Preface

15

Acknowledgments

17

1 Introduction to MRP with SAP S/4HANA

19

1.1 MRP Basics

19

1.2 MRP within the Supply Chain in SAP Systems

20

1.3 MRP with SAP S/4HANA

23

1.3.1 Classic MRP

24

1.3.2 MRP Live

24

1.3.3 MRP Cockpit

25

1.3.4 Demand-Driven MRP

26

1.3.5 Predictive Material and Resource Planning

27

1.4 Summary

28

2 MRP Basics

29

2.1 MRP Procedures

29

2.1.1 Material Requirements Planning

30

2.1.2 Master Production Scheduling

31

2.1.3 Consumption-Based Planning

32

2.1.4 Demand-Driven MRP

33

2.2 MRP Planning Process

34

2.2.1 Reading the Planning File

35

2.2.2 Calculating the Net Requirements

37

2.2.3 Calculating the Procurement Quantity

38

2.2.4 Determining the Replenishment Proposal Type

40

2.2.5 Scheduling Replenishment Proposals

42

2.2.6 Exploding the BOM

48

2.2.7 Creating Exception Messages

50

2.3 Summary

51

3 Master Data and Basic Settings

53

3.1 Material Master

54

3.1.1 Material Master Overview

54

3.1.2 MRP Type

60

3.1.3 Lot-Sizing Procedures

73

3.1.4 Procurement Types and Special Procurement Types

80

3.1.5 Scheduling Parameters

83

3.1.6 Net Requirements Calculation

85

3.1.7 MRP Area

87

3.2 Procurement Master Data

89

3.2.1 Internal Procurement

91

3.2.2 External Procurement

106

3.2.3 Quota Arrangement

114

3.3 Planning File

119

3.4 Summary

121

4 Configuring MRP

123

4.1 Overall Plant Parameters

124

4.1.1 Maintain Environment

125

4.1.2 Maintain Master Data

128

4.1.3 Maintain Planned Orders

132

4.1.4 Maintain Planning Run

133

4.2 MRP Group

147

4.2.1 Consumption Mode/Adjustment Horizon

149

4.2.2 Horizons

149

4.2.3 Determine Production Storage Location

151

4.2.4 Convert Planned Order

151

4.2.5 Program Plan: Independent Requirements Split

152

4.2.6 Evaluation

152

4.2.7 Planning Run

152

4.2.8 External Procurement

156

4.2.9 Availability Check

157

4.3 MRP Type

158

4.4 Lot-Sizing Procedure

161

4.5 Availability Check

165

4.6 MRP Areas

167

4.7 Parallel Processing

172

4.8 Summary

173

5 Running MRP

175

5.1 MRP Live versus Classic MRP

175

5.2 Classic MRP

179

5.2.1 Control Parameters

179

5.2.2 Single-Item/Single-Level Planning

183

5.2.3 Single-Item/Multilevel Planning

184

5.2.4 Single-Item Interactive Planning

188

5.2.5 Multilevel Sales Order/Project Planning

190

5.2.6 Total Planning Run

191

5.2.7 Master Production Scheduling

194

5.3 MRP Live

195

5.3.1 MRP Dispatcher

196

5.3.2 MRP Live Control Parameters

197

5.3.3 Running MRP Live in SAP GUI

199

5.3.4 SAP Fiori

201

5.4 Planning PP/DS Materials in MRP Live (One MRP Run)

206

5.5 Summary

208

6 Evaluating the MRP Results

209

6.1 Exception Messages

209

6.2 Rescheduling Checks

214

6.3 Stock/Requirements List

218

6.3.1 Individual Access

219

6.3.2 Collective Access

236

6.4 MRP List

242

6.5 Information and Settings for Materials in MRP on SAP HANA

245

6.6 Order Report

246

6.7 Pegged Requirements

250

6.8 Evaluation of the Planning Situation

252

6.9 MRP Cockpit

254

6.9.1 Shortage

254

6.9.2 Accessing SAP Fiori Applications for MRP

256

6.9.3 Monitor and Manage Material Coverage

259

6.9.4 Monitor and Manage Internal Requirements

264

6.9.5 Monitor and Manage External Requirements

266

6.9.6 Monitor and Manage Production or Process Orders (MRP View)

268

6.9.7 Handover Purchase Requisitions

271

6.9.8 Display MRP Master Data Issues

272

6.9.9 Manage Change Requests

273

6.9.10 Detect MRP Situations

280

6.10 Summary

286

7 Managing Planned Orders

289

7.1 Planned Orders

289

7.2 Planned Order Availability Check

294

7.3 Planned Order Conversion

297

7.4 Additional Options for Mass Processing

303

7.5 Summary

307

8 Advanced MRP Features

309

8.1 Subcontracting Planning

309

8.2 Planning Calendar

315

8.3 BOM Explosion Number

318

8.4 Parts Interchangeability

321

8.4.1 Creating an MPN-MRP Set

321

8.4.2 Planning an MPN-MRP Set

324

8.5 Range of Coverage Profile (Dynamic Safety Stock)

325

8.6 Time-Dependent Stock Levels

329

8.7 Segmentation

333

8.7.1 Segmentation Master Data

334

8.7.2 Using Segmentation in MRP Master Data

339

8.7.3 Running MRP with Segmentation

342

8.8 Summary

345

9 Demand Management

347

9.1 What Is Demand Management?

348

9.2 Planning Strategies

352

9.2.1 Planning with Final Assembly (Strategy 40)

354

9.2.2 Net Requirements Planning (Strategy 10)

355

9.2.3 Gross Requirements Planning (Strategy 11)

356

9.2.4 Make-to-Order Production (Strategy 20)

358

9.2.5 Planning without Final Assembly (Strategies 50 and 52)

359

9.2.6 Planning with a Planning Material (Strategies 60 and 63)

361

9.2.7 Planning at Assembly Level (Strategies 70, 74, and 59)

363

9.2.8 Assemble-to-Order (Strategies 81 through 86)

365

9.3 Creating a Demand Plan

366

9.3.1 Maintenance of Planned Independent Requirements in SAP GUI

366

9.3.2 Maintenance of Planned Independent Requirements in SAP Fiori

367

9.3.3 Splitting Independent Requirements

370

9.3.4 Planned Independent Requirements Reorganization

371

9.4 Configuring Demand Management

371

9.5 Summary

374

10 Demand-Driven MRP

375

10.1 What Is DDMRP?

375

10.1.1 Buffer Calculation

377

10.1.2 DDMRP Process

379

10.2 Setting Up DDMRP

381

10.2.1 Product Classification

382

10.2.2 Mass Maintenance of Products

389

10.2.3 Buffer Proposal Calculation

391

10.3 Running DDMRP

395

10.4 DDMRP Analytics

405

10.5 Integrating DDMRP with SAP IBP

407

10.6 Demand-Driven Scheduling

409

10.7 Summary

409

11 Long-Term Planning

411

11.1 Creating a Long-Term Planning Scenario

412

11.2 Running Long-Term Planning

416

11.3 Processing Simulative Planned Orders

418

11.4 Evaluating the Long-Term Planning Results

422

11.4.1 Evaluating the Long-Term Planning Stock/Requirements List

422

11.4.2 Evaluating Work Center Capacity

425

11.4.3 Transferring the LTP Results to the Logistics Information System

426

11.5 Cleaning Up the Long-Term Planning Scenario

430

11.6 Summary

433

12 Predictive Material Requirements Planning

435

12.1 pMRP Basics

435

12.1.1 What Is pMRP?

436

12.1.2 Business Scenarios

436

12.1.3 Comparing pMRP with Long-Term Planning

440

12.1.4 Prerequisites

444

12.2 Master Data

445

12.2.1 Material Master

445

12.2.2 Bill of Material

446

12.2.3 Work Center and Resources

447

12.2.4 Routings and Master Recipes

447

12.2.5 Production Version

447

12.2.6 External Procurement and Quota Arrangement

448

12.2.7 Flexible Constraints

448

12.3 Creating Simulations

451

12.3.1 Scheduling a pMRP Simulation Creation

451

12.3.2 Template Selection

453

12.3.3 Scheduling Options

454

12.3.4 Parameters

455

12.3.5 Evaluating the Simulation Creation Logs

457

12.4 Processing Simulations

459

12.4.1 Process pMRP Simulations App

459

12.4.2 Demand Plan Simulation

462

12.4.3 Capacity Plan Simulation

464

12.4.4 Simulation Components

466

12.4.5 Multilevel Material Simulation

468

12.4.6 Issue List

470

12.4.7 Simulation Summary

472

12.5 Releasing Simulations

472

12.6 Configurable Products

476

12.6.1 Creating PIRs for Configurable Products

477

12.6.2 Simulation for Configurable Products

478

12.6.3 Releasing PIRs for Variant Configuration Components

479

12.7 Demand-Driven Scenarios

480

12.7.1 Using pMRP with DDMRP Products

480

12.7.2 Forecasting Delivery Schedules for Components

482

12.8 Summary

482

13 Administering MRP

483

13.1 Housekeeping MRP

483

13.1.1 Keeping the Planning File Consistent

483

13.1.2 Managing Background Jobs

485

13.1.3 Deleting Old MRP Lists

487

13.2 Troubleshooting MRP

488

13.2.1 Material Not Planned

488

13.2.2 Inconsistencies

490

13.2.3 MRP Live Support Functions

496

13.2.4 Support Tool for MRP

500

13.3 Improving MRP Performance

503

13.3.1 Classic MRP

504

13.3.2 MRP Live

507

13.3.3 Frequent Problems and Solutions

516

13.4 Summary

517

14 Enhancing MRP

519

14.1 Enhancing Classic MRP

520

14.2 Enhancing MRP Live

524

14.3 Enhancing Predictive Material and Resource Planning

527

14.4 Enhancing the SAP Fiori Applications of the MRP Cockpit

528

14.5 Modification of Supply and Demand List

530

14.6 CDS Views

532

14.7 Summary

532

15 Migrating to SAP S/4HANA

533

15.1 Performing a Readiness Check

533

15.2 Assessing Simplifications in MRP

535

15.2.1 Planning File

535

15.2.2 Storage Location Planning

536

15.2.3 Subcontracting

538

15.2.4 Production Versions

539

15.2.5 External Procurement

539

15.2.6 Total Requirements Cleanup

540

15.3 Reviewing Custom Code

542

15.4 Evaluating New MRP Features

543

15.4.1 MRP Live

543

15.4.2 Demand-Driven MRP

544

15.4.3 Predictive Material and Resource Planning

544

15.4.4 SAP Fiori and the MRP Cockpit

544

15.5 Summary

545