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GEOGRAFÍA E HISTORIA
Lesson Overview
When you firm planned orders you can protect a master production schedule from changes that are made automatically during material requirements planning.
Lesson Objectives
After completing this lesson, you will be able to:
• Firm a planned order in different ways
• Use firming in requirements planning
Business Example
No more planning is to take place in the short term. To ensure this, the planned orders are firmed.
Firming
Figure 80: Firming: Philosophy
You can use the firming period to protect the master production schedule for master schedule items (in the MPS run) and for non-master schedule items (in the MRP run) from being changed automatically in the near future and therefore
stabilize planning. Within the firming period, which is defined individually for each material, procurement proposals are no longer changed automatically during the MRP run.
You should define the firming period on the basis of the total lead time of the material.
In the above example, the order finish date of the planned order, E1, lies one day before the end of the firming period. The system therefore treats it as firmed and does not automatically reschedule it. The master production schedule for the components is therefore stabilized.
You can define the firming period using the planning time fence or a manual firming date. Planned orders can also be firmed and unfirmed manually.
The system will draw your attention to any possible changes to the master production schedule in the form of an exception message in the MRP list. It is then up to the MRP controller to process these changes.
Figure 81: Firming a Planned Order
If a planned order is changed manually, the system automatically sets the firmed indicator for this planned order. This means that the header data of the planned order will remain unchanged in the next planning run.
If a component in a planned order is changed manually, the system also sets the firmed indicator for the components. This means that the components of the planned order will not be changed in the next planning run.
The firming indicators for the planned order or the components of the planned order can be changed manually.
If the planned orders are flagged as firmed through the definition of a firming period in the stock/requirements list and the MRP list, this occurs independently of the firming indicator for the planned order or its components.
By resetting the conversion indicator in the planned order, you can prevent the planned order being converted into a production order or purchase requisition.
Figure 82: Firming Period and Firming Types
The firming type determines how the procurement proposals (especially planned orders and purchase requisitions) are to be firmed for the planning run and in which order they are to be scheduled within the firming period.
You specify the firming procedure to be used for each material using the the MRP type. The firming type is defined in Customizing for the MRP type.
You can use firming for materials planned with both master production scheduling and material requirements planning. Corresponding MRP types are available for this in the standard system.
Figure 83: Overview of Firming Types
• With firming type “0”, no firming period is effective.
• With firming types “1” and “2”, “automatically firmed” indicates that any procurement proposals inside the firming period will now be firmed automatically. They can therefore no longer be changed by the planning run, only manually. Likewise, all procurement proposals that are moved into the planning time fence are firmed automatically.
• Firming type “1”: The planning run covers all new shortages that have occurred within the planning time fence at the end of the firming period.
• Firming type “2”: The planning run does not cover any new shortages that have occurred within the planning time fence.
• Firming type “3”: All procurement proposals that have not been manually firmed within the planning time fence are moved to the end of the firming period. If new shortages occur within the firming period, they are covered at the end of the firming period.
• Firming type “4”: All procurement proposals that have not been manually firmed within the planning time fence are deleted. If new shortages occur within the firming period, they are not covered.
Figure 84: Planning Time Fence
You can use the firming period to protect the master production schedule for a material from being automatically changed in the near future. Procurement proposals within the firming period are no longer changed automatically during the MRP run. You can define the firming period using the planning time fence. The system calculates the finish date of the firming period on the basis of the MRP date.
You can specify the planning time fence either for each material in the material master record or using the MRP group assigned to the material master. The length of the planning time fence (in working days) should be based on the total lead time of the material. The planning time fence is only effective in connection with an MRP type that has a firming type.
The firming type determines how the procurement proposals are firmed for the planning run and how the dates are set within the planning time fence. Existing procurement proposals which slip into the planning time fence are firmed automatically with firming type 1, as shown in the graphic, as soon as the date of the procurement proposal falls at least one day before the end date of the planning time fence.
The date for new purchase requisitions that were created within the planning time fence and not created manually, is postponed to the final date of the planning time fence with firming type 1. This means that these new procurement proposals are not firmed.
Figure 85: Manual Firming Date
You can also define the firming period by manually entering a date lying in the future - that is, the “manual firming date”. The manual firming date causes automatic firming of the procurement proposals for materials with firming types 1 and 2 and lie before the manual firming date.
Unlike the planning time fence, materials without a firming type (firming type 0) are treated like materials with firming type 1 as far as the manual firming date is concerned. This means that the procurement proposals that lie before the manual firming date are firmed, and new procurement proposals are moved to the manual firming date. If you have set a manual firming date and a planning time fence is active, the firming period is determined by the end of the planning time fence, providing this date is later than the manual firming date. If the manual firming date is the later of the two dates, then this defines the firming period. You set and reset the manual firming date in the stock/requirements list, in the planning results, or in interactive single-item planning. You can apply this function in material requirements planning, master production scheduling, or long-term planning.
Figure 86: Roll Forward Period
As well as the planning time fence, you can also maintain the roll forward period in the MRP group. You can use the roll forward period to delete firmed but out-of-date planned orders in order to automatically update the production master schedule.
The Roll Forward indicator in Customizing for the MRP type controls whether or not the roll forward mechanism is applied for a material.
All firmed planned orders with an end date within the roll forward period are deleted in the planning run and either new planned orders are created with suitable dates or, if the corresponding firming type applies, they are moved to the end of the planning time fence.
Exercise 10: Firming
Exercise Objectives
After completing this exercise, you will be able to:
• Use firming to restrict requirements planning
Business Example
Since some end products including pump R-F2## are frequently ordered by customers at short notice, you want to use firming to stabilize requirements planning in the short term. New customer requirements do not automatically lead to new (on time) procurement elements.
Hint: In this exercise, you will work with material R-F2## in plant 1000, and not with R-F1##.
Task 1:
In material R-F2## in plant 1000 on the MRP views 1 and 3, maintain a firming horizon of 20 (working) days and the strategy group 40 and save your changes.
1. Ignoring any previous entries that have been made from the demand management menu for material R-F2## in plant 1000 create the following active VSF planned independent requirements in planned requirements version 00 (use W (week) for the planning period):
Current
Confirm any warning messages that may appear with Enter and save the requirements.
Task 2:
Execute single-item, single-level planning (and not multi-level planning) using the preset parameters for material R-F2## in plant 1000 and call up the current stock/requirements list for this material.
Menu path: Logistics → Production → MRP → Planning → Single-Level Single-Item Planning
1. Is a planning time fence active for this material (does the system display a corresponding time fence)? Why (not)?
______________________________________________________
2. Check that a planning time fence has been entered in the material master R-F2## for the plant 1000. Why is no firming active?
______________________________________________________
Task 3:
Convert the material using the MRP type to planned MRP with fixing type 1 in order to satisfy the production demands: To do this, go the MRP 1 view of material master R-F2## in plant 1000 and change the value of the MRP Type field to P1. Save your changes. Take another look at the (refreshed) stock/requirements list for material R-F2## in plant 1000.
1. Does the system display a planning time fence? _____________________
2. To which date is the end of the planning time fence set?
______________________________________________________
Why are the planned orders within the planning time fence flagged as firmed?
______________________________________________________
3. Choose Display Element to display the header screen of a firmed planned order inside the planning time fence. Is the firming indicator for planned order set?_________________
Task 4:
A sales order is received for 100 pieces of material R-F2##, delivering plant 1000.
Requirements date is today's date + 3 weeks.
1. From the demand management menu, create a corresponding customer requirement (use the data specified for this customer requirement) and then save it.
2. Now call the stock/requirements list and analyze the (consumption) situation.
For which date is there a material shortage, in other words, on which date does the quantity available for planning fall below zero?
______________________________________________________
Task 5:
Execute interactive single-item planning for material R-F2## in plant 1000.
1. Call the transaction. When planning is called, the system reads the current planning situation. You have to trigger planning manually by choosing Execute Planning. After you have executed this function, you can see the planning results that have, at this point in time, not yet been saved to the database.
2. On which date is the material shortage corrected, in other words, on which date is a planned order created so that the available quantity is greater than or equal to zero?
________________________________
What is the number of this planned order?
_________________
3. Why is the shortage situation determined above not covered on time?
______________________________________________________
4. Select the planned order, and display the exceptions by choosing Element details (to the very left of the planned order row).
Go back, select the planned order and execute the function Reschedule Proc.
Proposal (button to the bottom left).
What is the receipt due date for the planned order now?
______________________________________________________
Save the planning results.
Task 6:
Call the stock/requirements list for material R-F2## in plant 1000.
1. View the planned order that you have rescheduled, the number of which you have noted. Is the firming indicator set in this planned order?
____________
Give a reason for your result:
___________________________________________________
2. In the stock/requirements list, set the manual firming date for 3 working days later than the end of the planning time fence. Refresh the list.
Which firming date takes effect?
__________________
Task 7:
1. Increase the customer requirement that you created before by 15 pieces.
Save and then execute single-item, single-level planning again. Analyze the planning result: When has an additional procurement element for the increased quantity of the sales order been scheduled?
__________________________________________________________
2. Then clean up material R-F2## as described at the beginning of exercise 5.
Note that you might have to reverse the firmings first (in the material master, in the stock/requirements list and maybe manually on the individually firmed planned order) and that you can also delete the customer requirement in change mode.
Solution 10: Firming
Task 1:
In material R-F2## in plant 1000 on the MRP views 1 and 3, maintain a firming horizon of 20 (working) days and the strategy group 40 and save your changes.
1. Ignoring any previous entries that have been made from the demand management menu for material R-F2## in plant 1000 create the following active VSF planned independent requirements in planned requirements version 00 (use W (week) for the planning period):
Current
Confirm any warning messages that may appear with Enter and save the requirements.
a) Menu path: Logistics → Production → Master Data → Material Master → Material → Change → Immediately
Menu path: Logistics → Production → Production Planning → Demand Management → Planned Independent Requirements → Create
Task 2:
Execute single-item, single-level planning (and not multi-level planning) using the preset parameters for material R-F2## in plant 1000 and call up the current stock/requirements list for this material.
Menu path: Logistics → Production → MRP → Planning → Single-Level Single-Item Planning
1. Is a planning time fence active for this material (does the system display a corresponding time fence)? Why (not)?
______________________________________________________
a) Planning time fence active: No
2. Check that a planning time fence has been entered in the material master R-F2## for the plant 1000. Why is no firming active?
______________________________________________________
a) Reason: The effect of the planning time fence is controlled by the MRP type in the material master. The MRP type PD in the material master R-F2## determines that no automatic firming is to take place.
Task 3:
Convert the material using the MRP type to planned MRP with fixing type 1 in order to satisfy the production demands: To do this, go the MRP 1 view of material master R-F2## in plant 1000 and change the value of the MRP Type field to P1. Save your changes. Take another look at the (refreshed) stock/requirements list for material R-F2## in plant 1000.
1. Does the system display a planning time fence? _____________________
a) Planning time fence displayed: Yes
2. To which date is the end of the planning time fence set?
______________________________________________________
Why are the planned orders within the planning time fence flagged as firmed?
______________________________________________________
a) End of the planning time fence: Varies (Today + 20 working days) Planned orders within the planning time fence firmed: The planned orders within the planning time fence are flagged as firmed, because the MRP type P1, which you have entered in the material master, defines that procurement proposals that fall within the planning time fence are firmed automatically.
3. Choose Display Element to display the header screen of a firmed planned order inside the planning time fence. Is the firming indicator for planned order set?_________________
a) Indicator for firming planned order: No
Task 4:
A sales order is received for 100 pieces of material R-F2##, delivering plant 1000.
Requirements date is today's date + 3 weeks.
1. From the demand management menu, create a corresponding customer requirement (use the data specified for this customer requirement) and then save it.
a) Menu path: Logistics → Production → Production Planning → Demand Management → Customer Requirements → Create
2. Now call the stock/requirements list and analyze the (consumption) situation.
For which date is there a material shortage, in other words, on which date does the quantity available for planning fall below zero?
______________________________________________________
a) Date quantity available for planning below zero: The available quantity falls below zero on the requirements date of the customer requirement.
Task 5:
Execute interactive single-item planning for material R-F2## in plant 1000.
1. Call the transaction. When planning is called, the system reads the current planning situation. You have to trigger planning manually by choosing Execute Planning. After you have executed this function, you can see the planning results that have, at this point in time, not yet been saved to the database.
a) No solution is required.
2. On which date is the material shortage corrected, in other words, on which date is a planned order created so that the available quantity is greater than or equal to zero?
________________________________
What is the number of this planned order?
_________________
a) Available quantity greater than or equal to zero: The available quantity is greater than or equal to zero at the end of the planning time fence.
Planned order number: This varies
3. Why is the shortage situation determined above not covered on time?
______________________________________________________
a) Why not on time: Behind the MRP type P1 is the firming type 1.
For firming type 1, recent shortage situations within the planning time fence are not covered with a new procurement element until the end of the planning time fence. You can perform rescheduling manually at a later stage.
4. Select the planned order, and display the exceptions by choosing Element details (to the very left of the planned order row).
Go back, select the planned order and execute the function Reschedule Proc.
Proposal (button to the bottom left).
What is the receipt due date for the planned order now?
______________________________________________________
Save the planning results.
a) Planned order date now: The planned order is now (normally) on the requirements date for the KSV customer requirement (Note: Due to the relatively long in-house production time for the planned order in the finished product, forward scheduling may be necessary. In this case, an exception message is attached to the planned order and the creation time is delayed).
Task 6:
Call the stock/requirements list for material R-F2## in plant 1000.
1. View the planned order that you have rescheduled, the number of which you have noted. Is the firming indicator set in this planned order?
____________
Give a reason for your result:
___________________________________________________
a) Firming indicator set: Yes, the firming indicator in the planned order header is set.
Reason: The planned order was rescheduled manually in single-item, interactive planning. This manual change led to the firming indicator being set.
2. In the stock/requirements list, set the manual firming date for 3 working days later than the end of the planning time fence. Refresh the list.
Which firming date takes effect?
__________________
a) Firming date: The date varies. The firming date that was set manually takes effect, because it is later than the end of the planning time fence from the material master.
Task 7:
1. Increase the customer requirement that you created before by 15 pieces.
Save and then execute single-item, single-level planning again. Analyze the planning result: When has an additional procurement element for the increased quantity of the sales order been scheduled?
__________________________________________________________
a) Menu path: Logistics → Production → MRP → Planning → Single-Level Single-Item Planning
When an additional procurement element is scheduled: The date varies. The additional procurement element is scheduled for the end of the effective planning time fence, that is, on the manual firming date that you entered previously.
2. Then clean up material R-F2## as described at the beginning of exercise 5.
Note that you might have to reverse the firmings first (in the material master, in the stock/requirements list and maybe manually on the individually firmed planned order) and that you can also delete the customer requirement in change mode.
a) No solution required.
Lesson Summary
You should now be able to:
• Firm a planned order in different ways
• Use firming in requirements planning