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PRIMER CURSO
Exercise Objectives
After completing this exercise, you will be able to:
• Explain the functions of planning without final assembly
• Monitor consumption between planned independent requirements and customer requirements
• Explain the purpose and the characteristics of planned orders in the planning segment
Business Example
To be able to respond more quickly to sales orders, Precision Pumps Inc.
would like to manufacture assemblies for pumps in advance and place them in stock. Only when a sales order is received should the pumps be assembled in make-to-order production.
Hint: Caution! In order to gain a clearer overview in the following exercises, delete old planning data at this point:
1. Call the current stock/requirements list for material R-F1##
(transaction MD04). Choose Details of element for a planned independent requirement and then choose Change element. In the table for the maintenance of planned independent requirements, select all the rows (items) you have used and choose Delete item.
Save and refresh the list.
2. Then carry out single-item, multilevel planning for material R-F1## in plant 1000 (transaction MD02).
3. Check the current stock/requirements list for the finished product again by calling it for material R-F1## and, if necessary, refreshing it. Only plant stock should be available in the end. Further cleanup for the assemblies is not necessary.
Task 1:
In plant 1000, you want to create a demand program that will plan a monthly quantity of 100 pieces in three months’ time. First of all, choose the planning strategy planning without final assembly for the pump (VSE requirements, planning without final assembly). To do this, proceed as follows:
1. Maintaining the material master: In the material master for pump R-F1## in plant 1000, enter strategy group 50 (planning without final assembly). As in the preceding exercises, call MRP3 view using the transaction Change material immediately. Make the change in the corresponding field and save the change.
2. Creating the planned independent requirements: Use the transaction Create Planned Independent Requirements again from the Demand Management menu for the material R-F1## in plant 1000. Set the indicator M for monthly format in the planning period field in the initial screen for the transaction.
On the Table screen, examine the line for material R-F1##. You first save the new monthly requirement for strategy 50 completely in this (as yet blank) line: Enter a planned independent quantity of 100 pieces in month Current Month + 3 Months. Select the row and proceed to the Schedule Lines tab page. Note the requirements type VSE.
In the Period indicator for split field, enter W for week quantities and confirm this using Enter so that the allocation takes effect. Save the planned independent requirements.
Task 2:
Carry out a planning run for material R-F1## in the form of single-item, multi-level planning.
1. Use the creation indicator that you used in the preceding exercises. Start the planning run by confirming twice using Enter.
Task 3:
Look at the planning results in the stock/requirements list.
1. Call the stock/requirements list for material R-F1## (plant 1000). Make sure that the planned independent requirements quantities and the planned orders they belong to are listed in a separate planning segment.
Double-click (Additional Data for Element) to check whether these planned orders can be converted into production orders and explain this:
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2. Look at the current stock/requirements list for assembly R-B2## (the flywheel) in plant 1000.
Are these planned orders also taken up in a planning segment? Are they convertible? (Give a reason)
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Task 4:
A customer requirement with the desired date 3 days later than the date of the second planned independent requirement is received for the finished product.
1. Now enter a customer requirement of 10 pieces for material R-F1## in plant 1000 from the Demand Management menu. Make sure the requirements type is KEV (make-to-order production with consumption) and save your entries.
Task 5:
Carry out a new MRP run for material R-F1##, plant 1000 in the form of single-item, multi-level planning.
1. Use the creation indicator that you used in the preceding exercises. Start the planning run by confirming twice using Enter.
Task 6:
Call the current stock/requirements list for material R-F1## in plant 1000 and, if necessary, refresh the list.
1. What has happened?
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2. Can the procurement element for the customer requirement be converted?
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Solution 5: Planning Without Final Assembly
Task 1:
In plant 1000, you want to create a demand program that will plan a monthly quantity of 100 pieces in three months’ time. First of all, choose the planning strategy planning without final assembly for the pump (VSE requirements, planning without final assembly). To do this, proceed as follows:
1. Maintaining the material master: In the material master for pump R-F1## in plant 1000, enter strategy group 50 (planning without final assembly). As in the preceding exercises, call MRP3 view using the transaction Change material immediately. Make the change in the corresponding field and save the change.
a) Menu path: Logistics → Production → Master Data → Material Master → Material → Change → Immediately
2. Creating the planned independent requirements: Use the transaction Create Planned Independent Requirements again from the Demand Management menu for the material R-F1## in plant 1000. Set the indicator M for monthly format in the planning period field in the initial screen for the transaction.
On the Table screen, examine the line for material R-F1##. You first save the new monthly requirement for strategy 50 completely in this (as yet blank) line: Enter a planned independent quantity of 100 pieces in month Current Month + 3 Months. Select the row and proceed to the Schedule Lines tab page. Note the requirements type VSE.
In the Period indicator for split field, enter W for week quantities and confirm this using Enter so that the allocation takes effect. Save the planned independent requirements.
a) Menu path: Logistics → Production → Production Planning → Demand Management → Planned Independent Requirements → Create
Task 2:
Carry out a planning run for material R-F1## in the form of single-item, multi-level planning.
1. Use the creation indicator that you used in the preceding exercises. Start the planning run by confirming twice using Enter.
a) Menu path: Logistics → Production → MRP → Planning → Multilevel Single-Item Planning
Task 3:
Look at the planning results in the stock/requirements list.
1. Call the stock/requirements list for material R-F1## (plant 1000). Make sure that the planned independent requirements quantities and the planned orders they belong to are listed in a separate planning segment.
Double-click (Additional Data for Element) to check whether these planned orders can be converted into production orders and explain this:
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a) Can the planned orders be converted? The planned orders in the planning segment have the order type VP (or IndR, respectively) and therefore cannot be converted or changed (the Detail view does not offer a pushbutton to convert the planned order into a production order or a change mode, for example). They merely serve to create dependent requirements at subordinate BOM levels.
2. Look at the current stock/requirements list for assembly R-B2## (the flywheel) in plant 1000.
Are these planned orders also taken up in a planning segment? Are they convertible? (Give a reason)
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a) Planned orders for assembly R-B2##: Planned orders for assembly R-B2## are not taken up in a planning segment. They have order type LA (or PC, respectively) and can be converted into production orders. The reason being that the individual/collective indicator in the material master for the assembly has been set to collective requirement. This allows production of assemblies before a sales order is received.
Task 4:
A customer requirement with the desired date 3 days later than the date of the second planned independent requirement is received for the finished product.
1. Now enter a customer requirement of 10 pieces for material R-F1## in plant 1000 from the Demand Management menu. Make sure the requirements type is KEV (make-to-order production with consumption) and save your entries.
a) Menu path: Logistics → Production → Production Planning → Demand Management → Customer Requirements → Create
Task 5:
Carry out a new MRP run for material R-F1##, plant 1000 in the form of single-item, multi-level planning.
1. Use the creation indicator that you used in the preceding exercises. Start the planning run by confirming twice using Enter.
a) Menu path: Logistics → Production → MRP → Planning → Multilevel Single-Item Planning
Task 6:
Call the current stock/requirements list for material R-F1## in plant 1000 and, if necessary, refresh the list.
1. What has happened?
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a) Menu path: Logistics → Production → MRP → Evaluations → Stock/Requirements List
What has happened? The customer requirement received is managed in an individual customer segment. Consumption has occurred between the related quantity and a planned independent requirement from the planning segment. Due to the planning run, a procurement element (planned order) has been created. This procurement element is produced in make-to-order production and covers the customer requirement. In addition, the planned order quantity that belongs to the partially consumed planned independent requirement has been adjusted.
2. Can the procurement element for the customer requirement be converted?
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a) The planned order in the individual customer segment (order type KD (or Ord., respectively)) can be converted into a production order.
Lesson Summary
You should now be able to:
• Use planning strategies for make-to-order production
• Explain assembly processing