Production Planning SAP

8/8/2019 Production Planning SAP

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TABLE OF CONTENTS

1. MASTER DATA ......................... ......................... .......................... ......................... .......................... ..........2

1.1 PRODUCT STRUCTURE – TWIN SIZE BED..................................................... ...2

1.2 DETAILS OF PRODUCT STRUCTURE – TWIN SIZE BED.................................3

2. STOCK LEVELS .......................... ......................... .......................... ......................... ................ ....... ....... ...3

2.1 STOCK LEVELS – TWIN SIZE BED......................................................................4

2.2 TRANSACTION CODE AND MENU PATH...................................................... ....5

3. BILL OF MATERIALS ........................ .......................... ......................... .......................... ................... .....5

3.1 GRAPHICAL HARDCOPY......................................................................................6

3.2 BOM - EXPLODED VIEW – LEVEL BY LEVEL........................................... .......6

3.3 BOM – FUNCTION APPLIED TO TWIN SIZE BED..................................... ........7

4. MATERIAL REQUIREMENT PLANNING ......................... ......................... ........................ ........ .......84.1 DEFINITION OF FIELDS IN MRP VIEWS................................................. ...........8

4.2 FINAL MRP RUN – Twin Size Bed.........................................................................9

5. WORK CENTRE ......................... ......................... .......................... ......................... .............. ........ ....... ..10

5.1 WORK CENTRE GRAPHICAL VIEW..................................................................10

5.2 WORK CENTRE INFORMATION SYSTEM AND TRANSACTION CODE......11

5.3 FUNCTION OF WORK CENTER IN SAP PP.................................................. .....12

6. ROUTING ........................ ......................... ......................... .......................... ......................... ............ .......13

6.1 ROUTING REPORT...............................................................................................14

6.2 ROUTING FUNCTION.................................................................................... ......14

6.3 PRODUCTION ORDER DISPLAY.......................................................................15

7. REFERENCES .......................... ......................... .......................... ......................... .................. ........ ....... .16



1. MASTER DATA

1.1 PRODUCT STRUCTURE – TWIN SIZE BED

Twin Size Bed(FinishedProduct)

FootboardAssembly

(Semi-FinishedProduct)

HeadboardAssembly


Side RailAssembly


MiddleSupport

Slats(SemiFinishedProduct)

Wheel Set(Semi-FinishedProduct)

MetalScrews(RawMaterial)

WheelSet(Semi-Finished

Product)


WheelSet(Semi-Finished

Product)




1.2 DETAILS OF PRODUCT STRUCTURE – TWIN SIZE BED

Table 1: Details of Twin Size Bed

ItemCode

Description Type Unit of Measure

GrossWeight

Unit of Weight

Size

M-639-S Metal Head FrameAssembly

Semi FinishedPC 10.0

Kg 25inchesx 28inches

M-639-IMetal Screws (1/2"x 1/16")

Raw Material PC 1.0 G 5mm

M-639-NWheel Set for Head Frame, FootFrame, and MiddleFoot

Semi FinishedPC 1.0 Kg

M-639-R Metal Foot Frame

Assembly

Semi FinishedPC 9 Kg 20

inches

x 28inches

M-639-TSide Frames withmiddle leg Semi Finished

PC 10 Kg 79inches

M-639-U Middle Support(Slats)

Semi FinishedProduct

PC 10 Kg 38 x27inches

M-639-Z Twin Size BedFinishedProduct

PC 50 Kg

2. STOCK LEVELS



2.1 STOCK LEVELS – TWIN SIZE BED

Item Code StorageLocation

UNe Plant Stock onHand

MW-639-A 0001 PC

3000

500

MW-639-B 0001 P 30 6,000

MW-639-C 0001 P 30 3,000

MW-639-D 0001 P 30 500

MW-639-E 0001 P 30 1000

MW-639-F 0001 P 30 1000

MW-639-Z 0001 P 30 500



2.2 TRANSACTION CODE AND MENU PATH

TRANSACTION CODE: MB52MENU PATH: Logistics > Material Management > Inventory Management > Environment > Stock > Warehouse Stock

3. BILL OF MATERIALS



3.1 GRAPHICAL HARDCOPY

3.2 BOM - EXPLODED VIEW – LEVEL BY LEVEL



3.3 BOM – FUNCTION APPLIED TO TWIN SIZE BED

Bill of Materials function defines multilevel bill of materials - one level at a time. The structure of BOM has an hierarchical arrangement of

components. All the sub-assemblies and raw materials that are required to assemble and produce the finished product are shown under theBOM.



The product chosen here is Twin-Size Bed. The sub-assemblies in this can be divided into two levels – first and second. First levelassemblies are the head board assembly, footboard assembly and side rail assembly. These semi-finished products further moves down tosecond level where in wheel sets (Semi-finished Product) are fixed to it using the metal screws (Raw Material).

4. MATERIAL REQUIREMENT PLANNING

4.1 DEFINITION OF FIELDS IN MRP VIEWS



Safety Stock and service level: Safety Stock and Service Level: Safety stock as the name suggests is the stock level till whichthe dead stock or stock out situation will not arise (probable figure based on past data maintained in master). As such this figure is notstock, it is cut-off figure maintained in master which is used for Planning and once the stock level dips below this value, we canconfigure system to generate PR, orders automatically. It has its relevance in MRP. Safety Stock is the quantity of stock held tosatisfy unexpectedly high requirements in the stocking-up period. The purpose of the safety stock is to prevent a material shortagefrom occurring. In order to determine the safety stock level, we must first specify the risk of a material shortage and also the desiredservice level.

The purpose of the safety stock is to prevent a material shortage from occurring.

In order to determine the safety stock level, we must first specify the risk of a material shortage and also the desired service level .

The safety stock depends on the service level that we specify in the MRP 2 view of the material master record and on the accuracy of the forecast. The more accurate the forecast, the smaller our safety stock can be.

Lead Time: A lead time is the period of time between the initiation of any process of production and the completion of that process.For example, the lead time for ordering a new car from a manufacturer may be anywhere from 2 weeks to 6 months depending on the

internal processes involved in processing the end product. It needs calculate all the upstream product movement and upstream anddownstream information movement and the time consumption in each step.

Minimum Lot Size: We define the minimum lot size on the Lot Size tab page in location product master data in conjunction with theFixed Lot Size or Lot-for-Lot lot-sizing procedure. The SNP optimizer takes these settings into account for integration purposes (withPP/DS, for example). The minimum lot size defined in the product master applies to all the PPMs that use this product as the header material. If the minimum lot size in the product master is larger than the minimum lot size in the PPM, the optimizer takes into accountthe value from the product master. The maximum lot size defined in the product master has no relevance for the SNP optimizer.

Planned Delivery Time: A finished component is made of several sub components. Once the order is received by the system, ithas several process to be followed. Once we create our material by giving the subcomponents- each component and subcomponenthas a procurement cycle which includes the planned delivery time. The material requirements are calculated using the following

formula:

Forecast value for the interval (cycle + purchasing department processing time + planned delivery time + goods receipt processingtime) + safety stock. The planned delivery time is included in the calculation in the calendar days and the purchasing departmentprocessing time and goods receipt processing time in workdays.

4.2 FINAL MRP RUN – Twin Size Bed



5. WORK CENTRE

5.1 WORK CENTRE GRAPHICAL VIEW



5.2 WORK CENTRE INFORMATION SYSTEM AND TRANSACTION CODE

Transaction Code : CR60



5.3 FUNCTION OF WORK CENTER IN SAP PP



The work center includes the details on capacity requirement planning, costing (resources), scheduling, and execution times.

6. ROUTING



6.1 ROUTING REPORT

Transaction Code – CA51

6.2 ROUTING FUNCTION



As the diagram above shows, routings show the flow of the production process. It is a template which we use in the production process.The above diagram shows the structure of routing which gives a detailed description of the products used, the capacity, time etc.

6.3 PRODUCTION ORDER DISPLAY



7. References

1. SAP 2010,SAP,Viewed 5th September 2010,

< http://www.sap.com>

http://www.sap.com/

http://www.sap.com/



2. Vollmann TE et.al 2005, Manufacturing Planning and Control Systems for Supply Chain Management, NewYork.

Production Planning SAP

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