MRP Presentation Draft 8-27-04
-
Upload
prakashmanogaran -
Category
Documents
-
view
217 -
download
0
Transcript of MRP Presentation Draft 8-27-04
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 1/47
1
Production & MaterialRequirements Planning with
SAP R/3 System
Vincent A. Mabert
Kelley School of Business
Indiana UniversityAugust 18, 2004
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 2/47
2
Objective
• Identify Key Elements of Mfg. Planning &Control Systems
• Review End Item Material & Components
• Navigate and Display Basic Production
Planning & MRP Data in R/3• Describe MRP Processing Logic in R/3
• Demonstrate Production Planning and MRPProcess Logic in R/3
• Illustrate Some Useful R/3 Features
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 3/47
3
Manufacturing Planning & Control System
• The MPC system provides information to efficiently manage the flowof materials, effectively utilize people and equipment, coordinate
internal activities with those of suppliers, and communicate withtrading partners about requirements. The MPC system does notmake decisions or manage the operations, managers perform thoseactivities using information from MPC system.
• Typical support by the MPC system include:
– Plan capacity requirements and availability to meet marketplace needs. – Plan for materials to arrive on time and in the right quantities needed for
product production.
– Maintain appropriate inventories of raw materials, work in process, andfinished goods-in the correct locations.
– Schedule production activities so people and equipment are working onthe correct things.
– Track material, people, customers' orders, equipment and other resources in the factory.
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 4/47
4
Approach
• Part 1: Present Product Overview – Review sample product and structure components
– Understand the MPC elements and steps in the SAP R/3• Part 2: Review key data elements:
– Bill of material
– Routing Data
– Work Center Information – MRP Processing Parameters
• Part 3: Outline Basic Process Logic
• Part 4: Use Pre-Populated Item (Precision Pump, T-F100) in R/3 System to illustrate data & process logic
• Part 5: Highlight some useful R/3 features
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 5/47
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 6/47
6
Precision Pump (1)
T-B100
Casing (1) Flywheel (1) Hollow Shaft (1) Turbo Drive (1) Hex Screw (8)
Blank (1) Flywheel Blank (1) Shaft Blank (1) Drive Casing (1)
Gasket (1)
Hex Screw (8)
T-T300
T-T100
T-T200
T-T300
T-T000 T-T400 T-T500
T-B200 T-B300 T-B400
T-F100
Precision Pump (T-F100)Product Structure Tree (# required)
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 7/47
7
Shop FloorSystems
Capacity
Requirement
Planning
Material
Requirement
Planning
Material and
Capacity Plans
Vendorsystems
Forecasting Sales and
OperationsResourcePlanning
Rough-Cut
capacityPlanning
Master
ProductionScheduling
RoutingBOM
MaterialMaster
Inventory
Status
Manufacturing Planning & Control System
Key Components
= processing logic= data input
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 8/47
8
Part 2: Basic Data
Requirements
• Bill of Material
• Job Routing
• Work Center
• MRP Processing
Parameters
Shop Floor
Systems
Capacity
Requirement
Planning
Material
Requirement
Planning
Material and
Capacity Plans
Vendor
systems
Forecasting Sales and
OperationsResourcePlanning
Rough-Cut
capacityPlanning
Master
ProductionScheduling
Routing BOM
MaterialMaster
Inventory
Status
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 9/47
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 10/47
10
Bill of Material for T-F100Drawing Data
Click on ‘Document’ tab
to see more informationconcerning part drawing
Subassemblies and
components that
comprise pump.
There are 5 differentmaterial items for the
pump
Quantity requirements
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 11/47
11
Part Drawing Data
1. Double click on drawing row
2. Double click on
‘BMP’ files
3. Click and then ‘Material’ to return to Overview
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 12/47
12
Bill of Material for T-F100Product Structure
To see subassembly information,
double click ‘ √’ for T-B100 under
‘Asm’ column.
Or back up by clicking and then
see BOM for component T-B100
Subassemblies
and
components
that comprise
pump. There
are 5 different
material itemsfor the pump
Quantity
requirements
T-F100
T-B400T-B100 T-B200 T-B300 T-T100
Product Tree Structure
Column ‘ICT’ indicates
material type, like stock or
non-stock item
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 13/47
13
Look at Component Part T-B100 (Casing)
At Initial Screen type in material
number T-B100, plant number 1000
and BOM usage indicator value of 1,
then hit enter key or click
For material T-F100 there are 3 different
material items for the casing subassembly
T-B100
T-T300T-T100 T-T200
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 14/47
14
View Routing Data for T-F100
Click ‘Operations’ button
for display
Logistics Production Master Data Routings Routines Standard Routines Display(click)
Enter part number
and plant data
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 15/47
15
T-F100 Routing Data
Routing sequence
and work center
numbers and
descriptions
Set up timedata per lot
Process time data (machineand labor) per piece
Description Translation:
Bereitstellung gemäß Kommissionierliste = provision / allocation according to picking list
Einpressen Laufrad in Gehäuse = force fitting of the blade wheel in the casing
Lackieren Gehäuse = painting of the casing
Einbau Welle in Gehäuse = installation of axle / shaft in the casing
Endmontage Pumpe = final assembly of the pump
Abliefern an Lager = deliver to warehouse
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 16/47
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 17/47
17
Work Center DataTo move to work center data, position cursor on row for
work center (e.g., T-M00) and click ‘Work Center’ buttonWork center screen shows basic data.
For w/c T-M00, labor is the primary
resource (Work Center Cat.).
Click on ‘Capacities’ tab to
see work load estimate
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 18/47
18
Work Center Loading
For Set Up put cursor on
SAP005 entry and click ‘Form.
To view Process formula, put
cursor on SAP007 and click
‘Form.’
The work center load estimate is based upon the number of orders and order quantity. Formulas are used to
determine the load estimate using data shown on the Work Center Capacity Overview screen.
Set Up formula –
expected set up for each
job order Process formula – when Base
Qty is 1, then load equals
LaborTime*OrderQty
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 19/47
19
MRP Processing Parameters
Enter part number
(e.g., T-F100 &
Click check (or
enter key)
Enter plant number & Click check mark (or enter key)
Click MRP1 and check
mark (or enter key)
Logistics Production MasterData Material Master Material Display Display Current (click)
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 20/47
20
MRP Parameters (MRP1)
Numerous parameter options that user
can utilize to customize processing. For
example, many different lot sizing choices
available. Currently set for Lot-for-Lot.
Click on cell to see drop down menu.
Drop down menu here shows choices.
Click on MRP2 tab
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 21/47
21
MRP Parameters (MRP2)More alternatives to customize MRP processing
Parameters for:
Lead timeSafety stock
Safety lead time
Service target
Etc.
While lead time normally reflects process andset up time, the ‘Scheduling Margin Key’ allows
the user to add more time for before and after
operation delay.
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 22/47
22
Part 3: Processing Logic
• Since the R/3 system is not a live system with routinetransactions, the following approach uses anindependent planning logic – Start with sales estimate by period for end item
– Determine rough cut production schedule to support sales(similar to master production schedule)
– Transfer production schedule to material planning
– Explode material plan based upon BOM and MRP parameters toget Planned Orders
– Convert Planned Orders to appropriate Production Orders for shop execution
– Review Work Center load profile base upon Production Orders• The colored boxes in the MPC flow diagram (next slide)
indicate key system logic elements that are employed
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 23/47
23
Shop Floor
Systems
Capacity
Requirement
Planning
Material
Requirement
Planning
Material andCapacity Plans
Vendor
systems
Forecasting Sales and
OperationsResourcePlanning
Rough-Cut
capacityPlanning
Master
ProductionScheduling
RoutingBOM
MaterialMaster
Inventory
Status
Manufacturing Planning & Control System
Key Logic Components
= processing logic= data input
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 24/47
24
Part 4: Production & Material
Planning Example –Precise Pump (T-F100)
Precision Pump (1)
T-B100
Casing (1) Flywheel (1) Hollow Shaft (1) Turbo Drive (1) Hex Screw (8)
Blank (1) Flywheel Blank (1) Shaft Blank (1) Drive Casing (1)
Gasket (1)
Hex Screw (8)
T-T300
T-T100
T-T200
T-T300
T-T000 T-T400 T-T500
T-B200 T-B300 T-B400
T-F100
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 25/47
25
Start with R/3 Rough Cut Capacity
Planning for Part T-F100
Enter appropriate part
number and plant number
Click ‘Active Version’
Logistics Production SOP PlanningFor Material Material Create (double
click)
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 26/47
26
Use ‘Change Rough-Cut Plan’
Screen to develop an initial
time-phased schedule for an
item’s production. Two optionsfor sales estimation are: time
series forecasting or user
provided. This slide demos user
provided from Excel sheet.
Highlight starting cell and type <Ctrl> & ‘V’ to paste data vector.
Copy desired sales data from Excel
Provide Sales Estimates to Initiate Planning
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 27/47
27
Develop Rough Cut Production Schedule
Under ‘Edit’ drop down there are a
number of planning options for
coordination production with sales,
here the Synchronize to Sales is
demonstrated to crate a Rough-CutProduction Schedule for T-F100
Click save icon
Under ‘Extras’ want to transfer
Production Schedule by Clicking
to Transfer to Demand
ManagementShop calendar uses weeks and the beginning
of August is Week 32
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 28/47
28
Transfer Production Schedule for T-F100
Click on ‘Transfer now’ and save data
when requested
Summary report on transfer.
Next step is to conduct MRP explosion.
Click return icon to go to SAP Easy Access screen
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 29/47
29
Conduct MRP Explosion
Enter appropriate part number, MRP area and
plant number (e.g., T-F100 , 1000 & 1000)
Click to display info
Click Check mark or enter key twice to
complete explosion
Logistics
Production
MRP
Planning
Single Item – Multi- level (double click)
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 30/47
30
End Item Material Summary
Explosion summary for end item
showing Planned Order quantity,
timing, available material, etc.
Click Save icon
Click ‘Continue’ to finalize process
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 31/47
31
View MRP Results(Stock Requirements List)
Fill in P/N T-F100 and plant 1000 number ,
then click check mark or hit enter
Logistics ProductionMRP EvaluationsStock Requirements List (double click)
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 32/47
32
Click ‘Show Overview Tree’
Click Tree Icon
Click Cancel
Stock Requirements List & Tree View
List Shows:
Planned Orders
Exception Messages
Quantities
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 33/47
33
View Indented Product Structure
See tree structure on left
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 34/47
34
Move Down Product StructureDouble click on T-B100 on left side to get lower level view of product requirements.
Return back to T-F100 (Double click T-F100 on left side in tree)
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 35/47
35
Convert Planned Orders to Production Orders
Click on ‘Eye Glass’ for PlOrd row to create Production Order
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 36/47
36
Create Production Order
Click Prod. Ord
If all is okay, then
click ‘FLAG’ in
upper left corner.
Otherwise,
change quantity,
dates, etc.
See Production Order now
release, light FLAG and
RLAL indicator.
Now click save icon and
click return icon to
Stock Req. list
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 37/47
37
Released Production Orders
See PrdOrd replaced PlOrd entriesClick Refresh Icon to see updates
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 38/47
38
Release More Production Orders
Repeat steps in prior three slides for PlOrd until Jan 3rd, after
updating you see the following PrdOr listed.
With Production Orders released, one can now go
see the expected loads on work centers
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 39/47
39
Capacity Work Load Analysis
Fill inappropriate WC number (e.g., T-M00) andplant number 1000, click check mark or enterkey. (Note - T-F100 requires the following W/Cs:
T-M00, T-V00, T-L00, T-E00 & T-F00
Click ‘Standard Overview’
to see detail
Logistics Production Capacity PlanningEvaluationWork Center View Load (double
click)
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 40/47
40
click graphic for plot
Double click left row box and see detail
production orders for load
close to return
Click return arrow to go back to Overview.
Work Center T-M00
Standard Overview Load Summary at
period 35 for work center for weeks 35
- 44, measured in hours .
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 41/47
41
Part 5: Other Useful Points
•Change MRP Parameters, e.g., Lot Size Logic•Cancel Production Orders
•Help System
•Part Numbers Available
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 42/47
42
Change MRP Lot Size Logic for T-F100Go to Material Master and MRP1 screen: Logistics Production Master DataMaterial Master Material Display Display Current (click) and then
completing steps to get to MRP1 screen
Want to adjust lot sizing logic.
Will use Lot-for-Lot but will have
a Min (300) and Max (400) order size requirement. Change
appropriate cell values and save.
Complete MRP explosion process
by going to: LogisticsProduction MRP PlanningSingle Item – Multi- level (doubleclick) and then complete required
steps .
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 43/47
43
New MRP Lot Size Logic Results
New PlOrd results for Min and Max
logicOld PlOrd results for Lot-for-Lot logic
Note: The new lot size logic results in fewer Planned Orders being placed
Cancel Prod ction Orders
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 44/47
44
Cancel Production OrdersThere are times that a Production Orders should be canceled because of demandchanges or other conditions, which reduces the shop work load. Here are the steps.
First go to Stock Requirements List for appropriate part.
1. Go to Stock Requirements List
for appropriate part. [ LogisticsProduction
MRP
Evaluations Stock Requirements List
(double click)] and select
appropriate part number
2. Click on order line for change, e.g., 11/02/2004
3. Click PEN icon at bottom
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 45/47
45
Production Order Change: Cancel Order
At Header screen go to Functions > RestrictProcessing >Technically Complete and
select
Screen entry color changes to inactive,
indicating the order is cancelled.
Click save icon, which returns
you back to Stock Requirements
List.
Cancel Order: Revised Stock
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 46/47
46
Cancel Order: Revised Stock
Requirements List
Click Refresh icon
Note removed
order. This also
reduces load on
WCs
Cl E i
8/8/2019 MRP Presentation Draft 8-27-04
http://slidepdf.com/reader/full/mrp-presentation-draft-8-27-04 47/47
47
Classroom Exercise• The Precision Pump end item is
preconfigured in the SAP R/3 system,
supported by the SAP Competency Centers
and available for use by University Allianceinstructors.
• There are 31 part numbers available for
assignment in R/3 that have been configuredin the same manner. They run from T-F100
to T-F130.
• Remember, only one user can be active witha part number or data element at any
moment.