MRP does more than 100% ?

Question

Hello experts
My scenario is as follows (my key-useru2019s request):
Production units in all plants are allowed to exceed production by 15% thus giving them authorisation to convert any production order from anywhere between 100% - 115% & still be deemed within allowable production parameters.
The Issue here is that as far as we are concerned there is nowhere in SAP that we can put data to automatically calculate the extra 15% material requirements. Schedulers at least once a week (& it is usually done on a Thursday when placing the bulk of purchase orders) review each and every material on their respective MRP list to manually ensure that there is at least 115% material on hand to cover production.
Question:
Is there any field in SAP / MRP that you know of that we could place data that would allow for auto calculation of an u201Cextrau201D 15% material usage.
What do they do (the process Iu2019ve seen):
Once a week they run MRP list for each plant and change MRP elements : goto Pur. Requisition(s) and increase quantities manually. Then run MD01 or MD02.
This process is related to ROH and VERP materials only.
Solutions:
1.     To change the standard MRP function or new enhancement (ZMRP);
2.     To use a standard features as u201CCoverage Profileu201D, safety stock, u2026..;
3.     u2026?
Please do not ask me TO CHANGE THE BUSINESS.
I am more after PRACTICE than a theory.
Thank you masters.

Answer 1

Based on everything I'm hearing here, I do believe I know who company this is, and that I used to be the PP guy there! LOL!
I ran into this same problem and also questioned the sanity of the business actually allowing this type of behaviour, but knowing this business, PPIO_ENTRY is duely correct in saying they will not accept a change to the business process.
The problem with using the assembly scrap in the BOM or material master is that during backflushing scrap quantities are actually issued to the order, meaning your guys will consume 115% of component materials to produce 100% of the order. Obviously this is not a great outcome.
In my time there we also looked into a BAdI at the end of the MRP run which changed the replenishment proposal qty (on reqs only) to include the 115%. I cannot remember why this did not work but it didn't, so they stopped using it.
Assuming this is the company I think it is, SAP MRP is used only for procurement of ROH and VERP materials. i2 is the planning software, and they load in production orders for the next two weeks, then planned orders for demand out to a 12 month horizon.
If I were going to address this again, I would suggest using planned independent requirements. Build the logic into your integration (as you have this capability with the software you guys use). During your production order upload, also load a PIR for the 15%. During your planned order deletion run each night also delete the PIRs. These will be included in the requirements calculations.
It's stupid though, because where do you stop adding the 15%? I mean if you only add it to the next order, which is say tomorrow, and a component is not available and has a 3 week lead time then you are screwed. On the other hand, if you add it to every order for the next 3 months then you are going to be carrying WAY too much stock.
Safety time or coverage profiles don't really work either because you might only produce something once every 2 months, and you want to run components down to nothing between production runs....
It just isn't a valid business requirement.......