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Production Planning Questionnaire


InstructionsThis questionnaire is an online tool that you can use to collect information about your business that will

then be used for tailoring the R/3 System to your business needs. You will need Microsoft Word for

Windows to work with this document. Enter your answers in the fields after the questions, using the TAB

key to move from field to field. You may save, and later change, your answers in this questionnaire just asyou can with any other Word document. This document can be password-protected to allow entrance of

information only in the answer fields.

1 Enterprise Structure

1.1 Plants

A plant is an organizational unit that representsa production facility, warehouse, sale office, or

distribution center. In addition, MRP is

executed separately for each plant.

1.1.1List the different type of plants you will need,and briefly describe why each should be aseparate plant:

2.1 Basic Data

2.1.1Do you use engineering change managementfor your BOMs?

Yes No

2.1.2What application areas are your BOMs linkedto (for example, materials management, MRP,

costing, etc.)?

2.1.3Do you plan to use the default setting by SAPfor your BOMs validity or effectivity dates?

Yes No

If no, define your validity settings for your

BOMs.

2.1.4Do you maintain your BOMs using a CADsystem?

Yes No

If yes, explain.

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2.1.5Select the BOM types you maintain in yourorganization with associated units of measure.(i.e., pieces, each, die, etc.)

Material BOM

Equipment BOM

Functional location BOM

Document structure

Sales Order BOM

2.1.6BOM usage

Please select in what area(s) your BOMs willbe maintained.

Production

Engineering

Universal

Plant maintenance

Sales and Distribution

Costing

2.1.7Define material provisionindicators

Do your BOMs include material that is

provided by the customer?

Yes No

2.1.8Define explosion types

Select which BOM explosion type(s) your

company uses.

Phantom assembly off: you control how an

assembly with the Phantom assembly is exploded.

Phantom in planning: no dependent requirements

are produced for materials, and the materials are not

planned.

Collective order off: used to control how assemblycollective orders are exploded. (A collective order is

a structure of planned or production orders linked

over several manufacturing levels.)

Long term planning off: allows you to simulate

materials planning, in parallel to operational

materials planning, across all low-level codes. Thismeans that you can use the current bills of material to

determine the effects of a planned production

program on the material requirements and thecapacity load.

Individual/collective requirements:planning for

dependent requirements. This controls whetherindividual or collective customer requirements

planning is allowed for dependent requirements.


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2.1.9Will you be transforming BOM data from anexisting system into the SAP system?

Yes No

If yes, indicate the number of BOMs.

2.1.10 Are there several alternative BOMs forone material (different production processes or

proportions of quantities), or is this situationplanned for the future?

2.1.11 Are there BOM items that are not keptin stock, but are externally produced for orders?

Yes No

2.1.12 What are your requirements foradministering BOMs (copy functions, mass

changes, and so on)?

2.2 Work Center

2.2.1 If you are using Work Centers, select whatbusiness function(s) apply at your organization.

Costing

Scheduling

Capacity Planning

Printing Shop Floor Paper

Shop Floor Control

Confirmations

2.2.2Will you integrate Work centers with theHuman Resources sytem?

Yes No

If yes, briefly describe the type of data that will

be used (e.g., required skills).

2.2.3 List the type(s) of data that are maintained atyour work centers (i.e., costing or scheduling)

2.2.4Work centers can be categorized according totheir relevant use, for example, by maintenanceor inspection. Indicate how your work centers

are categorized and give the number of work

centers for each category.

2.2.5List the type(s) of parameters you use for yourvarious work center(s). (e.g., WC1=setup,machine & labor, WC2=labor only)

2.2.6What are the name(s) of the person or group ofpeople responsible for maintaining the data in

your work center(s)?


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2.2.7 If you are in a Kanban/JIT environment, list thenumber of supply areas you have, including a

brief description. (A supply area is used for

material replenishment and is situated on the

shop floor.)

2.2.8Select what default value(s) you plan tomaintain for your work center(s). (Defaultvalues help to simplify the maintenance of

work centers.)

Basic Data (General data)

Default operation

Scheduling

Capacity data

2.2.9Control keys allow you to determine thebusiness functions you want to carry out with

an operation and how the operation is to be

processed. Which business function(s) will be

processed at your operations?

Scheduling

Capacity planning

Costing

External processing

Completion confirmation (whether the

operation is confirmed)

Printing of time tickets

2.2.10 If you are using the HR module inSAP or if you are not planning to maintain

wages or salaries of your employees, skip this

question.

The wage and salaries of employees can be

calculated based the wage type (e.g., hourly,salary and bonus) What wage type(s) do you

maintain at your company?

2.2.11 In the SAP system, performanceefficiency rates are used in costing and in

capacity planning. What are the expected

efficiency rates that typically occur at several

work centers in your company? (e.g., 90, 100,

or 110%)

2.2.12 Define capacitycategories

What capacity categories are maintained atyour work center(s)? (e.g., machine, labor,

setup crew, emissions)

2.2.13 Determine capacityplanner

List the name(s) of people or groups of people

responsible for planning capacity at your


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company.


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2.2.14 Define shift sequence

Using the table below, indicate what shift

definition(s) are common for several work

centers at your company.

Shift Description Start Finish Break Wrk. Hrs.(e.g.)Day1 Normal Day 08:00:00 16:00:00 Noon 8.00

2.2.15 Indicate the work center formula(s)that you use in the following areas. (e.g.,

Machine Requirements = Machine* Operation

Qty. / Base Qty.)

Setup time

Machine time

Labor time

Setup Requirements

Machine Requirements

Labor Requirements

2.3 Routing

2.3.1 If you choose not to use the number rangeassignment in SAP, list your number range(s)

for internal and/or external routings.

2.3.2Skip this question if you are not using repetitivemanufacturing.

If you choose not to use the number range

assignment in SAP, list your number range(s)

for internal and/or external routings. (Rate

routings are used in repetitive manufacturing.)

2.3.3Profiles with default values are proposed when

you create a new routing. This data can eitherbe saved or overwritten. To assist when

creating a routing profile, fill in the data.

Unit of measure

Status (select one) Created

Released for Production


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Operation increments (e.g., 10, 20, 30)

Base quantity

Currency

2.3.4Select which material type(s) will be used inyour organization.Finished products: materials that are produced andsold to the customer

Semi-finished products: materials that can be sold

to the customer, or used in a higher assembly

Trading goods: materials that you buy and

sell without any manufacturing

Configurable material: the selectable

items form a BOM that are used to make a

Finished product in various combinations.(i.e., a car)

Non-stock material: material that you buy

and track qty., but in value is not kept.

Raw material: material you buy to producesomething with

2.3.5What are the name(s) of people or group ofpeople that are responsible for maintaining your

routings?

2.3.6The control key for an operation is used tocarry out business functions and dictate how an

operation is to be processed by the system.

What business functions are processed at the

operation level in your organization? (Selectwhere applicable.)

Scheduling

Costing

Inspection characteristics

Print operation

External Processing

Automatic goods receipt

Capacity Planning

Time tickets

Rework

Confirmation

Print Confirmation

2.3.7Reduction strategies are used to determine howthe opeation lead time can be reduced step by

step. Do you use reduction strategies in

manufacturing at your company?

Yes

No


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If yes, please explain.

3 Sales and Operations Planning

3.1 Master Data

3.1.1 If currency conversion is required, which typeof exchange rate will be used?

Average rate

Buying rate

Selling Rate

3.1.2Should capacity information be displayed? Yes

No

3.1.2.1 If yes, which type of resources willrequire resource leveling?

Work Centers

Materials

Production Resources and Tools

Costs

3.1.3Will SOP data be transferred from any non-SAP systems/sources?

Yes

No

3.1.4Which plant should be used as the planningplant when no other plant is identified?

3.2 Functions

3.2.1Will sales quantities be transferred from the R/3Sales Information System (SIS)?

Yes

No

3.2.2Which transfer strategy will be required whentransferring SAP data to Demand Management?

Direct from the sales plan

From the sales plan as a proportion of the

product group of which it is a member

Direct from the production plan

From the production plan as a proportion of

the product group of which it is a member

From an Information Structure


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3.2.3Application Link Enabling(ALE)

Will Sales and Operations plans (information

structures) be distributed to remote systems?

Yes

No

3.2.4Maintain planning types

Will more than one view of the planning table

be required?

Yes

No

If Yes, define the following for each user:

Planning Start Date

Number of time periods to plan

3.2.5Where will planning quantities be copied from? Sales Information SystemProfitability Analysis (CO/PA)

3.2.6Will non-SAP data be copied into the SAPplanning table?

Yes

No

4 Master planning

4.1 Planning Strategy4.1.1What type(s) of Planning Strategies are used

your company? (e.g., make-to-stk., make-to-

order, repetitive, etc.)

4.1.2What planning time fence duration is requiredfor planned independent requirements?

4.1.3Will planned independent requirements betransferred from the legacy system?

Yes

No

4.2 MPS4.2.1What individuals or groups of individuals will

be responsible for the monitoring of material

availability (MPS)? Identify the materials that

will be managed by each individual or group.

4.2.2What is the desired planning time fence forMRP processing? Should out-of-date plannedorders and firm planned orders in future periods

Yes

No


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be deleted before each material planning run?

4.2.3What evaluations (on-line reports) need to beprovided for the analysis of MPS results? How

should the report be structured?

5 Material requirements planning

5.1 Master Data

5.1.1Define MRP controllers

What individuals or groups of individuals will

be responsible for the monitoring of material

availability (MRP)?

5.1.2What individuals or groups of individuals will

be responsible for the processing of missingparts (MRP)?

5.1.3Will any of the following conditions exist formaterials produced in-house?

phantom assembly

production in an alternative plant

external reservation (withdrawal from an

alternative plant)

independent requirements

5.1.4Will any of the following conditions exist formaterials procured externally?

consignment

subcontracting

stock transport

5.1.5 In what time bucket is your horizon? (i.e., days,weeks, months)

5.1.6What is the required duration of the planningtime fence for each plant?

5.1.7For each plant, what percentage of safety stockshould be available for material planning?

5.1.8Should stock in transfer and/or blocked stock(material that is not available) be included in

the net requirements calculation as available

stock?

Yes

No

5.1.9For each plant, what is the desired maximumnumber of purchase order proposals that should

be created during the material requirements

planning run?


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5.1.10 Which lot-sizing procedures will beutilized?

static lot-sizing

period lot-sizing

optimizing lot-sizing

5.1.11 Will the proposed lot-sizes for anymaterials need to be adjusted to match the

deliverable/transportable units? For example, amaterial can only be delivered in crates of 10

pieces.

Yes

No

5.1.12 Should the system continue to utilizethe backward scheduling procedure even when

a planned start date lies in the past?

Yes

No

5.1.13 What is the maximum number of daysallowed between MRP runs?

5.1.14 Will R/3 be interfaced to an externalassembly cord system?

Yes

No

5.1.15 Will the hardware system environmentallow the splitting of the MRP planning run

process among multiple R/3 application

servers?

Yes

No

6 Production Orders

6.1 Master data

6.1.1Define order types

6.1.1.1 Do you use order settlement (planned vs.actual) for production orders?

Yes

No

6.1.1.2 What type of number assignment do youuse for production orders?

Internal (assignment automatically by the

system)

External (assigned by the user)

6.1.1.3 Define the length and format of yourproduction order numbering scheme.

6.1.1.4 If routing selection is required, will it beprocessed automatically or manually?


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6.1.1.5 Will batch determination be required priorto releasing a production order to the shop

floor?

Yes

No

6.1.1.6 Do you use the same scheduling data fromyour planned orders for your production dates?

Yes

No

6.1.1.7 Do you use external processing in youroperations? If so, would you prefer to use one

purchase requisition per operation or one

collective purchase requisition per order?

6.1.1.8 Indicate below where you would want torecord change status to a document.

The document records:

which status changed

who changed the status

when the status was changed

Order Status

Operation Status

Material Status

Production Resources Tool (assigned to an

operation, e.g., tools, jigs and fixtures,

inspections, devices and drawings)

6.1.1.9 Indicate at which point(s) you conductmaterial inspection.

Goods receipts inspection

Deliver to customer

6.1.1.10 Do you document goods movements with

reference to an order? If so, select whereapplicable.

Good receipt for a purchase order

Good receipt for a completed order

Planned goods issue

Unplanned goods issue

6.1.2 If you choose not to use the predefined numberranges in SAP, list your order types and their

number range(s).

6.1.3Define number ranges forconfirmations

If you choose not to use the predefined numberranges in SAP, list your number range(s) foroperation confirmations.

6.1.4Define number ranges forreservations

If you choose not to use the predefined number

ranges in SAP, list your number range(s) for

component reservations. (Only internal number


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assignment is allowed for reservation number

within production orders.)

6.1.5Define number ranges foroperations

If you choose not to use the predefined numberranges in SAP, list your number range(s) for

operations.

6.1.6Define number ranges forcapacity requirements



tracking capacity requirements.

6.1.7Define control key

Indicate which business functions you will usein your routing.

Scheduling

External processing

Capacity planning

Printing shop papers

Inspection characteristics

Costing


Processing of confirmations

6.1.7.1 Are setups used in capacity planning? Yes

No

6.1.7.2 Are formulas used for variable size items? Yes

No

6.1.8Define (standard) triggerpoint usage

Trigger points are used to trigger certain

functions, (i.e., operation release, insertion of

reference operation sets) when the status of

operation changes. A trigger point can be

assigned to an order or routing.

6.1.9Are you planning to use trigger points?

Yes

No

If yes, please give some examples as to how


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you will use trigger points.

6.2 Operations

6.2.1Select which criteria you use for routingselecting.

When creating a routing using the copy

function

At the time of order creation (prior to

release)

During scheduling

During costing

6.2.2Select automatically

Will you use automatic routing selection for

alternative routing?

Yes

No

6.2.3 If yes, what type of criteria will you use?

6.2.4Availability check

How do you process availability checks for

material/components when creating production

orders? Select where applicable.

All material must be available prior to

creating/releasing order

Create/release with shortages (not all

material available)

User decides on whether to release

Check material in groups (grouping materialbased on material and/or MRP type)

Material quantities confirmed in the

availability check are to be locked

Check ATP quantities

Check accumulated ATP quantities

Take into account replenishment lead time

Take into account stock categories

Take into account purchase requisitions-

MRP

Take into account purchase orders-MRP

Take into account planned orders-MRP

6.2.5What process do you use for checkingbackorders?

6.2.6Are capacity requirements (work orders, Yes


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planned orders) taken into consideration when

scheduling?

No

6.2.7Specify scheduling type

When scheduling production orders, what

criteria does your organization use? Selectwhere applicable.

Forwards

Backwards

Only capacity requirements

Current dates (The system schedules

backwards from the basic date and then

forward from the current date.)

6.2.8Define time units

Do you use time units for scheduling (i.e.,

second, minute, decade, etc.)?

Yes

No

If yes, list time units.

6.2.9Define key for performanceefficiency rate

Do you use performance efficiency rates (actual

work done by an employee vs. average work

done)?

Yes

No

6.2.10 Define schedulingmargin key

Select which type(s) of floats/buffers you use

when scheduling order(s).

Float before production: This is the time between

the order start date and the schedule start date.

Float after production: This is the time between the

order finish date and the scheduled finish date.

Release period: Number of working days in the

release period of an order.

6.2.11 Define move timematrix

Does your organization use move time betweenwork orders?

Yes

No

6.2.12 Define reductionstrategies

Will you use reduction strategies reduces lead

time if the basic dates given are not adhered to,or schedule dates lie outside of the basic dates?

Yes

No

If you are currently using reduction strategies,

what is your process?


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6.2.13 Define confirmation

parameters

Confirmations are used for order monitoring.

They can be performed at the operation and

sub-operation level. Partial confirmation is the

confirmation of an order that can still be

processed.

Select the area(s) in which your organizationuses confirmation control.

Check dates

Logs only warning messages or

information messages

Goods movement system to display all

components assigned to the operation.

Variances:

Scrap on a quantity basis

Excess consumption of activities

Longer execution time

6.2.14 What inventory valuation does yourorganization use?

Price control (standard cost) delivered

quantity is valuated with the standard cost.

The difference between inventory valuation

and credit posting to order is posted to the

cost differences.

Moving average cost.

7 Kanban

7.1 Will any stock points be situated directly at theproduction line or work center(s)?

Yes

No

If yes, how many are there are how and they

identified/named?

7.2 ReplenishmentStrategies

7.2.1Which of the following will be used to controlthe production of Kanban materials?

Kanbans (cards) and a cost collector

Planned orders and a cost collector

Production orders

7.2.2How will stock transfers need to be carried out? using a stock transfer reservation

using a direct transfer posting


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7.2.3For each status change, which of the followingshould occur?


Print Kanban card

8 RepetitiveManufacturing

8.1 Basic Settings

8.1.1Define number ranges forrun schedule headers



run schedule headers.

8.1.2Define number of thenumber ranges for backlogs


ranges in SAP, list your number range(s) forbacklogs.

8.1.3Define number of numberrange for document log



document logs.

8.1.4What repetitive manufacturing profile(s) doesyour organization use or will use?

The data and costs incurred in productionare assigned to the run schedule header andare settled.

All the costs incurred in production are

assigned to the cost collector where they are

settled. (Production orders are not required.)

8.1.5Select how cost collectors are created at yourcompany.

Automatically, when creating the run

schedule header

Manually, in the CO system.


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8.1.6Specify control data forrepetitive manufacturingprofiles.

Select the repetitive manufacturing profiles

your organization plans to use.

Activities are automatically backflushed to

the cost collector

Discrepancies in backflushing are corrected

manually

The withdrawal of an item with a

discrepancy is refused

Master plan is reduced after a goods receipt

Planned orders are recreated when reversinga backflush

Reporting points for backflushes

Goods receipt is automatically posted at the

last reporting point backflush

Goods receipt and a goods issue is posted

when backflushing

Only post goods receipt

8.2 Planning

8.2.1Define planning periodicity

Select which planning period or buckets your

organization uses when creating a run schedule

header. (A run schedule header is an order in

repetitive manufacturing for the production of

finished products or semi-finished products that

are produced on a repetitive basis over a longerperiod).

Day

Week

Month

Posting period

8.2.2 If you do not use capacity planning in repetitivemanufacturing, skip this section.

You have two options for executing capacity

leveling. Select which option(s) you plan to use

in your organization.

via the planning table (spreadsheet format)

via the graphic table that you access via the

planning table

8.2.3How will requirements be distributed?Select one only.

Continuously (lineraly)

Discretely to defined points


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8.2.4Define distributionaccording to usage time

The distribution of orders is based on operating

time that takes available capacity into account

and shifts. Do you use operation time todistribute orders?

Yes

No

If yes, what is your process?

8.2.5When backflushing, what sequence for materialwithdrawal do you or will you use in your

organization? Indicate using 1 3

withdrawal of unrestricted stock-use stock

withdrawal of consignment stock

withdrawal of pipeline material

8.2.6Select which movements type you plan to use

in repetitive manufacturing. (Movements typesare automatically used for backflushing.)

goods receipts

goods issue

scrap

by-products

movements referring to individual customer

orders

8.3 Cost Object Controlling

8.3.1Define generation of costlog

Does your organization log costs in repetitive

manufacturing when backflushing activities?

Yes

No

8.3.2Select which distribution rule for settlementyou will use.

full settlement

settlement by period specifies variancecalculation is done out by period

8.3.3Select which cost collector your organizationwill use for backflushing in repetitive

manufacturing.

cost collector is created automatically by the

system, no search is required

use search strategy to define which cost

collector is used. If selected, choose one

option below:

on material is settled to one cost

collector

one material and one production version

are settled using several cost collectors

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