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

Similar Messages

Schedule with dependent lot size problem

Hi,
    I maintain the setup/process/tear down time(base qty is 10) in Work Schedule view in MM02(dependent with lot size)..But the begin date/end date in these POs are the same when I create Production Orders with different qty.
    It seems my setting doesn't take effect..Do you have any suggestion?
PO 1:   100 qty      Start date 11/10 End DAte 11/11
PO 2:    1 Qty      Start date 11/10 End DAte 11/11
PO 3:1000000 Qty Start date 11/10 End DAte 11/11
Why the start/end date doesn't change based on my PO qty?thanks..

Hi,
Monst Yang wrote:
>     I maintain the setup/process/tear down time(base qty is 10) in Work Schedule view in MM02(dependent with lot size)..But the begin date/end date in these POs are the same when I create Production Orders with different qty.
In-house production time (lot size dependent or independent) is used for calculating the basic dates of planned orders when MRP is run with basic dates parameter (instead of lead time scheduling). However when production orders are created basic dates are always determined according to the production dates and production dates are determined by lead time scheduling. In other words, the lot size dependent production time data that you have maintained could only determine basic dates of planned orders, only if MRP is run with that parameter. In the case of your production orders, standart values of the operations and formulas of the work centers are used by lead time scheduling. Dates might be equal because scheduling formulas of work centers does not consider order quantities or labour hours, which would be multiplied by order quantities, are not maintained in routings. Investgate the production dates and scheduling of the operations in production orders. Also have MRP create planned orders to see the effects of lot size dependent times in master data. Be sure to emty the lot size independent production time in material master to avoid it overwriting lot size dependent time.
Regards.
Edited by: Özgen Canan on Nov 10, 2011 3:58 PM

Lot Size Planning for Procurement

Hi guys
In our company we work with minimum lot sizes for procurement, and we need to configure minimum lot sizes for procurement in the SNP optimization run. It´s posible to do it in SNP, pls can someone tell me how to configure this in SNP?
David

Hi David,
I am glad to hear that.
Regarding your performance issue: it is very usual to have long runtime when using discrete model.
The complexity of this model is much higher than a linear problem; so the optimiser takes time to find THE optimal solution.
However there is a lot you can do to make it better:
1. Split your model: instead of running 1 big optimiser, run serveral smaller one in parallel.Ensure your model are all independant (e.g. no common product or resource)
2. Use decomposition: (product/ time/resource; based on your scenari) to simplify the porblem, hence speeding the solution.
3. Set a maximum time
You do not have to wait for THE optimal solution. The optimiser can sometime very quickly find a very good solution; the last hours are spent "fine tuning" it. Potentially, you might not be able to see the difference between a 4h job and the 15H one).
Hence SAP advises to set a maximum runtime when working with discrete model.
The question is how to define this maximum time to optimise the ratio solution quality / runtime.
Answer: test it, check the result. Be aware that perfomrance testing for the optimiser can take a while.
4. fine tune you optimiser setting
There is a couple a finetuning that can be done to improve performance, especially for discrete model.
I will not be able to help you woth that.
As far as I am aware only the SAP optimiser team has the expertise to help here.
I strongly recommand to contact them; their help is often invaluable. They will also help you to define the 3 first points.
I hope this will help you.
Thanks and Regards
Julien

Manual Lot Size issue in SNP

Hi Gurus,
I have an issue while creating planned orders manually in the planning book as it is not splitting into the lot size which was maintained in the product master.
Some details on the issue:
I have a product X and I maintained '4000' as the fixed lot size in product master. When I enter 20000 it should spilt it into 5 batches and which is not happenning and it is placing the entire thing as one bulk order of '20000'.
(If I run heuristics, it is splitting basing on the lot size maintained).
It was working correctly for 1 product and for many of the products it is not working. All the parameters for the products are same and there is no difference.
For the product which was working correctly for one user and for the same product if I try it is not working.
I probed more into the issue to see if any parameters were added in his profile, there is one custom parameter which is assigned which splits the planned orders basing on the lot size maintained. I even assigned that profile, it worked once and later it is not working.
The strange thing is for one user it works and for other users it doesn't even work for the same product.
Note: We recently moved from SCM 4.0 to SCM 5.1.
Did any one faced such kind of issues before? Any suggestions are highly appreciated.
Thanks and regards,
Murali.

Hi Murali,
I am surprised to read the issue. I will never expect manual planned order to get split. The lot size settings are applicable only for automated planning i.e. heuristic (MRP in R/3)
If you have indeed observed that the system splits the orders by lot size, I have nothing to comment. (probably that is why you did not get a reply for almost a day.
If you have found some settings and find that they do not work, please raise a message to SAP for the same.
I do not think system should split the manual planned order.
Regards,
Nitin Thatte

Maximum lot size - create order manually

Hi Experts,
we are in the implementation phase of the project (PPDS) and need your help.
For the products we have the data of Maximum Lot Size, that is a constrain for the process. But when we execute manual adjustments/creation of the planned orders, this maximum lot size is not respected, because for the manual orders is used the heuristic SAP_PP_001 Change Order Manually.
We need to consider the maximum lot size even for manual adjustments/creation.
Does anyone knows a way to consider the maximum lot size when create orders manually?
Thanks in advance
Thiago Cyrillo

Hi Hans,
If as per the requirement you want the system to take into account the period of 63 days reqirement , then as my experience the lot size field should be changed from the daily lot size .......or else the setting is quite redundant in nature........in accordance to your business requirement.
Check for the period lot sizing for detail information..........incase you have any query then let me know ......
Please reward points if it is helpful.........
Thanks
Kaushik

Lot Size different to master data

Dear Gurus,
In master recipe, when I am trying to save the following error message is appearing.
Lot size different to master data
Can anyone help me on this issue.
Thanks in advance,
Arul.

Dear,
Please check,
When a master recipe is scheduled, the lot size can be proposed in two different units of measure
If a base quantity is maintained in the material master (view Work scheduling), the lot size is entered in the base quantity of the material master. If no base quantity is maintained, it is entered in the unit of measure of the recipe header (header unit).
That is, the unit of measure of the lot size is predefined by the system and you cannot choose it.
If the lot size is entered in base unit of measure for scheduling, up to now, no conversion between base unit of measure and header unit occurs. The lot size (in base unit of measure) is converted into the operation quantity directly via the conversion factors of the operation. The scheduling result is incorrect. and system display the message Lot Size different to master data.
Regards,
R.Brahmankar

Min max lot size time based for use with SNP and PPDS

Hi all, Is there anyway to set up time based min and max lot sizes? ie we want to have a Max lot size which is small for use with the first 3 months of our plan which starts life in SNP and then converts to PPDS and into blocks for block planning, but months 4 to 36 we want to leave as large max lot sizes as there is no need to have the small max lot sizes for the different horizon.
As far as I can see there is only a material/plant lot size and Max lot size and no way to have a different setting in a different time period.
Thanks
j

Hi John,
As you know, in the product master, the lot size maintenance is time-independent, so that obviously can not be used for your scenario. As per my understanding, to meet this using standard functionality, you can maintain multiple product specific t-lanes (for STRs) and PDSs (planned orders) with required lot size ranges and validity dates (for short or long term horizon). But, again since the validity of t-lanes and PDSs will not be automatically rolling forward so the updating the validities will be a challenge.
The other option could be to enhance the heuristic functionality at lot size selection step while creating order.
Regards,
Umesh

Parameters controlling: Lot Size

Dear,
I'm a jobstudent at NV Niko and I have to do some research to introduce new features about SAP.
It is about inventory controlling : parameters controlling.
For certain articles, I can access the parameter controlling and for exemple get the bar chart of the Lot size.
The bar takes place at a certain range of coverage at the average receipt and value of the average receipt. Now I have a few questions about this topic:
Are these 2 variables determined by SAP or is it possible to change them and try to optimize?
In the chart, the bar has a specific place, is their a possibility to see what the perfect place would be? By perfect place I mean in which segment should the lot size be in the optimum for a specific article. Maybe their is a function to see this.
How can we do follow-up-analyze-actions? For exemple, when we select more than 1 article, is their a possibility to take out the bad ones (these that are not in their optimum) and that way spot and improve them?
For the safety stock, I have the same problems, so I hope you can help me with these too.
Thank you
Best regards,

Dear,
I'm a jobstudent at NV Niko and I have to do some research to introduce new features about SAP.
It is about inventory controlling : parameters controlling.
For certain articles, I can access the parameter controlling and for exemple get the bar chart of the Lot size.
The bar takes place at a certain range of coverage at the average receipt and value of the average receipt. Now I have a few questions about this topic:
Are these 2 variables determined by SAP or is it possible to change them and try to optimize?
In the chart, the bar has a specific place, is their a possibility to see what the perfect place would be? By perfect place I mean in which segment should the lot size be in the optimum for a specific article. Maybe their is a function to see this.
How can we do follow-up-analyze-actions? For exemple, when we select more than 1 article, is their a possibility to take out the bad ones (these that are not in their optimum) and that way spot and improve them?
For the safety stock, I have the same problems, so I hope you can help me with these too.
Thank you
Best regards,

Rounding value and Minimum lot size

Hi all,
Finish material is X and Raw material is Y.
Bom- For Preparing Xu2019s 1 Qty, 1 Qty of Y is required
In Material Master of Y - Rounding value and minimum lot size is 10,
Project needs 5Qty of X.
When MD51 for Project execute u2026 PR of Y must be of 10 as per rounding value and minimum lot size, but it is creating PR of 5 qty.
Above scenario working properly if I take MRP run with MD02 for material X for 10qty, after MRP PR of Y will be created for 10qty.
With Regards,
Ashish

Dear,
By default, the lot size works as lot-for-lot quantity in the make-to-order and project scenario.
Go to OMI4 select your Lot size and define Lot Size: SOP 1 or 2Lot-for-lot with rounding. Better create new Lot size as ZX with these setting.
If you always want lots to be created for the multiple of the rounding value, you must specify a minimum a multiple of the rounding value.
Example: minimum lot size: 10 and rounding 10.
Please try and come back.
Regards,
R.Brahmankar

Costing Lot size in CK11N

Hi,
When we do Cost estimates using CK11N or CK40N the lot size arising is not the costing lot size (We gave 1000).
For ex: We gave lot size as 1000, system give 987 or 990 etc.
I have checked if scrap is playing any role in the calculation. But this is coming for materials even without scrap.
Please let me know what might be causing the problem.
Thanks
Naveen

HI,
Is it for all the materials or for some of the materials.
Check the material master, is it maintained wrongly with some value.
Check in the BOM, is there any scrap % is maintained. Check in the material master also the scarp %.
One more thing, Maintain material master with 1000 as lot size and run CK11n for the same material. Let us know the out come.
Vijay

Lot size dependent / independent

Hi, please advise when the system uses this lot size times data in mrp4 view? Where we need to specify that whether lot size dependent or independent need to select? When the system uses this data and when the system uses the planned delivery days and in-house production days which is in mrp2? Pls advise.

Dear,
Planned Delivery Time use for external procurement Like raw materials.
In-house production time use for in house manufacture materials like HELB and FERT.
In-house production time is independent of the order quantity.
Lot size depnendent timing calculate from the routing. It is calculated byadding the lead times of all operations, the float before production, and the float after production.
You schedule the routing for a base qty The in the scheduling results screen click the button" scheduling results"
You will get the results screen in days.
In that screen at the botton there is abutton update material master.
After this go to CA96 There update the material master.
Please refer this link,
Re: set up time dependant and independant of order qty
Regards,
R.Brahmankar

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

How to make lot size dependent in Material master?

Hello Experts,
I created a Material master for a Finished product in Pharma industry and in work scheduling screen, under the section "In house production time in days", I see that "lot size independent". What change(s) in my settings in the Material Master can change it to "lot size dependent"?
Does any changes in the "Lot size data" section in the view "MRP1" have any effect on this field?
Also one more question:
Where is the Usage for BOM first specified? Is it in material Master or when creating a BOM?
Thank you.
Message was edited by: Visu Venkat

Hi Visu
No,Lot size data in MRP1 view will not have any effect in inhouse production time in work scheduling view.
You need to maintain the base qty in work scheduling in order to get the scheduling time for lot size dependant.
BOM useage is first specified only during BOM creation.
Suppose if u maintain the BOM useage in material master before creation of BOM, then still u can create a BOM with different useage. During these case, there will be always inconsistencies.
Hence Useage is always specified first during BOM creation.
Hope u r clear now.
Regards
Vijay

Different fix lot size depending on the production version

Hi all,
I have the next scenario:
2 production versions. 2 different fix lot size por each. So:
Prod Version 1 - Fix lot size 200
Prod Version 2 - Fix lot size 300
I created the Quota Arrangement just to make SAP to take my favourite version. And trought the quota, I can define the lot size for each version. BUT.
If I change the version in the order or in the planned order, the quantity don't change.
So: How can I manage 2 different fix lot size for 2 different product versions? If I change the version once the order is created, how can I do the system change de quantity to the right one?
Thanks in advante
<< Please do not offer points >>
Edited by: Rob Burbank on Oct 1, 2010 2:53 PM

I have n't tried this scenario,
This is my Idea
Create a two production version
for ex: lot size 100 to 1000, set the rounding profile qty as 1000
for lot size 1001 to 99999, set the lot rounding profile value to 5000
BY this way u can get the two lot based on the rounding profie
Expert; please correct if i am wrong
Edited by: Sundaresan . E. V on Oct 1, 2010 4:12 PM

MRP run on basis of lot size

Dear all
I have two different lot size routing for a inhouse product are 0-2000 and 0-1500 nos . I planned for 5500 nos , after MRP run system should create planned order as per selection of lot size as 0-2000 for 2 planned order and 0-1500 for 1 planned order .is it possible ?
thans in advanced
regards
siva

Dear,
Quota arrangement can be used if the demand (100) is created in which is define the ratio 60:40 but it will create two planned order after MRP Run. Go to transaction MEQ1 maintain a quota arrangement for this material. In MRP 1 view choose lot size with quota splitting and in MRP 2 view maintain quota usage as 4.
Refer this thread
Re: Quota Arrangement
Please try and come back.
Regards,
R.Brahmankar

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

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