Planning on assembly

Hi ,
I need advice on following scenario.
There is Finished product which i sold .The assembly for this is kept in stock . There is requirement that the sales order from FG should consume the PIR of assembly.
The consumption can be at GI of sales order or when booked. Which startegy i can use or need to configure this ?
Regards
ShankarR

Hi,
You can use strategy 30 or 10.
30-Pir in FG.Sales oder consumed PIR.
10-Pir on Fg.Goods issue for delivery will consume the PIR.
In both cases RMPM & semifinished wil be kept in storage.
Hope this will help.
regards,
kaushik

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SAP PP-Planning at Assembly level(70)u201D & u201C Planning at Assembly level witho

Hello SAP-Guruu2019s
Pls explain the Strategy u201C Planning at Assembly level(70)u201D & u201C Planning at Assembly level without final Assembly (74)u201D and pls give any examples if possible.
Thanks in advance

Hi,
Planning at Assembly Level (70)
Purpose
This planning strategy is particularly useful for manufacturers of products with variants if a more
reliable forecast can be produced for certain assemblies than for the multitude of product
variants.
Prerequisites
You must maintain the master data of the assembly as follows:
Strategy group 70 on the MRP screen.
Set the indicator for assembly planning, the Mixed MRP indicator, to 1 on the MRP
screen.
Consumption parameters (Consumption mode, Bwd consumption, Fwd consumption on
the MRP screen) to allow for consumption of planned independent requirements.
If you are using this strategy in a make-to-stock environment, you also must set the
Individual/coll. indicator to 2 on the MRP screen.
Reduction
Consumption
This strategy is very similar to Planning with Final Assembly (40) However, planned
independent requirements are consumed by production order requirements (or schedule lines in
repetitive manufacturing) and not to requirements of sales orders.
1. Stock for the assembly usually exists.
2. Planned independent requirements are entered at assembly level. Procurement (planned
by means of the planned independent requirements) is therefore triggered before the
production order stage (or schedule line in repetitive manufacturing).
3. The planned orders for the assembly/components are convertible.
4. Procurement smoothing according to order demand is possible. In this strategy,
however, the ability to react flexibly to customer requirements is more important.
5. An accurate availability check is performed according to ATP logic during production
order processing.
6. Requirements from production orders (or schedule lines) are passed on to production
and can lead to changes to procurement after the sales order stage, if the order
quantities exceed the planned independent requirement quantities. However the order
quantities cannot be confirmed if there is insufficient coverage of components. The
system automatically adjusts the master plan. For more information see Coping with
Insufficient Coverage of Components .
7. The planned independent requirements are consumed during the production stage. This
means that you can compare the planned independent requirements situation with the
actual order requirements.
Unconsumed planned independent requirement quantities increase the warehouse stock of the
component, and cause procurement to be decreased or not to take place at all in the next period.
This procedure is called "netting."
Sample Scenario: Strategy 70
Process Flow
This example is based on a production plan in which 100 pieces are planned for <reqdat1>,
<reqdat2>, and <reqdat1>.
Stage 1: Demand Management
1.In this scenario, planned independent requirements are created as follows for the
production plan.
Period indicator Reqmts date Planned qty Value
T (= day) <reqdat1> 100 10,000.00
T (= day) <reqdat2> 100 10,000.00
T (= day) <reqdat3> 100 10,000.00
The system will find requirements type VSFB because the strategy group has been set
to 70.
2. The requirements are passed on to MRP. The stock/requirements list (Logistics
Production MRP Evaluations Stock/reqmts list) displays the following
information:
Date MRP element MRP element data Received/
required
quantity
Available quantity
<today> Stock 0
<reqdat1> IndReq VSFB 100 - 100 -
<reqdat2> IndReq VSFB 100 - 200 -
<reqdat3> IndReq VSFB 100 - 300 -
Stage 2: Procurement Before Use in Production
1. A procurement requisition is created in the MRP run (Logistics Production MRP
Total planning). The stock/requirements list displays the following information:
Date MRP element MRP element data Received/
required
quantity
Available quantity
<today> Stock 0
<reqdat1> PlOrd. 123/STCK 100 100
<reqdat1> IndReq VSFB 100 - 0
<reqdat2> PlOrd. 124/STCK 100 100
<reqdat2> IndReq VSFB 100 - 0
<reqdat3> PlOrd. 125/STCK 100 100
<reqdat3> IndReq VSFB 100 - 0
This procurement requisition is the starting point for production or external procurement.
You have a variety of options for handling the procurement process in the R/3 System.
One possibility would be to convert the planned order into a production order, release of
the production order and a goods receipt of the yield quantity. It is also possible,
however, to use returns or other goods movements for make-to-stock production.
2. After goods receipt for the order, the stock/requirements list displays the following
information:
Date MRP element MRP element data Received/
required
quantity
Available quantity
<today> Stock 200
<reqdat1> IndReq VSFB 100 - 100
<reqdat2> IndReq VSFB 100 - 0
<reqdat3> PlOrd. 125/SDeb 100 100
<reqdat3> IndReq VSFB 100 - 0
Stage 3: Production Order and Allocation
A production order that uses the planned component is created (Logistics Production
Production control Order Create).
An availability check is performed in the order (Component Availability Check availability).
In this example, it is assumed that production is 50 pieces of the material and the
material has an in-house production time of zero.
A popup appears containing the following information:
Requirements date <today>
Requirements quantity 50
Availability check (checking group) 02
ATP quantity 200
Confirmation date <today>
Confirmation quantity 50
This availability check is always performed according to ATP logic. See Availability Check [Page
157].
The production order quantity, which is not visible in the production order, is allocated to the
component quantity. You can, however, control the allocation in the stock/requirements list or in
the total requirements list. The total requirements list displays the following information:
Requirements type Date Allocated quantity Total quantity
VSFB 300
<reqdat1> 100
RESE <reqdat1> 50
<today> 50
<reqdat2> 100
<reqdat3> 100
After creation of the production order, the stock/requirements list displays the following
information:
Date MRP element MRP element data Received/
required
quantity
Available quantity
<today> Stock 200
<today> OrdRes SZ-10 50 - 150
<reqdat1> IndReq VSFB 50 - 100
<reqdat2> IndReq VSFB 100 - 0
<reqdat3> PlOrd. 125/STCK 100 100
<reqdat3> IndReq VSFB 100 - 0
Any parent material that consists of this component is automatically allocated to this plan. In
practice, there are several header materials (like SZ-10 in this example) that allocate this
material.
Stage 4: Procurement After Production
This does not apply to this strategy.
Stage 5: Goods Issue for Production Order
After goods issue for the production order (Logistics Materials management Inventory
management Goods movement Goods issue), the stock/requirements list displays the
following information:
Date MRP element MRP element data Received/
required
quantity
Available quantity
<today> Stock 150
< reqdat1> IndReq VSFB 50 - 100
<reqdat2> IndReq VSFB 100 - 0
<reqdat3> PlOrd. 125/STCK 100 100
<reqdat3> IndReq VSFB 100 - 0
Hope this helps.
Regards,
Tejas

Min Max Planning - Sub Assembly WO Demand Planning

Hi All,
WO for FG should be a demand for WOs for SA. Can Min Max look at the WOs of FGs and if SA is a component, create a WO for SA?
I observed Min Max doesn't support this. Let me know your pointers.
Regards

Hi All,
Min Max Planning Supports WIP Demand.
Regards

Left over of Sales Order creates new planned order of whole batch

Hi Gurus,
We are using planning without Assembly strategy (52) and Sales order is created in our sales plant and Purchase order from sales plant creates STO on manufacturing plant which than produces material using process order.
Now sales order says 5000 EA but actual production is if 4985 EA in Manufacturing plant which is transported into Sales plant and sales plant receives 4985 EA which keeps sales order of 5EA in the system
When MRP runs overnight creates planned order for left over quantity and it is of whole batch 5000 EA. This confuse our planner.
Can anyone provide me the solution please?
Regards,
SAPPPPI

Hi,
For strategy 52 FX never works so we have lot sixe "EX".
We have set up tolerance limit of +/- 10% but when less quantity is received (4985 instead of 5000) from manufacturing plant system thinks there is an open sales sales order of 15 and creates a new planed order.
If we have materials 4980 in stock and we create a sales order for 5000, tolerance will be considered for this and there won't be any open sales order but in our case Sales order allows us to procure and when GR quantity is less than sales order it is treated as left over and create planned order.
Please help me by replying if any one knows.
Regards
SAPPPPI

Assemble PDF with attachments

Hi All, I am planning to assemble a PDF document with attachments. Or as I see my requirement is to create a PDF and attach various files to it. The PDF would then be sent as an attachment to an email. The user should be able to open the emailed PDF and save the image/application attachments seperately. To achieve this I had generated the sample DDX and tried it in a process, but no luck. All the source objects are avaialble int he assembler map object of documents with the correct key value. <?xml version="1.0" encoding="UTF-8"?> <DDX xmlns="http://ns.adobe.com/DDX/1.0/"> <PDF result="pdf2image_res.pdf"> <PDF source="pdf2image_res.pdf"> <FileAttachments source="image-1.jpg" nameKey="image-1.jpg"> <File filename="image-1.jpg"/> </FileAttachments> <FileAttachments source="image-2.jpg" nameKey="image-2.jpg"> <File filename="image-2.jpg"/> </FileAttachments> </PDF> </PDF> </DDX> Then I extract the generated pdf in a document like '/process_data/docAssemblerMap[@id='pdf2image_res.pdf']' The generated PDF does not have the attachments embedded in it. Any thoughts/help would be greatly appreciated.

I tried it with your ddx (with minor modification)and it worked fine.
I would try to use the Record and Play back to make sure all the components of your map are set properly.
Jasmin

MST BP and Periodic BP in Assembly Process

Hi Friends,
Does any one have experience in the past having two types of Billing plans in Assembly Process?.
To elaborate more on this topic is, for example sales order line itme (10) has a blling plan copied from project (this would be either value basis or %basis milestones). These milestones were billed as and when milestones were confirmed from project.
I wanted to add one more line item (20) on same sales order which has periodic billing plan. Here, the billin plan will effect monthly as maintained.
Is it possible to have such kind of process?. Please let me have your opinion on this.
Thanks in advance.
Regards,
PSR

Hi Krisap,
Thaks for your reply. Yes you are right, both lines have different item categories (which I missed to post in my thread). Pros and cons of maintance of point of view.
Waiting for few more opinions from other members on my requirement.
Regards,
PSR

Deliveries consuming PIRS in planning strategy 40

Hi SAP Experts,
I have a customer who has a business processes where sales orders are immediately converted to deliveries on saving of VA01. Is there anyway to drive deliveries to consume PIRs in strategy 40?
Thanks for your help,
Geetha

Geetha,
Usually, deliveries don't hang around long enough to affect planning, so consumption is typically not so important. However, they can be made to consume PIRs if you want them to.
When a Sales doc is saved, it creates a requirement. The type of the requirement in strat 40 sales orders is normally one that consumes PIR. When the delivery is created, the Sales requirement is deleted and is replaced with the requirement for the delivery. In strat 40, this requirement can be configured to consume PIR.
You can review whether the delivery will consume by reviewing the requirements type assignment in OVZI. Enter the item category of the delivery you will be using, and the MRP type. Review the detail: you want the allocation indicator at the bottom to be "1" (consume planning with assembly). If it is not, you must assign a requirement type that consumes, or change the existing requirements type so that it consumes. Available requirements types can be seen in OVZH, where you can see and/or change the requirements class they are assigned to . The requirements class itself can be viewed and modified in OVZG if necessary. The field you want to be set in OVZG is "All in" (allocation indicator), which should be '1'. for strat 40.
Best Regards,
DB49

PP : Planning Strategies

Hi Gurus,
Is it possible to consider available stock in planning strategy 52? I want MRP run to consider available stock against a forecast and not to create new requirement.
I mean I have 100 pcs in stock and a forecast comes of 40 so it creates pland independent requirement. I want system not to generate any procument proposal when MRP runs. It should use available stock.
Thanks in advance.
RajaRam

Thanks all Gurus for your invaluable time and suggestions.
Still I can't get the solution I want. I have following situation:
Date                        MRP element                                        Req. Qty                     Available
25.01.2008     Stock                                                            200      200
25.01.2008     -
>     Planning without assembly               0      0
01.02.2008     PldOrd     0000108425/INDR               100      100      2001
01.02.2008     IndReq     ZVSE               100-     0
03.03.2008     PldOrd     0000108426/INDR               100      100      2001
03.03.2008     IndReq     ZVSE               100-     0
As we have got a stock I don't want system to create any requirement.
This happens with strategy 52 because we can't control anything below this line
"25.01.2008     -
>Planning without assembly"
please give me the solution.
RajaRam

Advantages of Implementing Demand Planning in APO

Hi All:
One of our company's business units is exploring the possibility of implementing their Demand Planning in APO. Since their business closely resembles retail, they do not run MRP in ECC to replenish. Instead they do Kanban for replenishment. Hence they do not need Independent requirement in ECC.
The as-is forecast model is a simple spreadsheet that they use that is used for financial forecasting. They have a lots of SKUs and with spreadsheet aggregation and disaggregation is a night mare. Hence they have products sitting in their inventory, worth millions of dollars that has not been sold yet for a year. In essense the top-level forecast data has too many errors. They also use this to forecast how much of components they have to procure. Again, they have millions of dollars work of components sitting in our inventory.
So, they are looking to implement their DP in some other software. Since we have APO, APO could be a choice. But we have to justify the cost involved.
They will not need APO to send back IR back to ECC.
Followiing are the benefits we see:
1. Highly integrated with ECC and hence forecasting will be based on their Sales and invoice history.
2. Since their products are seasonal, APO can offer advanced forecast methods to forecast SKUs as accurately as possible.
3. Ease of use.
4. Right now, the spreadsheet is accessible to one user at a time and been shared thru emails. This will change with APO
5. They could use DP-BOM to forecast component and help reduce components inventory
6. An integrated system that will sent forecast to CO-PA on a monthly basis.
Can you guys help me with anything else that will benefit the business? Any input will be of great benefit.

Hi,
before to begin: I don't really understand what you are saying: you say the forecast is not use for planning, however your think it is the cause of overstock... how can that be?
I understand the logic for componenents, but not for finish good here
Anyway, regarding your questions:
Of course DP will help you too, and the benefits you emntioned are good.
However I suggest you to do a bigger analysis of your business needs... it looks ot me that you will need more than DP.
You could use SNP to plan your finish good and components (or use a strategy such as planning at assembly level).
If your biggest challenges in inventory level then SNP is the tool that will give you a better visibility here.
I personnally think that DP BOM should be use only is specific cases. You better have to plan your component in SNP, which will be far more flexible.
In one sentence, I think that if you do decide for a DP implementation now, you biggest benefit should be: later on you will be able to use SNP for planning.
Well that is what I think....
Good luck for your challenges!
Julien

VP (planned order type)?

hI Gurus,
i am Prparing document About Planned orders and their Conversion Methods.... as of My understanding There are 7 different Planned Order types are there
NB - Standard Purchase Order
LA - Stock Order
RS - Reservation
KD - Individual Customer Order
KB - Consignment Order
OE - Run Schedule Quantity
VP - Planned Independent Requirement
so normally LA is generally used Order type. KD is used in MTO scenario, OE in REM manufacturing.
What is the use of VP order type Why it will Generated ?
regards,
Venkat.

Hello
Regarding VP plannes orders, take a look on the following note:
1595312 - Message "61322 - Planned order XXX may not be changed"
This note provides the following information regardin VP planned orders:
The planned order has the special type VP. Such planned orders are created when Planned Independent Requirement for a planning strategy such as 'Planning without assembly', 'Planning at Phantom Assembly Level' or 'Planning with a Planning Material' is created, for example.
VP planned orders should be listed on a separate segment on the MRP List (MD05) or the Stock / Requirements List (MD04). They are used to trigger the procurement of the components and they are not yet "real". They should be only relevant for production once a sales order for the finished product exists, in case of planning without final assembly, or when the production of the final assembly is executed, in case of planning at phantom assembly.
BR
Caetano

Req. Plan Number (MD61)

Hi, We have changed the planning stragegy (Consume planning without assembly to Consume Planning WITH assmebly).
Every thing is working per our requiement. However, all materials created before the configuration changes takes place are still pointing to the "OLD" config. I was able to delete the forecast and create new forecast using the Req. Planning number, this marked the line in table PBIM as deleted and created a new line in PBIM which pointed to the new config.
We receive the forecast from APO. I have deleted the forecast in R/3 and when APO sent the new forecast, it just activated the old config. but did not "replan".
I am not familiar with APO, and our APO team is releatively new to this. Is there a way APO can replan instead of just sending forecast?. What should I tell the APO team to look into.
Or Is there a way in R/3 to replan and move existing old forecast to point to new configuration?.
Thank you in advance for your helpl.
-Giri

Hi,
Either change the Planning horizon dates manually in the initial screen on MD61 or use T-code OMPD - Assign default values & presettings in PIR and change the value in the Planning horizon field.
Now the dates wil lie within the factory calendor.
Try this..
-Thaila Shree

Phantom components planning

Hi,
Please suggest me on following scenario. i have been posting planning related questions from so long but still waiting for proper suggestions. here it follows,
This is make to order scenario by keeping components stock through planning.
I have a KMAT material K with phantom assemblies P1(assume red) and P2(assume blue) with their components PR1(semi or raw), PR2 respectively. initially they want to forecast KMAT material for that i suggested PS 89, but they do not want to do probability for characteristic values. so i suggested them plan components directly but they want to plan phantom assemblies so that they procure their components separately from vendors. if i use PS 59 for phantom assemblies it is generating planned orders which nobody wants to convert to prod orders. if i use PS 70 for phantom components it is always generating planned orders for quantity 1 as dependent requirement for phantom assembly.
So what planning stratgies do i need to use for all level materials, if any SO comes for KMAT material K, P1 P2 PIRs should consume so PIRs of components PR1, PR2. they do not want to forecast for PR1 or PR2, they want to forecast P1, P2 should generate dependent requirements in order to procure separately. if i use PS 70 for P1, again its component PR1 is always generating planned order for quantity 1 as dependent requirement of P1. please suggest me if anybody faced similar scenarios.
Thanks in advance.

7,
You have fallen into the trap of allowing the client to pre-define the solution, and then make unreasonable and illogical demands as to how this preselected solution should work. You are much better off asking the client to list his business requirements, in greater and greater detail, until you find the best match between his requirements and one of the many Standard Solutions.
For instance, Configurable material is not a requirement, it is a solution. Phantom BOMs are not a requirement, they are a solution. First find out why the client thinks he needs all of these features to run his business.
I won't make a suggestion, and then have you tell me why it won't work, and then I respond, and so forth and so on. If it were my client, I woul tell him that there is no standard solution. If he wants all of his predefined requirements to be met, then I would tell him the only options are for him to revisit and relax his requirements, or face the expense of a customized solution.
Best Regards,
DB49

Help on Planning Strategy to be used

Hi,
I am using planning strategy 40 for MTS.
Scenerio : FERT1 in PLANT1 PRI created as 10000 each for week1 to week5. Total of 50000
After MRP run non-convertable planned order create for each week requirement.
Sales order created for 15000 and after MRP run planned order created with conversion indicator of 15000 qty. There is no reduction in PIR or planned order created from pegged requirement of PIR.
Requirement : PIR should be reduced 35000 and respective planned order should be removed created from PIR in earlier MRP run.
Please suggest solution.

Hi
Go to OPPS and check what is the Reqmts type for indep.reqmts and Reqmt type of customer reqmt assinged to strategy type 40.
Also check the consumption details in Reqmt type of customer reqmt.
No consumption with customer requirements
1 Consume planning with assembly
2 Consume planning w/o assembly
3 Consume planning material (w/o assembly)
Also go to OVZG and check the Reqmt type of customer reqmt which is assigned to strategy type 40
Regards
S.Senthil
Edited by: Senthilkumar Sivaramakrishnan on Mar 19, 2009 9:17 AM
Edited by: Senthilkumar Sivaramakrishnan on Mar 19, 2009 9:26 AM

Sales orders not appearing in MD04

Hi,
Certain sales orders are not appearing in MD04. They belong to a particular sales organization. What could be the reason and how to resolve such thing.
regards
sachin

sachin arora wrote:>
> Hi,
>
> Certain sales orders are not appearing in MD04. They belong to a particular sales organization. What could be the reason and how to resolve such thing.
>
> regards
>
> sachin
Hi Sachin,
MD04 is the stock requirement listing.
Normally it would not list general sales order that is Make to STOCK scenarion. It would not list those sales order as that requirment is taken care by PIR (planned independant Requirment).
However in scenarios like MTO (Make to Order) or Plan to assemble to name a few. MD04 will list the sales order.
For that you need to change the STRATEGY GROUP in Material Master to Planning with Asembly or Make to Order in MRP3 Tab.
Once you save the sales order for such a material it will get listed in MD04.
Hope it helps.
Thanks & Regards
Abhishek Swarup

Automatic creation of production order against the sales order.

Hi Experts,
My client requirement is he wants the production order to be generated or created automatically as the sales order is created, please suggest weather it is possible or not.
Regards,
Naveen.
Edited by: vaddapalli naveen on Mar 13, 2010 9:03 AM

Hi,
It is possible by selecting proper Planning strategies.
Example you can use the planning strategy Assemble to order with Production order, it is possible.
please refer the below help link for more details,
http://help.sap.com/saphelp_erp60_sp/helpdata/en/41/191eb845fd11d188ff0000e8322f96/content.htm
Thanks,
R.Loganathan

Planning on assembly

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