Select BOM as per lot size against planned quantity

Dear all
i hav prob. releated select BOM as per lot size against planned quantity , suppose i hav monthly plnned order for
1000 nos. quantity and having two alternative BOMs like lot size 0 to 500 and 0 to 200 , so after MRP run system should create planned order(inhouse prod.) as per lot size i.e. 500 x1 and 200x 2 ., how is it possible please guide me .
thankx in advanced

create a two production version , if the plan quantity is more than 200 system will take the Alternative BOM and take the BOM ( 0-500 ) otherwise system will take the BOm ( lotsize 0-200).
Or
Create a Production version, Manually change the PV as per your requirement , And rerun MRP with delete a recreate option
regards,
Sundaresan

Similar Messages

Planned order with Lot size and Planning Calendar in MRP

Hi All
I request your help in understanding MRP results in below mentioned scenario:
Material: A
Planning Calendar: D1 (Monday only)
MRP Type: PD
Lot size: Z1 (this is copy of PK with Period Start = Start Date)
Safety Days Time: 3
Safety time indicator: 2
In house Production time: 1
I am running MRP with
NETCH
Planning mode: 3 (Delete and recreate planning)
scheduling: 2 (lead time scheduling)
"My PIRs are:
"Date--------------------PIR   -----Receipt------Avail Qty------ATP Qty ----Actual Cover
"Friday :08.4.11" ---- "-100"   ------ "0" ----   "-100.00" ------ "0" ----   "-5"
"Monday: 11.4.11" --- "-200" ----- "0" -----    "-300.00" ------ "0" ----- "-2"
"Wed      : 12.4.11" --- "0" ---- "370" ---------- "70.00" --------"20"----- "5"
"Thursday 14.4.11" --- "-50" ------ "0" -------- "20.00" ------- "0" ------"3"
"Saturday 16.4.11" -- "-10" ---------- "0" ------- "0.00" -------- "10" ----- "1"
"Sunday    17.4.112" ---- "-10" ------- "0" ------- "0.00" ---------- "0" ----- "0"
"Tuesday   19.4.11" --- "0" ------- "2000" ------- "2000.00" ------ "2000" --- "6"
"Thursday 21.4.11" -- "-1000" ------ "0" -------"1000.00" ------- "1000" --- "4"
"Monday   25.4.11" --- "-1000" ------- "0" ---------- "0" ----------- "0"------- "0"
"Tuesday 26.4.11"---- "0" -------- "100" -------- "100" -------- "100" ----- "3"
"Friday      29.4.11" --- "-100" ---- "0" ------ "0" -------- "0" -------- "0"
I am executing MRP on 7.04.11
As shown above the, can you please explain why the planned order is on Wed 12th and it covers 5 days requirement and similarly Tuesday 19th and covers 6 days.
I am not able to relate the relation between Planning calendar and Lot size procedure used. Also what would happen if I make planning calendar valid for two days in a week.
Thanks in advance
Rahul

Thanks dear
Yes you are right the Planning Calendar starts 18.4.11 and ends 24.4.11
Now as far as first planned order is concerned I thought it should be scheduled to start&end on Monday 11.04.11, rather it starts&ends on Tuesday 12.4.11. Also the actual coverage days goes up to 5 days even though its maintained for 3 days.
Similarly the second planned order also comes up on Tuesday 19.04.11 and covers 6 days (more than the setting and planning Calendar of only Monday)
On the whole this is confusing me on Lot size and Planning Calendar relation and how it impacts MRP. Can you please help me on this.
Also if you can throw some details on: how to restrict MRP to give planned order only on, say, Monday and Thursday, as only then it could be produced.
Thanks in advance
Rahul

Lot size (materials planning)

Dear All
Pl explain me in details Concept of Lot size and its relavance in Planing of material
Regards
Manoj

Hi,
MRP will firstly determine the EXACT qty required.
It then looks at the Lot size indicator on the material to see what should actually be ordered / produced.
You might indicate an "exact" lot size, in which case it does just that, it tries to procure the exact amount it has determined.
You might want the system to replenish up to maximum stock and so the lot size would cause the exact requirement to be change to the qty to bring the stock up to the maximum qty.
You might want the system to bundle together the requirements over X days, weeks or months etc. and so produce one large requirement instead of one for each.
You can even get the system to determine if it is cheaper to have large stocks and few PO charges or more frequent POs and so cheaper storage costs.
there are lost of lots sizes and they all try to bring in sensible quantities, instead of just what is immediately required.
Steve B

MPS Lot size rounding

Hi,
We have following scenario:
1) FG X with planning strategy 11, MRP Type: M0, Fix Lot Size: 100 Box
2) PIR entered for FG X for 100 box.
3) MPS Run
4) Plan Order of 100 box created
5) Convert to Production Order and final confirmation of op 10 for 90 box.
6) Production Order appeared as receipt element as 90 box.
6) In next MPS Run, Plan Order of 100 box being triggered for the FG X again to cater for the outstanding requirement of 10 box.
The client do not want the Plan Order of 100 boxed to be generated again. the stock initial GR of 90 box is deem to be able to cater for the market. In generak if the requirement is less then the batch size (fix lot size), no plan order should be created.
Appreciate if you have any idea/solution that can overcome the above requirement, kindly share with us..
Thanks.
WH. ONG.

Hi Wan Haur Ong,
Well i gone through with your thread and i am having an idea for your requirement.
As you said that you want only for particularly the the remaining quantity like 10 boxes should have a production., It means only for 10 boxes:
I would like to suggest you there is a funcationality called rework process for that you have to use funcationality called Trigger point for that particular operation:
Please maintain these steps for that operation OK:
First check in Tcode OPJF for the selection id a Priority is defined for the Task list type S with usage 1 and status 4 and then Proceed as follows:
1. Create a Reference op set in tcode Ca11.
Enter the plant,Description , usage and status for the ref op set Enter lotsize and unit of measure.
Enter the op as 0010 / workcenter/op control key/Description for the op Enter the standard values and save.
2. Create a Standard trigger point in CO31.(Ex Production)
Enter the Trigger Point usage /Group as FERT.
3. Tick the Trigger Point Functions.
4. Enable the indicator create order with Reference.
5. Enter the system status as PCNF.
6. Enter change as +.
7. Enable the indicator once.
8 . Now place the cursor on the create order with reference.
9. Goto Parameters.
10. In the Parameter enter in the group the created Reference op set group no.
11. Order type as PP01 and group counter as 1 and save the Trigger Point.
12. Now goto the Routing for your Material.
13. Choose the last op to assign the Trigger point.
14. Select the OP -
> Goto ---> Trigger Point overview.
15. Enter the Trigger Point usage as FERT.
16. Now choose that line ,select the Details---> Trigger Point f7. The system will says standard trigger point exists from which you can select the created Trigger Point (EXx Production)and save.
18. MD02/MD04.
19. Convert the Planned Order into Production Order and Release the order.
20. Now confirm th ops.
21. For the last op enter the yield and rework qty and set the status as PCNF.
22. If the status of last op is PCNF then in the system a POP UP will appear as Activited by Trigger Point /Create order with reference/order number/sequence and op number which trigger point works and enter.
I hope it will helps you, please get back to me if you have any questions OK pop me again.
Regards,
Madhu.G

Reg: lot size and replenishment lead time

1. please explain about lot size and replenishment lead time.
2. please also explain about consumption based planing and in steps explain how to perform manual and automatic reorder point(transc code please)

You use the lot-sizing procedure to determine how the system is to calculate the reorder quantity in the planning run.
A lot size defining the lot-sizing procedure is assigned to every material master record applicable to materials planning.
The lot size is defined in Customizing by the combination of the lot-sizing procedure and the lot-sizing indicator.
Three procedures for lot sizing are available:
o static lot-sizing procedures
o period lot-sizing procedures
o optimizing lot-sizing procedures
You use the lot-size indicator to define the procedure.
The following parameters are also available for controlling the lot-sizing procedure:
o Short-term and long-term lot size
   You can split the lot-sizing procedure into a short-term and a long-term period. This means that you can select one lot-sizing procedure in the near future and a different one in the distant future.
You define the periods in the section of the screen entitled "End of the short-term period/start of the long-term period".
   The valid from date of the long-term lot size area is defined via:
   - a periodicity
   - a number of periods
   The beginning of the long-term period is calculated by taking today's date and adding the number of periods in the future; the long-term planning period then starts on the next complete period.
   Note
For materials that are planned using the short and long-term lot size,
   it is recommended that you define a maximum MRP period. Defining the
   MRP period has the effect that materials after a certain period are
   included in planning even if no changes relevant to the planning run
   have occurred. This avoids a situation where order proposals created
   with the long-term lot size move into the short-term period because no
   changes relevant to MRP have occurred for the material.
   You define the maximum MRP period in the step, "Define maximum MRP
   period". A material that is planned on a regular basis should also be
   provided with an MRP type that contains the indicator for regular MRP.
o Scheduling indicator
   For period lot sizes, you can use the indicator for scheduling to
   determine whether the availability date;
o is to be set to the first requirements date in the period
o or is to be set to the beginning of the period
o is to be set to the end of the period
o or whether the period start represents the beginning of the planned
   order and the period end represents the availability date (repetitive
manufacturing)
Interpretation of the delivery times
For the lot-sizing procedure, you can also define whether the period
start is to be interpreted as the delivery date or as the availability
date using the indicator, "interpretation of the calendar times".
NOTE
The indicators, Scheduling and Interpr.deliv.times are mutually
exclusive.
Indicator for the splitting quota
For the quota arrangements, you can determine whether the requirements
quantities are to be distributed to several items, that is, whether
they are to be split. With the splitting quota arrangement,
requirement quantities are not simply allocated to the smallest quota
rating. Instead, they are distributed among various sources using the
following formula:
Quantity for source of supply X = Quota of source X * reqmts quantity
Sum of all quotas
Overlapping indicator
The overlapping indicator along with the cycle time in the material
master record are used to split the planned orders into several
partial quantities whereby the in-house production time overlaps by
the cycle time.
Lot-sizing procedure for make-to-order production
In make-to-order production, you can use the indicator, Lot size for
make-to-order production to determine whether,
the order quantity is to be calculated using the exact lot size
the order quantity is to be calculated using the exact lot size and
the system is also to take the rounding quantity or the minimum and
maximum lot size into account
the order quantity is to be calculated using the lot-sizing procedure
defined for the short-term area
Maximum stock level variant
The system only displays the Maximum stock level variant field in the
lot-sizing procedure, Replenishing to maximum stock level. The
indicator only has an effect in connection with reorder point planning
taking external requirements into account and in connection with
material requirements planning and controls how the system calculates
lot sizes.

MRP planning Purchase REQ per fixed lot size

Folks,
I have materials which have MRP type PD with fixed lot size of 20 pieces. Safety stock = 200 pieces. MRP run results in 10 preqs of 20 pieces each. I would like to have 1 Preq of 200 pieces. How can this be achieved?
Regards,
MdZ

Hi,
This is because of Lot size "FX" you maintained as 20.
For FX lot size system will divide the total qty as per the fixed lot qty & throw that much of PR for that stock.
So Safety stock = 200, FX =20 so PR will be 200/20 = 10 PRs
If you want 1 PR for your safety stock, then change the Lot size to "EX" then system will throw 1 PR for 200 qty as per your Safety stock
rgds
gsc

MRP run with lot size as per prod. version and capacity levelling

Dear PP experts,
Hi, We are working with strategy 10. For SFG and FG produced inhouse we have created BOM and recipe with production version.
For example:
I have a production version with batch size as 100 Kg.
I load PIR for 500 Kg in MD61.
I have maintained lot size as EX in the material master but I have not defined mini. and max. lot size.
Is it possible during the MRP to consider the production version batch size if the mini. and max. lot size is not maintained in the system and create 5 Planned Order of 100 Kg each.
I know, how it can be done by using lot size in material master or by maintaining schedule lines in MD61 or by maintaining quota. But if nothing is maintained is it possible for the system to create 5 Planned orders as per the production version batch size.
Pl. check if this is possible and revert back.
Regards,
Prashant

Hi
No, system will not consider the size that maintained in the production version for the creation of planned order while the mrp run .
This lost size is used to validate the bom/ routing combiation for the particular pv of the material

Planned order not selecting BOM and Routing.

Dear All,
I am runing LTP, but for all simulative Planned order system is not selecting Routing and BOM.When i change it manually its selecting the correct BOM and Routing.
Please let me know what needed ....
Regards
Sathish

Dear,
First check the OPU5 setting for routing selection ID for your pant and order type?
Check setting of OPJM fo the selection ID linked application?
OS32 setting for alternative selection.
BOM is selected by the system based on the setting in MRP plant parameters(OPPQ) and in material master MRP view BOM explosion type. I. e based on the validity date, lot size. so on
Regards,
R.Brahmankar
Edited by: R Brahmankar on Apr 3, 2010 11:11 AM

Lot size in BOM as well as for alternate material

how can we define the Lot size and validity period for a BOM means we want to define that 1 to 100 qty are to be produced with alternate 1 and 101 to 1000 for alternate 2. How the same can be defined in the master BOM.
There is one component in the BOM and there is a alternate material is also, Users want to define that while issuing the material , system allow to issue only say qty " 50" and then alternate material for next lot.
Is there any possibility to define the BOM as per the above requirement.
thanks
harish

Dear Harish,
if u have alternative BOM's, then creat production versions
1) creat BOM with two alternatives (say alt 1 1to 100 & alt 2 101 to 200)
2) creat multiple Routings with two group counters
3) creat production version in MM02 in MRP 4 view or work scheduling view
4) in BOM slection in MRP 4 view maitain the prameter as 3 or 4
Then MRP takes care of lot sizes difined in PV & BOM and creat procurment proposals
Regards
kumar
Edited by: kumar kumar on Aug 3, 2009 8:02 AM

Lot size exclusion from planning run

Hi Gurus
My scenario is some materials are maintained with lot sizes as EX , VB, HB , when planning run executed , the system should not consider the VB and HB lot sizes ( these are not bom components) and no procurement proposal should exist , we are not following storage location MRP ,
Pl come back in full thanks in advance
Regards
Ram

Hi ramki
VB is MRP type not lot size. VB consumption based planning with manual reorder point. The planning proposal will be created based on your reorder level.
HB is lot size of " Replinishment to maximum lot size "
Normally oils and others are procured where the storage tank capacity is restricted. The max replish level will be your max tank capacity. You can define them as cosumable materials or bulk materials.
Regards
J . Saravan

Selecting the correct lot size...

Hi,
I have some problem in selecting the correct lot size, please help me solve it.
The requirement of raw materials per month is 100nos. But the vendor cannot supply them in qty required by us but supply can happen in 1000nos. I cannot purchase all the quantities as materials cannot be kept in store for long period.
Which type of lot size is suitable for this type of scenario. Is there any SAP standards available or configuration is required?
Regards,
Pavan

Hi Pavan,
This is not a lot size issue , but a process issue. You cannot choose a lot size unless you are clear what is the qty for which you expect PR in this case?
Once that is clear, you will get lot size as needed
cheers
Rav

Sequence dependent lot-size planning as a basis for PP/DS blocks?

Hi ,
I consider the following system setup for a Mill Products planning implementation .
1) In SNP one performs SOP planning with common goals to adjust sales plan, establish equipment maintenance plan, transportation plan, etc. The first month of the SNP plan is supposed to be in daily buckets. Using the SNP optimizer is a good option since the business goal is to use equipment more efficiently, let's say to minimize setup costs, and there are warehouse limitations for semifinished products as well.
2) In PP/DS we are going to use CDP and block planning since it is the best practice.
3) SNP planned orders can be used as a basis for PP/DS blocks on the resource, upon the condition that the configuration of SNP product - kmat variant and block requirements match.
In SNP i see that the SNP PDS has a duration of 1 day (that's fine), but the sequence dependent lot-size planning requires a bucket of at least 1 week long (1 month in my case) since the SNP orders are sequence-optimized only inside of one bucket. The result of such an optimization are additional counters assigned to SNP orders according to their sequence minimizing setup costs. However, orders are not scheduled according to the sequence.
So far it looks like such a combination is not useful as
- Orders in monthly buckets are not scheduled on days and cannot serve as a basis for block dates proposal for PP/DS block planning.
- If a product production volume is less than 1 day, SNP cannot create any more detailed block in principle since the minimal time bucket is daily bucket.
I searched over forums on these or similar topics, however no definitive answer so far for the question in the subj.
Could anyone bring more light on this ? Maybe I am missing something in the setup or sequence dependent lot size planning was designed for other purposes/industries?
Best regards
Vladimir

Hello Asim,
Issue one
in product selection for propagation range you can set your selection criteria which selects the products dynamically. You just have to change your report variants for planning run. Do I misunderstand your concerns?
Issue two
Changing to planning procedure 1 will not delete the PFE but will prevent APO to create a new entry after any MRP-relevant changes happen or heuristic SAP_PP_020 (which creates the initial entry and does the low level code determination) is run.
In some cases procedure 1 will still create a PFE. Please check customizing for details. Thats why I would recommend to create a new planning procedure with "no reactions".
As soon as you prevent APO from creating new PFEs you can just once delete the PFEs in /SAPAPO/NETCH by just setting the first column for these materials blank (select your materials, mark column, delete indicator).
Corresponding table to MDVM is /SAPAPO/PEGKEY. Indicator for PP/DS is NETCH_RRP.
If material is not planned in APO you do not need a PFE in APO.
Issue 3
Maybe utilize table /SAPAP/PEGKEY
As I said if you prevent creating the entry you just have to delete (set indicator blank) once.
Hope that helps.
Regards,
Uli

CTM Planning: How to Handle Min Lot Size Daily Resource Capacity?

Hello,
I am facing a situation where the Min Lot Size values require more than a days capacity of the Resource.
Finite Planning CTM is skipping all demands.
Example:
Daily Resource Availability = 24 Hrs,
Capacity Consumption per PPM = 1000 Kgs / 1 Hour.
Min Lot Size = 50,000 Kgs
Capacity requirement for the 50,000 Kgs = 50 Hrs
Is there a way CTM can plan this?
Thanks,
Ran

Yes the time buckets in CTM profile has nothing to do with this limitation...
Nor does the infinite/finite setting.
Basically its a limitation of how the resources are stored in livecache.
You can not exceed the capacity for which the resource is stored...
The only workaround is to define the resourcde in weekly time buckets by manually defining a capacity profile.
I don't like this as every order will take a week...
I am not aware of any other workaround...
I have seen other clients take out the minimum lot size for SNP, then when cif transfer the order back to R/3, it is combined to 1 large order...
Ken Snyder

PLANNING CALENDER IN LOT SIZE

Hi
What is the function of Planning Calender in Lot Sizing procedure in SNP.

Hi
You can define the planning calendar to define the periodicity of lot size.
For example in our case we want to SNP to create requirement only in alternate month based on lot size.
So we create planning calendar which consist only alternate month and attach to lot size.
Now when we execute the SNP planning, it will create supply element only in alternate month.
I hope this will give insight of it. Please let us know , if it helps you.
Thanks
Amol

Help on Planning Calender and lot size procedure settings

Hi Gurus,
We have 2 different schedule at the moment for our PO Placing to our supplier :
1. Planning Calendar D01 --> For Seafreight shipment, PO Placing on bi-weekly basis, every Monday and RDD (Request Delivery Date) is on Thursday (11 days after PO Placing)
2. Planning Calendar D02 --> For Airfreight shipment, PO Placing on weekly basis, every Friday and RDD (Request Delivery Date) is on Wednesday (5 days after PO Placing)
Now we have required to change the SEAFREIGHT process by having the PO Placing on weekly basis, every Monday and RDD (Request Delivery Date) is on Wednesday (9 days after PO Placing).
Please let me know the step by step procedure to create a new Planning Calendar and Lot Size Procedure to accomodate this requirement?
Thanks for your help.
Regards
Brijesh

Dear Brijesh:
1. I think you are planning to change the Planning calendare D01.
2. For this go to MD26- GIVE THE plant / palnning calendar id.
3. Then in the CAlc rule for spec peroid - change the day from wednesday to Monday.
4. SAve this and generate periods.
5. Now in the maeterial master- check if you have the lot size as PK and also planning calendar as d01.
6. In the planned dleiveyr times you enter 9 days.
Kindly check this and revert back.
Reg
Dsk

Select BOM as per lot size against planned quantity

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