately be planned for production even if stock is available to cover the individual order.
==============
Alternative Solutions
Any solution which allows that the above issue is avoided can be considered. The Max Quantity is probably only one of the possible alternatives.
Looking forward for your solution ideas.
==============
P.S. Custom development and User exits are always an option, but in this request we need to answer with standard functionality as much as possible.
P.S.S. I have been looking at the Quantity Optimization functionality for PO's and SO's, but I am not sure if it is really a solution as I do not have experience with it and did not understand how exactly it works.
P.S.S.S. I had problems formating this to come as structured text with some line breaks. Sorry for the output.
Thanks,
Valentin
Edited by: Valentin Yonchev on May 10, 2010 4:38 PM
Edited by: Valentin Yonchev on May 10, 2010 4:40 PM

Hi Kaan,
Here are the answers to your questions:
1) Is there a Max.Order Quantity field in the material master record like Min.Order Quantity field in the
Sales: Sales org.1 screen?
Answer: Unfortunately there is no such field.
2) How can we define a limit for the total amount of the order quantity per a sales order?
Answer: You could consider using USEREXIT_SAVE_DOCUMENT_PREPARE in MV45AFZZ.
This userexit will be called during the save process of sales document.
You could add additional check in it.
3) How can we control that one material no. could be written just one item line in the sales order?
Answer: You could consider using USEREXIT_CHECK_VBAP in MV45AFZB.
This userexit will be called after item creation. You could add check for material number.
Thanks and best regards,
Smile

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Sub: "We want that ASCP plans always full Lots, because the leadtime of the full Lot is always needed in reality. If ASCP plans with partial quantities, then the estimated/calculated leadtime for the planned orders will not be realistic."
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Dear Hoo,
ORDER MANAGEMENT & SALES
1.Briefly describe the types and structure of the sales document and give examples of data
that you find on the different levels.
Sales*related business transactions are recorded in the system as sales documents. There are, broadly
speaking, four different groupings of sales documents:
Sales queries, such as inquiries and quotations
Sales orders
Outline agreements, such as contracts and scheduling agreements
Customer problems and complaints, such as free of charge deliveries and credit memo requests.
Header Data
The general data that is valid for the entire document is recorded in the document header. This data
includes the:
number of the sold*to party
number of the ship*to party and the payer
document currency and exchange rate
pricing elements for the entire document
delivery date and shipping point
Item Data
Whereas data in the document header applies to all items in the document, some data applies only to
specific items. This data is stored at item level and includes the:
material number
target quantity for outline agreements
number of the shipto party and the payer (an alternative shipto party or payer can be defined for a
particular item)
plant and storage location specifications
pricing elements for the individual items
Schedule Line Data
An item consists of one or more schedule lines. The schedule line contains all the data that is needed
for a delivery. For example, a customer orders 20 pieces of a material and you enter this as an item in
the sales order. However, you can only deliver 10 pieces now and the remaining 10 pieces next month.
In other words, you need to schedule two deliveries. The data for these deliveries (dates, confirmed
quantities) are stored in two separate schedule lines. In sales documents where delivery data is not
relevant *for example: contracts, credit and debit memo requests * the system does not create any
schedule lines.
Data recorded in the schedule lines includes the:
schedule line quantity
delivery date
confirmed quantity
2.What is the difference between an inquiry and quotation ?
. Inquiry: Request made to a vendor for a quotation for required materials or services.
No availability check is done for inquiry.
. Quotation: Offer from a vendor to a purchasing organization regarding the supply of materials
or performance of services subject to predefined terms and conditions.
A quotation consists of a number of items, in which the total quantity and delivery date of an
offered material or service are specified.
The total quantity can be subdivided into several partial quantities with different delivery dates in the
lines of a delivery schedule.
3.Do you always have to have a material master record number when you enter an item on a
sales document (inquiry and quote)? If not what would you have to use to be able to enter
information at item level?
No. Customer Material Information or Material Description.
4.If a customer doesn't place an order with you after you have sent him a quotation, what happens to
the quotation document?
Remains active till the end of validity period.
5.Can you have alternative items in a sales order?
Yes.
6.If you reference an inquiry when creating a quotation ,would the inquiry be updated?
Yes.
7.Can you copy one inquiry to many quotations ?
No.
8.Can you copy several previous documents into one sales order?
Yes.
9.Do you always have to copy the entire quantities at item level when you reference a
previous document?
No.
10.Can you make sure that business data in a sales order is only possible to maintain at header
level?
Yes.
11.From where is the delivering plant transferred into the sales order?
Customer Master, Material Master.
12.Which partner function is relevant for the delivering plant? The soldtoparty ,
billtoparty, payer, carrier or the ship* to* party?
Ship*to party.
13.Can you manually change the delivering plant in the sales order once it was defaulted from
the master data?
Yes.
14.For what or why do you use the incompletion log?
To have a complete document so that it doesnu2019t affect subsequent processes.
15.Can you have different incompletion logs for different item categories? Schedule line
categories?
Yes.
16.If a document is incomplete can you still save the document?
Yes.
17.Which reference status can a document have at item level? Which statuses at header level?
Item level: Partial, Full.
Header level: Full.
18.What's the advantage of using text as a reference instead of duplicating it?
Can be modified if needed.
19.What three sources provide data for the creation of a sales document?
Material Master, Customer Master, Previous referenced documents.
20.Can you change addresses of partners manually in the sales document?
Yes.
21.Name several input tools that make order entry faster and give a definition of them?
Customer Material Information, Product Proposal , Referencing Documents.
22.In which business environment would you use only the single*line entry screen to create
and save the order?
Telephone Sales, Simple Business.
23.If you do not specify the delivering plant in the sales order, what could the system then not
do?
Delivery Scheduling.
24.For what would you use the fast change function in sales entry?
Alternate Plants, Delivery or Billing Blocks
25.Name two ways to control that customers can receive only certain materials?
Material Listing, Exclusion.
26.What does the item category control?
General Data
. Should pricing be carried out for the item?
. When should an item be regarded as completed? A quotation item, for example, can only be
regarded as completed if the entire quantity has been copied into a sales order.
. Is it an item that refers to a material or is it a text item?
. Are schedule lines allowed for the item?
. May general business data, for example, the terms of payment at the item level, deviate from
those at the header level?
. Should a system message appear if the item cannot be fully delivered?
. Which fields are relevant for the incompletion log?
. Which partner functions are allowed at the item level and which are mandatory?
. Which output (for example, an order confirmation) is allowed for the business transaction and
which output determination procedure is used?
Shipping Data
. Is an item relevant for delivery?
. Should the weight and the volume of an item be determined?
Billing Data
. Is an item relevant for billing?
. Should the cost of the item be determined?
. Is it a statistical item? Pricing is carried out for statistical items. However, they are not added
to the value of the order, that is, the customer is not charged for them.
. Should a billing block be set automatically for an item? For example, this may be important for
items whose prices have to be clarified before billing
. Is it a returns item?
. Name the influencing factors for determining the item category in the sales document?
. Sales Document type, Item Category Group, Higher Level Item, Item Usage.
. Name the influencing factors for determining the scehdule line category in the sales document?
. Item Category, MRP Type.
. What does the sales document type control?
General Data
. Can the document be entered only with reference to a preceding document?
. Should the existing customer
. material info record be taken into consideration?
. Should the delivery date be proposed?
. Must a customer number be entered when creating a document? For example, product
proposals can be entered without reference to a particular customer.
. Which order probability is defined?
. Should the division be taken from the material master record for every item or should an
alternative division specified in the header take precedence over the item specifications?
. How should the system respond if the division entered in the header deviates from the division
in the items?
. Should a credit limit check be made?
. From which number range should the document number for internal or external number
assignment come?
. Which fields are relevant for the incompletion log? The validity period, for example, is
important for contracts and must therefore be specified in the document.
. Can an incomplete document be saved or must all data be complete?
. Which partner functions are allowed and which ones are mandatory?
Shipping Data
. Which delivery type should the delivery resulting from the order have?
. Should delivery scheduling be carried out?
. Should transportation scheduling be carried out?
. Should a delivery block be set automatically for a specific reason? For example, a delivery
block may be appropriate for a freeofcharge delivery.
. You can define shipping conditions for a sales document type. These are copied into the
document regardless of what is defined in the customer master record.
Billing Data
-->Which billing type should the invoice resulting from the order or the delivery have?
Should a billing block be set automatically for a specific reason? For example, a billing block may be
appropriate if a credit memo request should first be checked before it is used as the basis for a credit
memo.
-->Can the sales document type be determined by the system?
No.
-->In R/3, can you automatically substitute one product for another? How? What would you
have to create?
Yes. Product Selection / Material Determination.
-->Give a definition of replenishment lead time?
Total time for the inhouse production or for the external procurement of a product. In inhouse
production the replenishment lead time is determined to cover all BOM levels.
What's the difference between checking availability with or without replenishment lead time (RLT)?
With RLT : Availability check is done only upto end of RLT. If material is not available the date on
which RLT ends is displayed as Material Availability Date.
Without RLT : Availability check is unrestricted. Displays Delivery Dates as on which partial deliveries
can be made with available stock.
-->Name at least three item categories?
Standard Items : AFN, AGN, TAN.
Free of charge Items: AFNN, AGNN, TANN.
Non*stock Items : AFX, AGX, TAX.
Text Items : AFTX, AGTX, TATX.
-->Why would you use different item and schedule line categories?
Item categories are defined to provide additional control functions for the sales documents and thus
meet the demands resulting from the different business transactions.
The items in a sales document are divided into one or more schedule lines. These schedule lines differ
from each other with respect to date and quantity. For some schedule lines, material requirements
planning is not carried out; for other schedule lines, it is carried out. Also goods receipt, not goods
issue, is posted for a schedule line defined in a returns document.
-->Can you change existing standard item categories?
Yes.
-->Can you create new sales order types?
Yes.
-->Different dates will be calculated in order entry scheduling . Can you name the lead time
variables that will be taken into account?
Transportation lead time, Pick/pack time, Loading time, Transit time .
If you run out of stock in a specific plant can you check if there are quantities available in other plants?
Yes.
-->When you carry out availability check, which quantities or movements can the system take
into consideration?
The following elements can be included in the availability check:
Stocks : safety stock, stock in transfer, stock in quality inspection, blocked stock.
Inward and outward movements : purchase orders, purchase requisitions, planned orders, production
orders, reservations, dependent reservations, dependent requirements, sales requirements, delivery
requirements.
-->Give some examples of sales document types (description, not necessary the short code)
that already set up in the standard system?
Indicator used to control the processing of the various sales documents which are defined in the
system. E.g., OR, SO, BV, KR. Document types allow the system to process different kinds of business
transactions, such as standard orders and credit memo requests, in different ways.
-->Can you maintain texts for a specific customer and store them in the system? If yes, where?
Yes. Customer Material Information.
-->When the system checks availability which scheduling would it use first?
Backward Scheduling.
-->Name the influencing factors for the determination of the availability date?
The following data is required for determining this date:
Route from the shipping point to the ship*to party location
Shipping point from which the goods are issued
Loading group from the material master record
Weight group determined from the order using the order quantity.
-->Name the three delivery possibilities when there is not enough stock available?
One Time Delivery, Complete Delivery, Partial Deliveries.
-->Can you think of an example why you would have to create a text for a customer and copy it
to the sales order?
Customer specific instructions.
-->What is the function of item category group?
The item category group determines how a material is processed in the sales order. It defines, for
example, that pricing does not take place for a free of charge item, such as a business gift; or that
inventory management is not carried out for a service. When processing sales and distribution
documents, the system uses the item category group to determine the item category. The system
determines the item category based on the item category group of the material and the current
business transaction, and proposes it in the respective document.
When creating the material types non*stock material and services, DIEN is proposed in both cases for
the item category group, because the order processing for both material types is identical: for
example, pricing is carried out for both, but no availability check.
-->On sales order, when the system confirms 20 pieces to be available at a certain date, would
these 20 pieces still be available for other new sales order coming in later?
No.
-->What is a delivery group and why would you use it?
The complete delivery and delivery group functions enable you to combine some or all of the items in a
sales order so that they are delivered to the customer together. The system determines automatically
the latest delivery date possible for the delivery group and adjusts the schedule lines accordingly.
Corresponding requirements for material requirements planning (MRP) are changed or re*determined.
-->What is backorder processing?
The backorder processing functions enable you to list relevant sales documents for specific materials
and process them from the point of view of availability. You can assign available to promise (ATP)
stock to outstanding order quantities. In addition, you can withdraw already confirmed quantities and
reassign them to different items.
Backorder processing is only available for materials with individual requirements.
-->Can you link items in a sales order? If yes, when would you do that?
Yes. Promotional Items.
-->For what would you use BOMu2019S in sales? What two methods of BOM processing do you have
in sales order entry? How can you control if the system should/should not explode a BOM in
the sales order.
A bill of material (BOM) describes the different components that together create a product. A BOM for
a bicycle, for example, consists of all the parts that make up the bicycle: the frame, the saddle,
wheels, and so on. When you enter the material number of a bill of materials that is relevant for sales
order processing, the system displays the material that describes the whole bill of materials as a main
item. The components are displayed as sub*items.
Processing by Main Item : ERLA & Processing by Sub*Item : LUMF
BOM explosion can be prevented by specifying Item Category Group as NORM.
Credit limit checks is an example of a very close link between which two SAP modules?
SD & FI.
-->What are the two techniques in delivery scheduling?
Backward Scheduling & Forward Scheduling.
-->How does a third party deal work? Do you use a special sales order type for that? How could
the system know that you want to process a third party deal?
By specifying item category as TAS using double*line entry in the sales order.
No special order type is available.
By the item category group and/or material type in Material Master .
Name the several steps in consignment processing.
Consignment fillup, Consignment issue, Consignment pickup, Consignment return.
Whatu2019s the difference between consignment pick*up and consignment return?
In consignment pick*up, customer returns consignment stock. When goods issue is posted, the
relevant quantity is deducted from the customer's special stock and is added back to regular stock at
the plant where the goods are returned. Total valuated stock remains the same since the returned
stock was regarded as part of inventory even while it was at the customer's premises.This transaction
is not relevant for billing.
In consignment return, customer wishes to claim on consignment goods which have already been
issued. When goods issue is posted, the relevant quantity is added to the customer's special stock at
the plant where the goods are returned. Since the ownership of the goods is passed from the customer
back to the company, the transaction is relevant for billing. In this case, the customer receives a credit
memo for the returned goods.
-->Can you control that an end user cannot copy a quote of customer A to a sales order for
customer B? If yes, where?
Yes. By customizing Copying Control for header data.
Give some example for data that is copied from the customer (soldto, payer, shipto) to the sales
order as well as for data that is copied from the material?
General data, payment terms, shipping details, delivery agreements, delivering plant.
-->What is returnable packaging processing?
Returnable packaging consists of materials that are stored at the customer location but which remain
the property of the company. The customer is only required to pay for the returnable packaging if he
does not return it by a specified time.
Name the two outline agreements in R/3 standard and explain the difference between them.
Agreements are arrangements between business partners regarding the granting of conditions over a
specified time period. The agreement contains conditions which apply over a particular time period and
which are settled together at the same points in time. An agreement can be settled once or
periodically. The two outline agreements include Contracts and Scheduling Agreements.
Unlike a contract * which only contains an overall target quantity or value * a scheduling agreement
also contains specific order quantities and delivery dates.
-->How many documents do you create when you release, deliver and invoice the first order
from a contract?
Three : Sales order, Delivery note, Invoice.
-->What types of output can you have in sales?
Printer, Telex, Fax, Mail, EDI.
-->Can you automate output processing ? Do you always have to specify it manually?
yes. No.
-->Where would you specify which data should be copied (at header, item and schedule line
level)when you copy from one document to another one?
Customizing Copy Control.
I hope it will help you,
Regards,
Murali.

Max order quantity to preserve service levels

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