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Consumption-based Planning

Consumption-based Planning. Material Planning. Material Planning (MRP Procedures). SAP Terms. Independent Demand (Consumption-based Planning). MRP-Material Requirements Planning. Reorder point planning. Forecast-based planning. Time-phased planning. SAP Exercise. Manual reorder

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Consumption-based Planning

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  1. Consumption-based Planning

  2. Material Planning Material Planning (MRP Procedures) SAP Terms Independent Demand (Consumption-based Planning) MRP-Material Requirements Planning Reorder point planning Forecast-based planning Time-phased planning SAP Exercise Manual reorder point Automatic reorder point

  3. In-house production External procurement Planning Run Planned Order Conversion Purchase Requisition Schedule Line Production Order Purchase Order Planning Process Can be automatic

  4. Planning Process • Planned Order: • Recommendation by the MRP planning process of quantity and timing of production or purchase order • Production Order: • Actual order given to shop floor to commence production. May be electronic or paper. Can include production details (routing, quality requirements, drawings, instructions, etc.)

  5. Planning Process • Purchase Requisition: • Request to purchasing to create purchase order • Purchase Order • Request to vendor to supply materials • Schedule Line • Direct request to vendor for materials, covered by scheduling agreement (blanket PO)

  6. Reorder Point Processing Lot Size Reorder Point Safety Stock Time Replenishment Lead Time

  7. Reorder Point Processing • When the inventory level for a product that is planned using consumption-based planning reaches the ROP, an order for the material is NOT created automatically • Consumption-based planning uses the Material Requirements Planning (MRP) planning process to create purchase orders • The MRP planning process is typically run overnight on a daily basis • Historically, might have used weekly runs • Time until MRP planning run is executed should be considered in ROP calculation (daily runs, add 1 day to lead time)

  8. Replenishment Lead Time Processing Time For Purchasing Goods Receipt Processing Time Planned Delivery Time Availability Date Purchase Order Date Today (Release Date) Goods Receipt Date Forward Scheduling forExternal Procurement

  9. MRP Planning Process • For a company with thousands of materials to plan, the computing resources needed to calculate material plans can be significant • To make sure that: • Only those calculations that are necessary are performed: • Only on materials that need planning • Two “filters” are used: • Planning Run Type • Planning Horizon

  10. Planning Run Types • NETCH: Net change in the total horizon • In the MRP Planning Process, materials are planned if there have been any: • Changes in material stocks (receipts, issues) • Addition of purchase requisitions, purchase orders, planned orders, dependent requirements • Changes in Material Master Data (Lot Size, ROP, etc.)

  11. Planning Run Types • NETPL: Net change in the planning horizon • Same at NETCH, EXCEPT: • Changes must occur within the planning horizon • Planning horizon keeps MRP planning process from making plans for future periods that: • Do not impact current operations • Will be made irrelevant through the dynamics of business

  12. Planning Horizon NETCH Planning Horizon NETPL Planning Run Types Order/ Requisition Requirement Time

  13. Plant Parameters: Planning Horizon

  14. Planning Run Types • NETUPL: Regenerative Planning • Plans all materials for total planning horizon • Good idea to run this option regularly (e.g. every weekend), even though it is more resource intensive • Customizing changes don’t trigger planning under NETCH or NETPL • “Time passage” problem with NETPL

  15. NETPL: Potential Problem Planning Horizon NETPL Today Passage of time is not an “event” Would require monitoring to detect Planning Horizon NETPL Today Solution: Run NETUPL

  16. Planning File • A Planning File entry exists for each material • Keeps track of changes that would require material to be planned under NETCH or NETPL options • MRP Planning process looks at planning file entries for each material to see if it should be planned

  17. Planning File Low-level Code NETCH Indicator NETPL Indicator

  18. Planning Run Options Planning Run Type: NETCH NETPL NETUPL Create Purchase Req: 1 – Purchase Requisitions 2 – Purchase Requisitions in Opening Period 3 – Planned Orders Defined by Schedule Margin Key Usu. does not impact consumption-based planning

  19. Planning Run Options Create MRP List: 1 – Yes 2 – Depending on Exception Messages 3 – No Planning mode: Determines how system deals with previous plans (planned order, purchase requisitions) Scheduling: Determines level of detail in schedule calculation for production orders Display results before they are saved Lets planner make changes before the results are saved

  20. Planning Run Options • With consumption-based planning in practice: • You would not run MRP for a single material, but do it as part of a group (MRP Area based on storage location) • You would have it scheduled to run automatically • You would have it either: • Create purchase requisitions automatically • Create schedule lines

  21. Order Proposal for Lot Size Shortage Fixed Purchase Requisitions Firm Planned Orders Reorder Point Purchase Orders Stock Net Requirements Calculation How does safety stock figure into this process?

  22. Exercise: Material Master Data MRP Type: VB sets consumption-based planning Reorder point Lot size: FX is fixed lot size Fixed lot size: Quantity in an order

  23. Exercise: Material Master Data Plnd delivery time: Vendor part of lead time SchedMargin key: Sets opening period, among other things Safety stock: Desired stock level when replenishment order arrives How does it work in SAP R/3?

  24. Exercise: Stock/Requirements List Stock/Requirements List: Your one-stop shopping location for all things material

  25. Exercise: MRP Planning Run MRP control parameters: Planning run parameters discussed previously

  26. Exercise: MRP Planning Run Planning run results displayed: Purchase requisition created

  27. Exercise: Purchase Requisition Can easily create purchase order from S/List

  28. Exercise: Purchase Order Purchase order screen is where the requisition is converted to a purchase order Vendors selected Price determined

  29. Exercise: Receive Purchase Order Goods Receipt Screen: In practice, could just be a bar-code scan Links receipt to purchase order Tell SAP R/3 system where goods have been stored

  30. Exercise: Goods Issue Goods Issue Screen: When goods are issued, something has to absorb costs (project, production order, cost center) In this case, we will charge costs to the warehouse cost center (P020) What is the downside to charging to a cost center?

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