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MATERIAL PLANNING
Plant Raw Not normally part of MRP because MRP doesn’t consider
Stock Final Good Activity Consum Stock Raw Assembly painting Areas of
Who does the work? capacities unless scheduling parameter is set in MRP.
Item Category: engineering responsibilities
3000 3000 3000 3000 Stock contain the list the sequence of steps
2 2 1 1
Non Stock BOM Activity Cost Work for producing a material:
Operations,
Variable size Routing
Documents Bill Of Material Types Center Center Operation Sequences
Usage
Text
Time elements
Material type: Class
Work Centers.
Raw materials Intra material MRP Net Requirements calculation Component allocations
Is executed in the planning run to determine if there is Control parameters for MRP
Operating supplies
Semi-finished products a shortage for a certain material. Processing key
SOP: planning and forecasting module with the
Finished products Create Purchase Requisit (mat. procured ext.)
logistic area. It provides a method for : Stock + fixed receipts that exists (PR, PO,Pln.O, PrO) Create Schedules lines (bis)
controls:
Sales plan: (data from the SIS, data from VS
Business process . Create MRP list (always, never, only except.
CO-PA, from past sales to forecast future MRP TYPES (how materials should be planned) Safety Stock + Requirements (Pln Ind. Req, Sales O) MRP Control Parameters
Views (Screens) = quantity available for planning. Planning mode (if existing data simply be
Department-specific data sales, from another P.group, or manually) MRP adjusted, whether BOM and routings should be (required for planning run)
Material # assignment NO PLANING re-exploded or whether the plann. Should be 1. Processing key
Procurement types CONSUMPTION BASED: Multilevel Backward Scheduling
The system calculates the start dates based on started from the beginning again. 2. Create Purchase Req.
GL- general ledger accounts _Based on historical rates of consumption (past cons) 3. Schedule lines
Production plan (based on sales plan) can _Appropriate for low value mat (b,c parts) a end date.
be created several ways: 4. Create MRP list
_No ref. to master plan (not triggered by ind. req) MRP RUN Scope of the Planning Run
= to sales plan, target stock level, days 5. Planning mode
_Net req. cons. is triggered when: Planning run can be done in 2 levels: Processing key field specify the type of planning:
Material supply, inventory to zero, manually) *stock levels fall below a reorder point (safety stock) or 1. Total planning (planning of all materials of NEUPL: Regenerative planning (plann of all MRP
Feasibility estimates *by forecast req. (from past cons. data). one or several plants.(online or in the background). relevant materials). (first time, errors)
_Appropriate for mat. with demand consistent 2. Single-item planning: NETCH: Net change for total horizon (plann all FI CO
_Ind-Dep. Req and sales order don’t affect them.
Variances
2.1. Multilevel. Planning of all BOM’s materials mat. we made changes).
NETPL: Net change for planning horizon settled
MD04: Stock/Req.list: info current status of stocks 2.2 Single-level. Planning of a specific material
Sales Info Controlling 2.2 Interactive. Interactive single-level planning
CO-PA Profitable
MRP list: info latest plann run
Syst E 2
Analisys The purpose of MPS (Master Prod. Sched) and MRP (Material Req. Header Mvt 101
Planning) is to guarantee material availability on a 2 step planning process (inhouse production) + Items Release
SOP Demand
Product Disaggregation MRP Goods
Sales & Operation
and transfer to
Management MPS Planned Orders Production Order
Group Material Requirements Planning Receipt
Planning (Admin of Ind Req.)
Items 1
Product MRP is set of techniques that uses BOM data, OP
Is a Product family.
Group Manual Forecast Items
It groups together inventory data, and the MPS to calculate
requir. for materials. Time-phased MRP begins
Items
products with similar Sales Order = Customer
plann. charact. Forcasting = Warehouse Req. (Created in SD)
with the items listed on the MPS and determines
Ind. Req. 1. The quantity of all components and mat. OP C.O.T
= Planned Ind. Req. F
required to fabricate those items and (Externally procured)
2. the date that the components and material
Product Items
Disaggregation
BOM
FI CO
Material Variances
settled
Availability Check: Checks for: Releasing orders: levels
MD04: Stock/Req.list: info current status of stocks (from Rout+BOM or manually) _Individual operation
Sales Info Controlling MRP list: info latest plann run _Whole order 2
Syst
CO-PA Profitable
E
Header + -Material components Mvt 101
(inhouse _Several orders together
Analisys -Capacities Release
production) Items
-PRT’s
SOP Disaggregation Demand MRP
Product Sales & and transfer to Material Planned Goods
Operation
Management MPS Requirements Production Order
Group Orders If a BOM is changed after a Pln Order is created but before is converted into Receipt
(Admin of Ind Req.) Planning a Prod. Order: BOM is not re-read and the Prod. Order uses the old BOM
Planning
`
Items Elements of a Prod. Order: 1
Product
Group Manual Forecast Items Order Header OP
Sales Order F Settlement rule
Forcasting = Warehouse (Created in = Customer (Externally Order Creation Options: Items
Costs
Req. = Planned Ind. Req. SD) Ind. Req. procured) Without BOM – Routing Operations
With BOM – Routing Operation sequences OP C.O.T
Planned With Routing Material components
Orders With Planned Order PRTs Items
Trigger points Costs debited
Purchase Schedule Documents links to Prod.Order
Requisition Lines Goods
Cost Object Controlling (COC): Status Prod. Order:
Order settlement: Issue
_Debits the stock account
CRTD
_Credits the order
Purchase Order related
.flexible production environment
Order .flexible product range
.Cost mgt of ind. production lots MM FI CO
Only in the opening .if controlling is required for each order
period .High setup costs
.Manufacture o co-products
Product related
Production Order: GI - Goods Issue Posting: Production Order: GR - Goods Receipt Posting
Is executed for a consumption of a material component for a prod. order. Realizes the stock receipt of a product produced using a production order.
List the application modules that integrate with Manufacturing Execution:
Inventory Management MM - Material document: describe the g. movt. from the MM (stock) point of view. MM - Material document:
Quality Management FI - Accounting document: describes the goods movt. from the FI point of view. FI - Accounting document:
FI - Financial Accounting CO - Cost accounting document: serve various cost analysis purposes CO - Cost accounting document: serve various cost analysis purposes
CO -Controlling _ Account affected:
_ Account affected:
.Finished good stock is debited
SD - Sales and Distribution .Consumption is debited .Plant activity is credited
Order .Raw material Stock is credited . NON consump, raw mat.
PS -Project Systems . NON Finished goods stock, Plant activity When you display the material document, you can branch to the other doc.
HCM -Human Capital Management Q + $ (value) in Material master data is updated GR doc. can be printed
Reservations is Reduced (for planned withdrawal) Delivery quantity in an order is Updated
Determination of actual costs (evaluation) and update of order lant activity is Updated
When you display the material document, you can branch to the other documents Evaluation of the receipt
GI doc. can be printed. Credit to order
The GI posting is controlled via a movement type 261. The GR posting is controlled via a movement type 101.
PROCUREMENT PROCESS www.sap-terp10.com.ar
G / L: P/L - Balance sheet
Material Management Integration:
Reconciliation Subledger (FI) Financial Accounting: Purchasing and FI maintains data on the VENDOR master data (is a creditor account in FI) that contains account.+ procur. info
Consumption Raw Stock Raw Bank GR / IR Vendor Vendor (SD) Sales and Distribution: requirements that arrives to Sales can be passed on to Purchasing. when a P.Req. is created, it can be directly assigned to a Sales Order.
300 3300 3300 3300 3300 3300 3300 3300 Production Planning: and MM are linked through inventory needs. Inv. Mgt is responsible for assuring all components required for production.
3000
Plant Maintenance and MM are linked by BOM. It’s possible to post a GR with ref to an equipment BOM and to withdraw part for maintenance orders too.
1 1 3 2 1 3 2 3 2 Integration in Logistics: the Inv. Mgt system (manages Stock (Q) quantity + ($) value) can be extended by the WMS which manages storage (also Storage Bins)
Invoice Verification and Vendor Payment
Account Posting If there are variances between the PO or GR vs INVOICE, the system warns the user and blocks the invoice for payment.
Posting the invoice completes the process of Invoice Verification.
Good Receipt : Debit Stock, Credit GR/IR
Cost Invoice Receipt: Debit GR/IR, Credit Vendor (Recon.+Subledger) (=> acc. payable) Logistics: Invoice Verification: Effects
element Pay Vendor: Debit Vendor (Recon.+Subledger), Credit Bank/Cash Types of Invoice Verification: FI - Accounting document is created
Invoice items can be posted with reference to: PO History is updated
Goods receipt based Invoice verification: invoices for quantities greater Open Item is created in the vendor’s account
than the goods receipt cannot be posted. If invoice $ differs from the PO $, the stock value and the current moving price is
Info Conditio Purchase order based Invoice verification: you can settle all items, recalculated and updated in the material master, for a material valuated with mov. aver. $.
Vendor Material Output _ Account affected:
record n irrespective of whether there have been partial deliveries.
The postings are automatically made to the corresponding G/L accounts. .Provision in the GR/IR clearing account are reversed - debited
Account Condition Output When an Invoice is posted, an open item is credited on the vendor account. .Reconc. Vendor is credited Account payable
Material type .Subledger Vendor is credited
group Industry sector types types
. NON Stock raw-consum. raw, Bank
Other Dpt (account) manage the payment and evaluation of invoices.
Therefore, Inv. Verif. creates a link between Mat. Mgt and external (FI) or Internal account. (CO)
Material Mgt, manages the procurement process until Invoice verif.
Is an Internal document
Manually by the Source of
Dep. Respons. Purchase supply Purchase Invoice/
Pay
Automatically Requisition order Billing
Info record with / without
by MRP Quotation reference Org. level needed for a PO
Contract Plant
10
Source list Purch. Org. MM FI FI
20 Vendor 2 3
10 Stock item
Header Data:
Storage loc not nec. until good
Doc Doc Doc
Doc. #
Item: are not received.
Date
20 Non-stock item Vendor Material # Vendor (Recon.+Subledger) are debited,
Terms of payment Delivery date Bank/Cash is credited
Item Category Currency Q, $, Text
Movement type: determines the kind of goods movements. What happens to
Consumable Material: Item category: defines the process used to procure a material
Goods Receipt the items, how they are handled…key to differentiate between goods
Are materials or services that are procured specifically for an account or service. movements (ex: GR, GI or transfer postings). (Inv. Mgt)
assignment object. (EX: office supplies; computer systems) Determines which stock or consumption accounts are updated (posted) in
Value is recorded in the cost element or asset accounts. S – Standard: material procured externally Financial Accounting.
S – Stock transport order: mat. is transf. from 1 plant to another 103 you enter goods receipt against Determines the structure of the screen when entering documents and updating
When a material is procured directly for consumption, no material master
S – Subcontracting: vendor manufacture a component production and purchase orders 101 quantity fields.
record is necessary. C – Consignment: Liability only when mat. is withdrawn from
In the case of consumable material with a master record: consg. stock, no when the stock is placed in the consg. store
o Not subject to inventory management (on either quantity or value basis) T – Third-party order: material order from a vendor with the
Storage location
o Subject to inventory management on a quantity, but not a value basis instruction to deliver the goods directly to a 3er party (customer)
F - Unrestricted Documents generated
Goods
Posting a Goods Receipt by referencing to a Purchase Order has a 3 advantages: receipt 105 Q – Quality Insp. MM FI CO
Account Assign. Objects 1
The goods receiving department can check whether the goods delivered are what was actually ordered.
MM area Doc Doc Doc
A – Asset Data from PO is copied automatically to the GR transaction. X – Blocked Stock
C – Cost Center PO history is updated upon GR creation. Doc
P – Project Stock type
P – Prod. Order When goods receipt to the warehouse is posted: Effects of Goods Receipt: Process of GR with Transfer Order
S – Sales Order A MM doc. is created: with info such as material delivered MM - Material document is created (quantity) GR posting is subject to WMS: checks for each PO item and
and quantity delivered; storage location and associated plant.
FI - Accounting document is created (value) generates:
An FI doc. is created: which record the effects the material
movement has on the value of the stock. CO – Cost Accounting document cost analysis purpose MM + FI docs for goods movt.:
Material master is updated (here not in the inv. verif) _MM doc.: Header + Item (q, descrip, stor.loc., plant), is
Goods movements: A transaction that causes a stock change. Include both external and internal identified by material document number and year.
movements. You can distinguish between: _ Account affected:
_FI doc.: Header + Item (G/L acc. #, $) records the effects of
Goods receipt (GR): is a goods movement in which the receipt of goods from both an external vendor .Stock raw (+ Consumption Raw) is debited material movements on the accounts. Is identified by CC (of the
and from production is posted. A GR leads to an increase of warehouse stock. .Provision in the GR/IR is credited plant); acc doc. #, fiscal year.
Goods issue (GI): is a goods movement in which a material withdrawal, goods issue, material . NON Bank, Reconc. Vendor, Subdledger Vendor Transfer requirement doc
PO History for a PO items is updated (when a GR is Incoming quantity of materials into the goods receiving area
consumption, or goods shipment is posted to a customer. A GI leads to a decrease of warehouse stock. An Interim storage area in the receiving warehouse number
entered with reference to this item)
Stock trasfer: is removal of materials from particular storage location and placement into another A transfer order is used to move the items from the receiving
storage location. Stock transfers can take place both within the same plant and between two plants. Quality Management (Inspection lot is created)
area
Transer posting: changes the stock identification or qualification of a material regardless of it’s a Warehouse Management (Transfer Requir. is created) (in a put away process) the destination storage type, the storage
physical movement or not. (EX: release of the stock for quality inspection). Output may be generated (GR slip) section, storage bin are determined
www.sap-terp10.com.ar
SALES ORDER MANAGEMENT ORDER TO CASH PROCESS
Pre-sales activities -> Sales order processing -> Inventory sourcing -> Shipping-> Billing ->Payment receipt
and posting
Info
Customer Picking: Inventory Customer
record You create transfer order for an outbound delivery Bank Revenue Customer Receiv/
Change Inventory/Stock Sub-Ledger
Creating a transfer order includes copying data A transfer order is generated for a warehouse number. The Reconciliation
from the delivery document to the transfer order system copies the relevant data from the delivery.
for processing within the warehouse. The 4000 4000 10000 10000 10000 10000 10000 10000
transfer order is essential for controlling the Picking in shipping processing:
movement of goods within the warehouse. You can control an item in an outbound delivery so that
Material Condition Output picking is required. 1 1 3 2 2 3 2 3
The transfer order is based on a simple principle:
where you are taking goods from and to, within Picking is carried out by creating transfer requests with Auto
your warehouse. There is a source location and a which you trigger and survey warehouse movements.
Material type Condition Output destination location for every transfer order. Packing:
Industry sector types types When packing you can combine delivery items and pack
them in different shipping units.
Documents generated
Pre sales activities: establishing and maintaining Sales order processing: Warehouse CO-
customer relationships MM FI CO MM FI FI
Contains all info.(Inquiries and quotations PA
Creating and tracking customer contacts docs) to process the customer’s request Doc Doc Doc Doc Doc Doc
Mailing campaigns Confirm Transfer Order Doc
during sales order processing. Sales process
Answering customer ques. received by email, fax etc data from master records. Pick Pick Quantity
Inquiries 1 quotation can = multiple sales orders. 1 2 3
Quantity TO Transfer Request
Quotations Multiple quotation can = 1 sales orders.
Document flow in the SAP system: docs in sales process Sales and distribution integration: Customer credit account is updated
are linked to each other using the doc. flow. Integrates with Materials Management for availability checking Status in all related sales, delivery and billing documents, is updated
This let you access the history and current status of Integrates with Production Planning for make to order product Sales statistics in the SIS are updated
your sales process at any time Integrate with Project Systems for delivery and billing processing _ Account affected:
1.Standard order Integrate with Warehouse Management module, where the product is picked and print shipping document Customer Receivables account is debited Open item posted on
2.Delivery Integrate with Materials Management, Financial Accounting and Controlling when posting a goods issue Customer Subledger account is debited cust.’s account
3.WMS transfer order Integrates with Profitability Analysis for sales order Revenue account is credited
4.GI- goods issue Integrates with Sales Information System Further documents for accounting can be automatically generated by
5.Invoice the system, for example:
6.Accounting document For the components controlling (CO) accounting
Profitability analysis (CO-PA) posted
Market segment analysis (CO-PA)
Consolidation (FI-LC)
MATERIAL MANUFACTURI INVENTORY AND ENTERPRISE ASSEST
PROCUREMENT SALES ORDER FI CO HR MANAGEMENT
PLANNING NG EXECUTION WAREHOUSE MGT MGT/CUST. SERVICE
Client Client Client Client CC Controlling Area Client Client Client
Credit Control
Storage Plant Business Area
Area
Storage Location Location Storage Location Plant Maintenance Plant Personnel Area Default values
Location-
Plant Based
Purch. Org. Storage Location Shipping Point Location Selection for reporting
Maintenance Work Enterprise
Purch. Org.
Purch. Group Shipping Point Storage Location Center Authoriz. Checks
Maintenance Wage structures, Work
Sales Org.
Warehouse Number Planning- Planning Plant schedules
Based Maintenance
Planner Groups Country groupings
Personnel Subarea Legal person
Time management
ORG. LEVELS Payscales