012 reorder point planning.docx
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012 reorder point planning.docx
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012reorderpointplanning
IfrequirementsforamaterialareplannedautomaticallyandMRPisactiveintheplant,thesystemautomaticallycarriesoutplanningfileentriesupontransactionsrelevanttomaterialsplanning(goodsissues,reservations,changeinamaterial'splanningdata,executionofaforecastformaterial...).
Youcanalsoenterplanningfileentriesmanually.
Youcancarryoutmaterialsrequirementsplanningonlineorinthebackground.
Plannedordersareproposalsusedforrequirementscoverage.Theycanbeconvertedtopurchaserequisitionsinasinglestep.
Youcanalsocreatepurchaserequisitionsdirectlyinsteadofplannedorders.
Thecreationindicatorcontrolsthecreationofplannedordersorpurchaserequisitions,schedulelines,andMRPlists.
Byenteringthecreationindicatorforpurchaserequisitionsintheentryscreenoftheplanningrun,youcancontrolwhetherthesystemshoulddirectlycreatepurchaserequisitionsorplannedordersfirst.
Ifaschedulelineexistsforamaterialandthesourcelistcontainsanentryrelevantforplanning,schedulelinescanalsobecreateddirectlyviamaterialsplanning.Thisiscontrolledbythecreationindicatorforschedulelinesintheentryscreenoftheplanningrun.
YoucansavetheplanningresultsintheformofMRPlists.ThecreationindicatorforMRPlistscontrolswhetherthesystemshouldalwayscreateanMRPlistforallplannedmaterialsorwhetheritshouldcreateanMRPlistforcertainmaterialsdependingontheexceptionmessage.
Intotalplanning,thecreationindicatorintheentryscreenisusedforplanningifnootherplantorMRPgroupparametershavebeenmaintainedforthematerial.
Whenthesystemcreatesanorderproposal,itcheckstoseewhetherthereceiptistobemadeviain-houseproductionorexternalprocurement.Thisisdefinedpermaterialbytheprocurementtypeandifnecessarythespecialprocurementtype.
TheprocurementtypeispresetbythematerialtypeinCustomizingfortheMaterialMaster.
Youusethespecialprocurementtypetodefine'in-houseproduction'or'externalprocurement'inmoredetail.
Themainfunctionofrequirementsplanningistodeterminematerialavailability,i.e.whatamountofwhichmaterialisneededonwhichdate.
NetrequirementscalculationiscarriedoutbythesystemforaspecificplantduringtheplanningrunaspartofMRP.Thesystemcheckswhethertheforecastrequirementscanbecoveredbytheavailablestockandplannedreceipts.Ifmaterialshortageoccurs,thesystemcalculatestheshortagequantityandcreatesanorderproposal.
Lot-sizecalculationiscarriedoutaspartofrequirementsplanningaccordingtothelot-sizecalculationproceduredefinedinthematerialmaster.
Duringthedeterminationoftheorderproposal,thesystemcheckswhethertherequirementsarecoveredbyreceiptsfromin-houseproductionorfromexternalprocurement.Thisiscontrolledbytheprocurementtypeand,ifapplicable,bythespecialprocurementtypeinthematerialmaster.
TheprocurementtypeispredefinedbythematerialtypeintheCustomizingforthematerialmaster.
Thespecialprocurementtypedefinesin-houseproductionorexternalprocurementinmoredetail.
Inscheduling,thesystemcalculatesthestartandfinishdatesoftheprocurementelementsforin-houseproducedorexternallyprocuredmaterials.Whenschedulingexternallyprocuredmaterials,thefollowingdatesaretakenintoaccount:
purchasingdepartmentprocessingtime,planneddeliverytime,goodsreceiptprocessingtime.
ThemanualreorderpointprocedureusestheMRPindicatorVB.
Thereorderpointprocedureisbasedonacomparisonbetweenthewarehousestockandthereorderpoint.Iftheavailablewarehousestockislessthanthereorderpoint,thesysteminitiatesrequirementscalculation.
Thereorderpointcomprisestheexpectedaveragematerialrequirementsduringthereplenishmentleadtimeandthesafetystock.Thefollowingvalueshavetobetakenintoaccountwhenthereorderpointisdefined:
Thesafetystock.
Priorconsumptionorfuturerequirements.
Thereplenishmentleadtime.
Thesafetystockisusedtocoverunplannedexcessconsumptionduringthereplenishmentleadtimeandadditionalrequirementsinthecaseofdeliveryhold-ups.
Inreorderpointplanning,theavailablewarehousestockiscalculatedfromthefollowing:
Warehousestock+orderquantity(purchaseorders,firmplannedorders,andfirmpurchaserequisitions).
Iftheavailablewarehousestockislessthanthereorderpoint,thereisashortageofmaterials.
Theshortagequantityisthedifferencebetweenthereorderpointandtheavailablewarehousestock.Thepurchaseorderquantityisderivedfromthelot-sizingprocedureinthematerialmasterrecord.
Thesystembasestherequirementdateontheplanningdate.
Fromthedateofthepurchaserequisition'screation,theR/3Systemcalculatesthematerial'savailabilitydatebytakingintoaccountthethreetimecomponents,purchasingprocessingtime,planneddeliverytime,andgoodsreceiptprocessingtime.
TheprocessingtimeforPurchasingisthetimerequiredtoconvertapurchaserequisitionintoapurchaseorderandissueit.Thetimerequiredismeasuredinworkingdaysaccordingtothefactorycalendar.Itisplant-dependentandsetinCustomizingforMaterialsPlanning.
Theplanneddeliverytimeisthetimefromtheissueofthepurchaseordertothereceiptofthegoodsatthevendor.Youenterthisincalendardaysinthematerialmaster,inforecord,and/orcontract.
TheGRprocessingtimeisthetimerequiredfromthegoodsreceiptuntilthematerialisavailable.Itisenteredininthematerialmaster,and/orcontract,inworkingdaysaccordingtothefactorycalendar.
Youcanevaluatetheplanningsituationortheresultofaplanningrunusingthestock/requirementslistorMRPlist.Youcanuseindividualorcollectiveaccessforthis.
Thestock/requirementslistisadynamiclist:
itshowsthecurrentstatusofstocks,requirementsandreceipts.Changesareimmediatelyvisibleassoonasthestock/requirementslistiscalleduportheelementsarereadfromthedatabaseusingtherefreshfunctioninthestock/requirementslist.
TheMRPlistrepresentstheresultofthelastplanningrunandthereforehasastatisticalnature.Changesthatweremadeaftertheplanningrunarenotvisible.YoucancontrolwhetheranMRPlististobecreatedduringtheplanningrun.
Thetwolistshavethesamebasicstructure:
-LinksareintheformofatreeintheMRPcontroller'sworklist(optional).
-Abovethelistthereistheheaderwiththematerialnumber.Inaddition,youcandisplayfurtherinformationusingtheheaderdetails.
-ThelistitselfcontainstheindividualMRPelementsandthecorrespondingavailablequantities.
User-specificsettingsenableyoutoadapttheliststoyourownpersonalneeds-thisappliestobothlists(seeCustomizing,EvaluationforMRP,"ConfigureMRPlist/stock/requirementslist").Youcanuseacustomerexittoshowadditionaldata,whichcanthenbecalledupusingafunctionkey(seeCustomizing,"Customerexit:
Programadditionalcolumns").
Thestock/requirementslistisanimportantinquiry,whichshowsthereal-timeviewofstocks,receiptsandrequirementsforamaterial.
Eachtimethestock/requirementslistiscalledup,thesystemreadsthedatabasefortheappropriateinformation.
Thislistisaccessedbymaterial,byplantorbyMRParea.
Youcanbranchintovariousrelatedtransactionsfromthestock/requirementslist.
Thestructureandcontentcanbeconfiguredtoindividualrequirementsusingvariousfiltersandprofiles.
Collectivedisplayofthestock/requirementslistispossiblewithvariousselectioncriteria.Forexample,youcandisplayallthelists,forwhichyouareresponsibleasMRPcontroller.
Thesystemthendisplaysamaterialoverviewwithallthematerialsselected.Ifyousetthe"Setuplistsinbackground"indicator,thefollowingisavailableasorientationhelp:
Trafficlights(youcandeterminethedisplaycriteria),varioussearchfunctionsintheoverviewandintheindividuallists,sortfunction(alsoforindividualcustomersegmentsbydateornumber).Usingthesearchfunction,itispossibletoselectmaterialswithparticularexceptionmessages.
Fromtheoverview,youaccesstheindividuallistsandcanprocessthematerialsthere.If,forexample,youhaveselectedseverallistsforprocessingusingthesearchfunction,youcanjumpdirectlyfromonelisttothenext.
TheselectioncriteriaforthecollectivedisplayofMRPlistsaredifferenttothoseforthestock/requirementslists.Forexample,youcanusetheMRPdate,theprocessingdateoreventheprocessingindicatorfortheselection.
Theorientationhelpinthematerialoverviewisthesameasforthestock/requirementslist.Therearetheadditionaloptionsofsearchingbyprocessingindicatorornewexceptions.
TheMRPresultsaremonitoredwiththehelpofexceptionmessages.Exceptionmessagesalertyoutosituationsthatrequirefurtherprocessingsuchasstartdateinthepast,stocksfallingbelowthesafetylevelandsoon.Usingexceptionmessagestohighlightplanningsituationsproblems,theMRPcontrollercanselectthosematerialsfromtheplanningresultsthatrequireadditionalprocessing.
IntheCustomizingIMGactivity"Def
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