1.5. Hipótesis
2.1.2. Antecedentes a nivel nacional
Demand Management
Unit Overview
In this unit, you will identify the origin and functions of planned independent requirements in SAP APO PP/DS. You will also explain the role of requirement strategies in SAP APO PP/DS and their relation with the SAP R/3 strategies. In addition, you will explain the relation between sales orders and planned independent requirements in SAP PP/DS. Finally, you will enlist the Customizing settings required for demand management.
Unit Objectives
After completing this unit, you will be able to:
• Explain the function of planned independent requirements in SAP APO PP/DS
• Identify how to transfer planned independent requirements
• Identify the requirement strategies for make-to-stock production in SAP APO
• Compare the make-to-stock production strategies in SAP APO and SAP R/3
• Configure make-to-stock production process
• Explain the concept of Planning with and without Final Assembly • Identify make-to-order production process
• Explain the process of Planning with planning product
Unit Contents
Lesson: Planned Independent Requirements... 50 Lesson: Requirement Strategies... 57 Exercise 3: Planning with Final Assembly in SAP APO PP/DS ... 77 Exercise 4: Make-to-Order Production in SAP APO PP/DS ... 89
Unit 2: Demand Management SCM242
Lesson: Planned Independent Requirements
Lesson Overview
In this lesson, you will identify the function of planned independent requirements in SAP APO PP/DS. You will also learn how to transfer planned independent requirements.
Lesson Objectives
After completing this lesson, you will be able to:
• Explain the function of planned independent requirements in SAP APO PP/DS
• Identify how to transfer planned independent requirements
Business Example
The Precision Pump company constitutes a number of independent business units located in various parts of the world. Each of its units is headed by a business unit head and is operated as an independent entity under the common parent company. As the planning manager, you need to evaluate different options, such as forecast and sales order for creating planned independent requirements.
Overview of Planned Independent Requirements
Figure 19: Planned Independent Requirements and Sales Orders
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SCM242 Lesson: Planned Independent Requirements
Demand Management pertains to the management of independent requirements. The way in which independent requirements behave in material requirements planning, that is, whether they affect requirements or are consumed by other requirements, can be determined by their requirement type or strategy.
Planned independent requirements are stock requirements, which can be derived from a future requirement forecast. In make-to-stock production, you want to initiate the procurement of the necessary materials, without having to wait for the actual sales orders. While on one hand, this means that delivery times can be shortened, on the other hand, it would be possible, through foresighted planning, to evenly spread the load over the individual production resources.
Planned independent requirements can either be created in SAP APO DP and released to SAP APO PP/DS or could be created in SAP R/3 Enterprise and transferred to SAP APO through the Core Interface (CIF).
Sales orders that is, customer requirements are created by sales and distribution in SAP R/3 Enterprise. Customer requirements can be received directly in material requirements planning, depending on their defined requirements type, as desired during customer-specific planning. For planning in SAP APO PP/DS, the sales orders should be transferred to SAP APO through CIF.
Sales orders can either serve as exclusive requirements sources, for which procurement can be specifically triggered (make-to-order production) or, together with planned independent requirements, they can constitute the total requirement. Consumption with planned independent requirements is also possible.
Unit 2: Demand Management SCM242
Processing of Planned Independent Requirements
Figure 20: Transfer of Planned Independent Requirements
Planned independent requirements, as a basis for planning in SAP APO PP/DS, can be created in various ways: 1. A SAP APO DP forecast can be transferred to demand management. This function is described as the release of planned independent requirements; 2. Planned independent requirements can be created in SAP R/3 Enterprise and then transferred to SAP APO through CIF. However, you must include planned independent requirements in an active integration model. The active planned
independent requirements are then transferred to SAP APO, however, inactive planned independent requirements are not transferred; 3. Planned independent requirements can also be created in test systems in the product view even when you enter an order quantity with a negative sign. Since these are saved in SAP APO, but not in the SAP APO database or in an InfoCube, it is not recommended to use this method for the maintainance of operational planned independent requirements.
Planned independent requirements that are created in SAP R/3 Enterprise are transferred automatically to SAP APO via CIF if an active integration model is available for the planned independent requirements of the relevant material.
Planned independent requirements created in SAP APO using SAP APO Demand Planning are not transferred via CIF. However, it is possible to transfer the planned independent requirements from SAP APO to SAP R/3 Enterprise using mass processing in Demand Planning (transfer profile
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SCM242 Lesson: Planned Independent Requirements
in Demand Planning). This is necessary if Demand Planning is carried out in SAP APO, and the other planning steps (production planning) are carried out in SAP R/3 Enterprise.
Figure 21: Transfer of Planned Independent Requirements from SAP R/3
Demand Management in SAP R/3 Enterprise, Production Planning in SAP APO, Shop Floor Control in SAP R/3 Enterprise
Demand management can take place manually in SAP R/3 Enterprise, where it can either be based on a forecast or based on the Sales and Operations Planning (SOP) in SAP R/3 Enterprise. It results in planned independent requirements, which can be transferred to SAP APO. Therefore, if you use this procedure, you should include planned independent requirements in an active integration model.
The planned independent requirements are the starting point for the production planning in SAP APO. Furthermore, storage location stock should be included in the planning.
As a result of the production planning, planned orders are created in SAP APO. In SAP APO, the conversion indicator in the SAP APO order is used to trigger the conversion of the planned order into a production order in SAP R/3 Enterprise. Shop floor control takes place in SAP R/3 Enterprise where activities in SAP R/3 Enterprise such as, confirmations, are transferred again to SAP APO.
To ensure that the materials are not unnecessarily planned again in SAP R/3 Enterprise, the MRP type must indicate that they are to be excluded
Unit 2: Demand Management SCM242
Planned independent requirements that are created in SAP R/3 and transferred to SAP APO are always created in SAP APO using the requirements strategy maintained in the SAP APO product master. They are independent of the requirements types in the SAP R/3 planned independent requirement.
Figure 22: Transfer of Sales Orders to SAP APO
Sales orders are entered in Sales (SAP R/3 SD) in the SAP R/3 Enterprise and from there, they are transferred to SAP APO via CIF.
The requirements type and class in SAP R/3 Enterprise controls how the sales order "behaves": Analogous to this, in SAP APO, the behavior of a sales order in demand management, that is, whether consumption should take place or not, is defined using the check mode. If, therefore, a sales order is transferred to SAP APO with a specific requirements class, its behavior there corresponds to the check mode with the same description. The check modes must be known in SAP APO. They can be transferred from SAP R/3 Enterprise to SAP APO via CIF. When ATP Customizing is transferred, the SAP R/3 Enterprise requirements classes are mapped to the corresponding SAP APO check modes.
Transaction data is generally transferred as orders with a specific category to SAP APO. For example, sales orders have the category BM and planned independent requirements have the category FA. These should be included in a corresponding integration model in order to transfer transaction data from SAP R/3 Enterprise to SAP APO.
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SCM242 Lesson: Planned Independent Requirements
Figure 23: Transfer of Planned Independent Requirements from APO Demand Planning
If you perform Demand Planning in SAP APO, the result might be a future requirements forecast. This forecast can be used directly as a planned independent requirement for Production Planning in SAP APO PP/DS. The relevant data is released from SAP APO DP to Demand Management, and planned independent requirements are created in SAP APO.
The transfer of planning data to production planning in SAP APO, that is, SNP or PP/DS, is described as the release of planned independent requirements. You execute the release from the Demand Planning menu transaction Release to Supply Network Planning. This is confusing as the released requirements are also relevant to PP/DS. However, the release can also be made in mass processing in the background, that is, demand planning, using a release profile.
Planned independent requirements that you get in SAP APO after the release from SAP APO DP cannot be transferred to SAP R/3 Enterprise via CIF. If production planning and detailed scheduling take place within the SAP APO, such a transfer is not necessary. Only the results of detailed scheduling, in the form of planned or manufacturing orders, have to be transferred to SAP R/3 Enterprise for execution. If you only execute Demand Planning in SAP APO and want to use the resulting planned independent requirements for further production planning in SAP R/3 Enterprise (SAP R/3 MRP), the planning figures from SAP APO DP can be transferred to SAP R/3 Enterprise. This function can only be executed in mass processing, that is, demand planning using a "transfer profile".
Unit 2: Demand Management SCM242
Lesson Summary
You should now be able to:
• Explain the function of planned independent requirements in SAP APO PP/DS
• Identify how to transfer planned independent requirements
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SCM242 Lesson: Requirement Strategies
Lesson: Requirement Strategies
Lesson Overview
In this lesson, you will identify the requirement strategies for make-to-stock production in SAP APO. You will also compare the make-to-stock
production strategies in SAP APO and SAP R/3. In addition, you will explain the concept of Planning with and without Final Assembly. Finally, you will explain make-to-order production process and the concept of Planning with planning product.
Lesson Objectives
After completing this lesson, you will be able to:
• Identify the requirement strategies for make-to-stock production in SAP APO
• Compare the make-to-stock production strategies in SAP APO and SAP R/3
• Configure make-to-stock production process
• Explain the concept of Planning with and without Final Assembly • Identify make-to-order production process
• Explain the process of Planning with planning product
Business Example
The Precision Pump company constitutes a number of independent business units located in different parts of the world. Each unit is headed by a business unit head and is operated as an independent entity under the common parent company. As the planning manager, you need to evaluate different requirement strategies for creating planned requirement quantities.
Unit 2: Demand Management SCM242
Overview of Requirement Strategies
Figure 24: Requirements Strategies
Requirements strategies represent the business procedures for planning production quantities and dates. Various requirements strategies are available ranging from make-to-order production to make-to-stock production.
Make-to-stock production is based on sales orders and/or planned
independent requirements at the finished product or at the assembly level. Assembly planning is used if you want to plan more easily on this level. The assemblies that are available in stock from planning can, for example, be used for the final assembly of a finished product in make-to-order production.
In planning without final assembly, planning is carried out at the finished product level. However, planning is not used to procure the finished product itself already. Rather, only the relevant quantities of the required assemblies are procured. Final assembly is only triggered upon receipt of the sales order that consumes the planned independent requirements. Make-to-order production only takes place without planning at the finished product level. Independent of this, the assemblies can be planned in order to shorten the delivery time.
The planning strategies available for a material can be found in SAP APO Customizing for Master Data under Specify Requirements Strategies. A requirements strategy is assigned to a product using the Requirements Strategy field.
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SCM242 Lesson: Requirement Strategies
Strategies for Make-to-Stock Production
Figure 25: Requirements Strategies for Make-to-Stock Production
Planning with make-to-stock production strategies basically consists of four phases: Creation of planned independent requirements, procurement, receipt of sales order, if available, goods issue with sales orders for delivery, and reduction of planned independent requirements.
Various requirements strategies are available for make-to-stock production in SAP APO: make-to-stock production, planning with final assembly, and planning at the assembly level. Make-to-stock production strategies are often combined with fixed lot sizes or rounding values. This allows you to produce the total quantity once a month, or only produce full pallets, for example.
In addition to the SAP APO strategies given above, production by lot size (SAP R/3 Enterprise strategy 30) is available in SAP R/3 Enterprise. In production by lot size, planned independent requirements and sales orders are relevant to requirements and no consumption takes place. If you use this strategy in SAP R/3 Enterprise, you can use strategy 20 in SAP APO. However, as no consumption is allowed for sales orders with requirements class 041, this ensures that no reduction takes place. The planning process in SAP APO is completely analogous to SAP R/3 Enterprise strategy 30. Note that only the make-to-stock production strategies 10 and 20 can be used in SAP APO SNP. Make-to-order segments are not taken into account in SNP.
Unit 2: Demand Management SCM242
Figure 26: Make-to-Stock Production Strategies in SAP R/3 and SAP APO
Planning strategies defined in the SAP R/3 Enterprise material master are transferred to the SAP APO product master via CIF. Note that the logic varies in both the systems. Even the numbers that indicate the strategy in SAP R/3 Enterprise and SAP APO do not usually agree because often several SAP R/3 Enterprise planning strategies can be mapped in SAP APO with one requirements strategy.
The strategy group, which contains one main strategy, is entered in the SAP R/3 Enterprise material master. The main strategy from the SAP R/3 Enterprise strategy group is always transferred to SAP APO.
In the SAP R/3 Enterprise material master, an MRP group can also be used to assign a strategy group to the material. When a material like this is transferred to SAP APO, the system also checks and, if necessary, transfers these settings.
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SCM242 Lesson: Requirement Strategies
Figure 27: The Make-to-Stock Production Process
In make-to-stock production, customer requirements are not included in the demand program. The procurement quantities are planned exclusively as planned independent requirements, usually before the sales orders arrive. Sales orders are not MRP-relevant but are displayed for information purposes. The sales orders are not relevant for pegging.
Production takes place in warehouse stock. Sales orders and other requirements for the product are covered from warehouse stock. An availability check can be performed in the plant. Goods withdrawals for a sales order reduce this sales order.
Reduction of planned independent requirements takes place at goods issue for the delivery. The oldest planned independent requirement is reduced first (FIFO rule). If there are no more planned independent requirements in the past, planned independent requirements in the future can also be reduced, provided that this is permitted by a corresponding forward consumption interval.
Unit 2: Demand Management SCM242
Figure 28: Configuring Make-to-Stock Production
To configure planning using strategy 10, you should enter the relevant proposed strategy in the product master for the finished product. If a reduction of requirements is permitted in the future, this can be controlled using a corresponding forward consumption period. This setting is made in the SAP R/3 Enterprise material master.
Sales orders that are not relevant for requirements, that is, strategy 10 with requirements type KSL or requirements class 030, are transferred to SAP APO with the not relevant for pegging indicator, so that they are not relevant for requirements in SAP APO.
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SCM242 Lesson: Requirement Strategies
Planning With Final Assembly
Figure 29: Planning with Final Assembly
Planning with final assembly is mainly used to enable you to react to customer demand in a flexible manner. The main difference between this requirements strategy and make-to-stock production is that sales orders are relevant for requirements.
In planning with final assembly, the planned independent requirements are also entered at the finished product level. This means that procurement and manufacture of the finished product is already started before the receipt of the sales order. As soon as a sales order is received, it consumes the planned independent requirement. Consumption of planned
independent requirements by customer requirements depends on the settings defined for the consumption mode and the consumption periods. Planned independent requirements left unconsumed increase the
warehouse stock - in so far as they are not adjusted to customer requirements. Since the requirements are not reduced according to the FIFO rule in this strategy, rather, the delivery to a sales order reduces this order and the planned independent requirements quantity it consumes, deletion of planned independent requirement quantities, which are no longer required, has particular significance in the requirements strategy 20. In SAP APO, you can adjust planned independent requirements created in SAP APO using the transaction Planning Adjustment (/sapapo/md74). The planned independent requirements that are no longer required are set to zero for the selected time period. This function can be scheduled periodically, such as daily. The transaction is comparable with transaction
Unit 2: Demand Management SCM242
MD74 in the SAP R/3 Enterprise. If the planned independent requirements were created in SAP R/3 Enterprise, they should also be deleted in SAP R/3 Enterprise (reorganization).
Figure 30: Consumption
The consumption mode determines the direction on the time axis in which the arriving sales orders consume the planned independent requirements. In backward consumption, that is, consumption mode 1, the sales order consumes planned independent requirements that lie before the customer requirement.
In forward consumption that is, consumption mode 3, the sales order consumes planned independent requirements that lie after the customer requirement.
Forward and backward consumption can be combined, taking both periods into account, that is, consumption mode 2.
You can define the consumption mode and periods either in the SAP R/3