Scope of MRP in REM

hi gurus,
i want to know the scope of MRP in a repetitive manufacturing scenario.
regards
sayeed

Dear
As far as MRP is concern , it is a one of the basic planning tools for any kind of business either REM or others.If the business process is REM , then you must have Demand as PIR which will be ur run schedule qty .Now this Demand can be created through SOP or Consumption Base Planning methods .You need to find out waht are all the materials you are looking for CBP or SOP based on the previous demand pattern , consmption through Sales .If you have FG/SFG , you have look into correct planning stategy like MTS-10 or 70 .
Basic setup will be same as like others ; Demand Management , MRP
Demand Managemet ; Through SOP/CBP-Forecast Base /ROP for RAW , SFG, FG.
MRP ; Either plant level , Group of Plant with SL etc needs to be checked .
Regards
JH

Similar Messages

Help scope out MRP process

We are kicking off an MRP project in a couple months and I need some help filling in a few gaps in my knowledge. I am fairly familiar with MM but hardly at all with PP. We are on ECC 6.0. Not running SRM/APO.
Some background: My company wishes to do forecast based MRP. We have about 2 years of MM transactional history and inventory of data. We have not implemented any PP but are prepared to put in whichever components are required in support of the MRP process. However, a non-SAP system will remain our production order system. We use SAP MM/WM for procure to pay and IM of raw materials. The desire is to marry SAP's generated forecast based on historical data with a future sales/demand forecast created in Excel. This sales forecast lists out the finished good. The forecast gets generated quarterly for the next 3 months.
A few questions I had:
1) Since we do not care to valuate or inventory the finished good, I assume that we need to represent the finished good as a phantom material with the BOM components being the raw materials?
2) What is the BADI that is used to import the Excel sales forecast? What transaction calls the BADI?
3) I assume that after SAP marries the historical and future forecast data, there is the ability to view the consolidated forecast and make adjustments...what transaction is used for this?
4) We have three plants and so far each plant has been carrying out its MRP planning (outside of SAP) on its own. However, there are many raw materials and finished goods that are common to the plants (ie same SAP material numbers) and, if not already, could be sourced from the same vendor for better pricing. On occasion, when there is a shortage in one plant we do a plant-to-plant transfer.
a) I assume there is the capability to run MRP using the summarized forecast of all three plants? I'd group the plants under an MRP area, correct?
b) Can some raw materials be planned at the plant level while other materials at the global level?
c) Or if MRP takes place at the plant level, is there any functionality for our global procurement team to see a more summarized global view of the material requirements? He'd need this, for example, to negotiate better pricing on centrally agreed contracts with the vendor.
Thanks!
Vlad

Vlad,
1) Since we do not care to valuate or inventory the finished good, I assume that we need to represent the finished good as a phantom material with the BOM components being the raw materials?
Don't know where you got that idea. I wouldn't do that, but I don't know all the particulars. If you intend to sell finished goods, you probably will want to put them in a plant as stock. If you intend to build finished goods, you probably shouldn't use a phantom.
3) I assume that after SAP marries the historical and future forecast data, there is the ability to view the consolidated forecast and make adjustments...what transaction is used for this?
Big assumption. There are several ways to approach forecasting within SAP ECC. These functionalities are not a 'transaction'. I suggest you look at standard online help to get a feel of what is and is not possible. Below is a bit of info about forecasting within SOP. SOP is one of the planning methods with the greatest feature sets. If SOP doesn't have enough functionality for you, then you probably need APO. There are also simpler methods of forecasting in SAP.
http://help.sap.com/saphelp_erp60_sp/helpdata/en/a5/63201843a211d189410000e829fbbd/frameset.htm
4) We have three plants and so far each plant has been carrying out its MRP planning (outside of SAP) on its own. However, there are many raw materials and finished goods that are common to the plants (i.e. same SAP material numbers) and, if not already, could be sourced from the same vendor for better pricing. On occasion, when there is a shortage in one plant we do a plant-to-plant transfer.
a) I assume there is the capability to run MRP using the summarized forecast of all three plants? I'd group the plants under an MRP area, correct?
another big assumption. MRP, unlike forecasting, is generally done at the plant level. There are ways to manage MRP so as to consolidate your demand into a single plant, but ultimately the purchased materials will have to be sent to the place where they are needed. If you have 5 places where your RM is needed, you will either cut 5 POs, or one PO and then ship the parts internally to the point of use.
b) Can some raw materials be planned at the plant level while other materials at the global level?
Generally MRP planning parameters are set at the plant level. There are, however, ways to manage your requirement.
c) Or if MRP takes place at the plant level, is there any functionality for our global procurement team to see a more summarized global view of the material requirements?
Yes
In closing, expert Mario Adler has given you some sound advice. What you are describing is a project. Some companies take months or years to implement a solution similar to the one you are describing. If you want to get the best bang for your buck, engage a consulting company who has done this before. You will end up richer in the end.
Best Regards,
DB49

Material in two plants, I run MRP with the BOM is not found in prod plant

Hi all,
I have plant 1020 material 12345
Plant 1020 is the production plant for material 12345
The material 12345 exists in plant 1070.
The material 12345 in plant 1070 has no MRP.
Plant 1020 material 12345 config in MM03
MRP1 --> MRP Type = PD
MRP1 --> MRP Controller = G03
MRP3 --> Planning material = PLAN_1020_GR03
MRP3 --> Planning plant = 1020
Plant 1070 material 12345 config in MM03
MRP1 --> MRP Type = P3
MRP1 --> MRP Controller = 017
MRP3 --> Planning material = empty
MRP3 --> Planning plant = empty
The BOM in cs11 for plant 1020 material 12345
has 3 components
Comp#1
Comp#2
Comp#3
The Dependency is code
TABLE TB_1020_SUPERBOM (PP_nuance_interne = $ROOT.PP_nuance_interne,
PP_dim_billette_bom = $ROOT.PP_dim_billette_bom,
PP_CODE_LONG_BILL = $ROOT.PP_CODE_LONG_BILL,
pp_component_bom =$self.pp_component_bom).
The dependency is not found because it is looking for it in the plant 1070 and not the plant 1020.
When the MRP runs for a Delivery type stock transfer order I get
CONFIG_1020_BILLET <---- This is the BOM item component field in CS11 in the Basic data tab
Comp#2
Comp#3
instead of
Comp#1
Comp#2
Comp#3
When I run MRP for the same material, if there's no
"Delivery based on Stock transfert orders" the MRP associates the correct components
Hope this explains m'I situation.
Regards!
Curtis

Hi,
If you want a reply in one line, it would be SAP R/3 does not supoort this feature.
You will have to go for APO module.
There are few things which can be done in R/3 side, as in maintaining a scope for MRP run in OM0E, maintaining special procurement key etc etc, but all these will not do any check of stock in another plant & can only help in a very limited way if all any for your specific need.
But SAP R/3 provides a cross plant evaluation via MD48 to know the stock & demands at all plants, this can help only for evaluation purpose.
Hope it clarifies.
Regards,
Vivek

REM Planned Orders being generated with Order type LA instead of PE

Hi All,
I'm running the Repetitive Manufacturing scenario and when I execute the MRP run for my Planned Independent Requirements, Planned orders are automatically generated with the order type LA. I understand that for repetitive manuf., planned orders should have the order typ PE.
Is there something missing in config? How can I get the orders to be generated with the Order type PE??

HI,
Check the following settings which is required for REM
1. Master Data -
- Create Material master - MM01
-Create BOM - CS01
-Create rate Routing - CA21
Create Rem profile - SPRO ->Production planning -> Rem.Manuf->Control data or use existing one
Assign Bom seelction method = 2 & 3 (Prod version) in MRP view
Rem MFG indicator - mrp view in MM01.
Assign the REM profile to a material - MRP view in MM01.
create Valid Production version - MRP view in MM01 & Check Rem mfg ind
Assign the BOM and routings in Prod. Version
2.For Preliminary Cost Estimate:
Create version specific product cost collecter for Header material and preiminary cost estimate - KKF6N as per the settings in Rem profile. -
3 For standard cat Estimate.
create std Cost estimation(CK11n)
std cost Estimation Mark & release(CK24)
Thanks
Hrishi

SO will not be taken into consideration for MRP until it is released for delivery.

Dear Sir,
We are following sales order basis planning (MTO basis planning strategy 50 is being used ).
When sales order are created by default it is blocked for delivery. In our present system, we have a scheduled total MRP procedure on daily basis. Hence, when sales are entered in the system it is taken into consideration for MRP RUN automatically.
But our new proposed system we want , until the sales order is blocked for delivery, it will not be considered for MRP RUN. It will only be taken into consideration for MRP RUN when sales order will be released for delivery.
Is it Possible ? If Yes, Please let me know the procedure.
Regards,
Amit Biswas

Hi Krishnendu ,
Then we are deviating from my requirement ,
My requirement >>
We are using MTO planning (Planning Strategy using 50),
1. Sales order are created for material requirement planning .
2. under MD04 list sales order will be shown under FERT material .
3. There is release procedure of Sales order.
4. Daily scheduled MRP RUN has been introduced on total planning.
5. MRP RUN only consider released sales order . If there is any sales order which is not released , that will not be consider for MRP RUN.
6. Under FERT material , there may be number of sales order both released and not released sales order.
Please let me know the process , sales order which are not released , this will not be under the scope of MRP RUN .
Regards,
Amit Biswas

MRP Process Execution

Hi,
Please guide me about the following query please:
Does MRP Process consideres the Purchase Requisitions and Purchase Orders in which items (Material Codes) are marked as deleted?
If yes, then please guide me how can i exclude these PRs and POs from the scope of MRP execution for the Materials got used in the PRs and POs.
Thanks and Regards

Hi,
Thanks for your reply please.
But my question is that the Materials are not deleted but their reference in the PRs and POs are deleted i.e. the PR line or PO line in PRs and POs are deleted but still is it possible that MRP considers these Material lines of PRs and POs?
Please guide.
Thanks and Regards

Planned order for Procurement type X

Hi Gurus,
I am working on REM.
Planned order generated through MRP for REM material with Proc Type "X" is not convertible into Purchase requisition or Production order.
This option I am not getting.
Any one can help me out.
Srini

Hi,
Eventhough the Procurement type is "X", by default system will consider the Inhouse Production.
Hence check your Planned Order Type : It should be PE.
For your Procurement Type; "X" to Work, you should have Quota Arrangement and Source List defined for your Material and Vendor also.
You need to mention the Quota arrangement all the Parameters like %, source, Inhouse or External Procement etc..
Then during MRP Run system will create the Planned Orders and PurReq for your Material.
Hope this helps..
Regards,
Siva

Repititive manufacturing flow

If i want to implement sap for repetitive manufacturing type, can u please give typical process flow.

HI
The following steps are necessary for REM,
1. Master Data -
- Create Material master - MM01
-Create BOM - CS01
-Create rate Routing - CA21
Create Rem profile - SPRO ->Production planning -> Rem.Manuf->Control data or use existing one
Assign Bom seelction method = 2 & 3 (Prod version) in MRP view
Rem MFG indicator - mrp view in MM01.
Assign the REM profile to a material - MRP view in MM01.
create Valid Production version - MRP view in MM01 & Check Rem mfg ind
Assign the BOM and routings in Prod. Version
2.For Preliminary Cost Estimate:
Create version specific product cost collecter for Header material and preiminary cost estimate - KKF6N as per the settings in Rem profile. -
3
for standard cat Estimate.
Create std Cost estimation (CK11n)
std cost Estimation Mark & release (CK24)
U can do any one of the cost estimation as per the settings in Rem profile.
4. create PIR in MD61.
5 .Run the MRP for your header material - MD02/MD01 - results run scheduler (PE type Planned order) will be created. Here planned order cant be converted to Producton order.
5. Use planning table for scheduling and capacity planning - MF50. Here u can assign u production quantities to production line
6. Use Pull list for material staging (if material stotage exists in prod location) - MF60
7. Backflush (confirmation) the planned order - MFBF. Results planned order will Reduced and GR, GI, activity cost will be posted. U need not convert the planned order to production order, Confirmation for planned order only.
8. To see Back flushed documents MF12
9. Then Go to KKF6n to see the Manufacturing cost.
10. Over head calculation - (CO42)
11 Variance calculation (KKS6)
12- Settlement (KK87)
Regards
Anupam Sharma

Repetitive manufacturig

HI.
Can some one explain me the process of repetitive manufacturing.
I mean.
what are the settings that i have to do in a FERT material. like MRP type , Planning strategy and MRp 4 view.
what is the process of production.
where do I confirm the process.

HI
The following steps are necessary for REM
1. Master Data -
- Create Material master - MM01
-Create BOM - CS01
-Create rate Routing - CA21
Create Rem profile - SPRO ->Production planning -> Rem.Manuf->Control data or use existing one
Assign Bom seelction method = 2 & 3 (Prod version) in MRP view
Rem MFG indicator - mrp view in MM01.
Assign the REM profile to a material - MRP view in MM01.
create Valid Production version - MRP view in MM01 & Check Rem mfg ind
Assign the BOM and routings in Prod. Version
2.For Preliminary Cost Estimate:
Create version specific product cost collecter for Header material and preiminary cost estimate - KKF6N as per the settings in Rem profile. -
3
for standard cat Estimate.
Create std Cost estimation (CK11n)
std cost Estimation Mark & release (CK24)
U can do any one of the cost estimation as per the settings in REMprofile.
4. create PIR in MD61.
5 .Run the MRP for your header material - MD02/MD01 - results run scheduler (PE type Planned order) will be created. Here planned order cant be converted to Producton order.
5. Use planning table for scheduling and capacity planning - MF50. Here u can assign u production quantities to production line
6. Use Pull list for material staging (if material stotage exists in prod location) - MF60
7. Backflush (confirmation) the planned order - MFBF. Results planned order will Reduced and GR, GI, activity cost will be posted. U need not convert the planned order to production order, Confirmation for planned order only.
8. To see Back flushed documents MF12
9. Then Go to KKF6n to see the Manufacturing cost.
10. Over head calculation - (CO42)
11 Variance calculation (KKS6)
12- Settlement (KK87)
Regards
Anupam Sharma

In scope of planning ( md01), How to maintain MRP areas in scope of plg?

Hello PP members,
In scope of planning ( md01), How to maintain plant or MRP areas in scope of planning ?
What is the transaction code for maintaining plants or MRP areas in the scope of planning
I tried transaction code SAMP, Also went to SE93( Maintain transaction) for any related transaction codes for maintaining plants in scope of planning, it wasn't much help
Thanks for your time,
Thanks Again,
Suren R

Hi,
we can use Total planning(MD01) for a single plant or use scope of planning to control whether total planning is to be carried out for single plant/sevaral plant/ for one MRP Area/sevaral MRP areas/ combination of plant and MRP Areas.
Steps :
1.Group together the plants which are to be planned in spro in --->Define scope of planning.(OM0E)
2. Define the scope of planning as 999 for ex and give description.
2. Now select that and Specify the sequence in which Plants and MRP Areas are to be planned,
3.Goto new entries and enter the plant as 1000/MRP Area as 1000 with counter 1 and plant as 1100 with counter 2 and save.
4.Execute the total planning either as online job or as background job.
5.The planning run has to be always started with paralle processing.
In SPRO in define parallel processing in MRP enter the destination for parallel processing for ex your server name and enter the no .of sessions as 1 and save.
6.Tcode MD01 enter the scope of planning group and selet the parallel processing and enter.
7. All the materials to be planned in the plant / mrp area will be planned now.
Regards,
nandha

Testing MRP scope of planning and MRP lists

Hi,
I am configuring the scope of planning and want to know how can I test if the planning is happening in the sequence as specified in the scope of planning. I would have around 20 plants in the scope. I thought of going after the time stamp on the receipts created by the system. Is there any table like MDKP which can show me the sequence of planning ?
Also what is the use oif the tcode MD08.... delete MRP lists ? what is the use of deleting these lists besides keeping the system clean
Thanks

Hi
Reorganization of the MRP Lists - MD08
A report is available for reorganizing the MRP lists which you can find in the menu for MRP under the menu option, Environment. If you enter the selection criteria, plant, material, and MRP date, the system deletes all the MRP lists from the database that are no longer required.This report can also be started in a test session and you can instruct the system to print out a list of all the deleted MRP lists.
Further
Deleting MRP Lists - Manually in MD05
If the MRP list is no longer required, you can delete it manually. In order to do this, choose MRP list ® Delete document. The MRP list will be deleted.If you do not delete the MRP list manually, it is stored in the system until a new MRP list is created by a further planning run.
regrads
muthuraman.d

Inter-plant planning in REM

Hi i need some suggestions for inter plant planning in REM before mapping in SAP.
Our Scenario is Repetitive manufacturing and we have 2 plants which have 3 assemblies in each plant in case of discrete/process scenario with using special procurement key we can do inter plant planning but in case of REM SAP HELP suggest its not possible but don't understand why it is so?
please refer this link : http://help.sap.com/saphelp_46c/helpdata/en/70/442986c48d11d1b59d0000e82d81c3/frameset.htm.
So i want some suggestions from any one you who might have already experienced this scenario to map in SAP.
As i understand this can be achieved by MRP at 2 plants or with scope of planning apart from these is there any other way which can be simplified the task.
Cheers
KK
Edited by: kiran kumar on Feb 7, 2011 4:54 PM

On which version are you working?
ECC6
Have you tried the Inter-plant planning in REM If yes then what the error are you getting?
No i haven't tried this scenario will try and update mean while i want some inputs from any one who might have already experienced this scenario.
It s possible a stock transfer of the production plant may also be executed to the plant of the sales order also.
Could you please elaborate more what do you mean by this statement?
Cheers
KK

What are the advantages of using SAP PP-REM?????

Hi,
Can anybody tell me the advantage of using Repetitive Manufacturing. How it will help a particular industry if implemented.
I want to know advantages involved in
Planning (MRP, Capacity), Product Cost Controlling,
WIP calculation, variance Calculation
if SAP PP-REM is implemented
Pavan

Hello Friend ,
PP REM has advantages following advantages-
Purpose
This component can be used for production planning and control in a repetitive manufacturing environment- ie the same product is manufactured repeatedly on the same production line.
You can use repetitive manufacturing as either make-to-stock REM or make-to-order REM such as in the automotive industry, for example.
The goals of repetitive manufacturing are the following:
Creation and revision of production quantities on a period and quantity basis (reduction in individual lot and order-specific processing).
Reduction in the production control effort and simpler backflushing tools(with the option of using the full scope of the PP functionality).
Implementation considerations
You can implement Repetitive Manufacturing if the following is true of your production process:
You produce the same or similar products over a lengthy period of time.
You do not manufacture in individually defined lots. Instead, a total quantity is produced over a certain period at a certain rate per part-period.
Your products always follow the same sequence through the machines and work centers in production.
Routings tend to be simple and do not vary much.
Hope this info helps u. Award points if benefitted.
Hemant

Cross Plant Planning- MRP activation indicator turned after the creation of Material code

Dear Experts,
Working on Cross plant planning, where 1001 Production plant will stock transfer material to 8 different plants.
Right now, only 10001 plant had MRP and planning file entry ticked in customizing OMDU.
The other 8 plants have Materials codes created and MRP views extended but no MRP activation is ticked.
Now, to have Cross plant planning MRP set, I have done necessary configurations, Scope of Planning, Special Procurement 40, and parallel processing is configured. All master datas are set properly. Tested few scenarios in IDES, working fine.
If my understanding is clear, than I thin I need to run MDAB, activation of planning file and MDRE, Planning file Consistency Check, because MRP will run in background?
Is this correct or something more needs to be done ?? Please suggest
Please also tell what is the use of MDRE t code.
Best regards
Shailesh

Hello Shailesh
MDAB (RMMDVM20) is at plant level, you need to create different variants as per your plants
Create a variant for the new plants and then schedule a job for these variants.
Check customizing transaction OMDU -> set up planning file
entry and consistency check of planning file entries.
Best Regards,
R.Brahmankar

Report for MRP controller and relevant purchasing document

HI
My requirement :We have MRP controller for different diciplines(mech, electrical, Instrumentation.......ect).
I want to search for a report Where it display me the Purchasing document(PO) number by respective decipline.
I tried all the report in MRP controller such as MC.E, MC.D, COOIS.........ect
Thanks in advance
Mujeeb

Hi Mangalraj
Thanks for your answer, but my question is not yet answered.
As you told i did follow accordingly.
When i enter the T.code: ME5A ( i can not find the scope of list ALV but did find the entried as below)
A     3-line + n special
B     2-line + n special
B1     2-line + 2 MRP list
B2     2-line + 2 stock/rq.
B3     2-line + 2 purch.dt.
C     1-line
C1     1-line + stock/rqts.
D
F     Collective release
G     3-line loop
H     2-line loop
I     1-line loop
If i select "C" from the list i'm getting 1 line display but as you told i did press the CTRL+F8 but unable to get the cost) it does not work at all like dat.
I'm using the system version 4.6C. Can you please suggest something on the report.
Thanks & regards,
Mujeeb

Scope of MRP in REM

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