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H10: Sales & Operations Planning (SOP), Long Term Planning and Capacity Evaluation
Business Process Procedure
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Copyright
Copyright 2006 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors. Microsoft, Windows, Outlook, and PowerPoint are registered trademarks of Microsoft Corporation. IBM, DB2, DB2 Universal Database, OS/2, Parallel Sysplex, MVS/ESA, AIX, S/390, AS/400, OS/390, OS/400, iSeries, pSeries, xSeries, zSeries, z/OS, AFP, Intelligent Miner, WebSphere, Netfinity, Tivoli, Informix, i5/OS, POWER, POWER5, OpenPower and PowerPC are trademarks or registered trademarks of IBM Corporation. Adobe, the Adobe logo, Acrobat, PostScript, and Reader are either trademarks or registered trademarks of Adobe Systems Incorporated in the United States and/or other countries. Oracle is a registered trademark of Oracle Corporation. UNIX, X/Open, OSF/1, and Motif are registered trademarks of the Open Group. Citrix, ICA, Program Neighborhood, MetaFrame, WinFrame, VideoFrame, and MultiWin are trademarks or registered trademarks of Citrix Systems, Inc. HTML, XML, XHTML and W3C are trademarks or registered trademarks of W3C, World Wide Web Consortium, Massachusetts Institute of Technology. Java is a registered trademark of Sun Microsystems, Inc. JavaScript is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape. MaxDB is a trademark of MySQL AB, Sweden. SAP, R/3, mySAP, mySAP.com, xApps, xApp, SAP NetWeaver, and other SAP products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other product and service names mentioned are the trademarks of their respective companies. Data contained in this document serves informational purposes only. National product specifications may vary. These materials are subject to change without notice. These materials are provided by SAP AG and its affiliated companies ("SAP Group") for informational purposes only, without representation or warranty of any kind, and SAP Group shall not be liable for errors or omissions with respect to the materials. The only warranties for SAP Group products and services are those that are set forth in the express warranty statements accompanying such products and services, if any. Nothing herein should be construed as constituting an additional warranty.
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Icons
Icon Meaning Caution Example Note Recommendation Syntax
Typographic Conventions
Type Style Description Example text Example text Words or characters that appear on the screen. These include field names, screen titles, pushbuttons as well as menu names, paths and options. Cross-references to other documentation. Emphasized words or phrases in body text, titles of graphics and tables.
EXAMPLE Names of elements in the system. These include report names, program names, TEXT transaction codes, table names, and individual key words of a programming language, when surrounded by body text, for example, SELECT and INCLUDE. Example text Screen output. This includes file and directory names and their paths, messages, source code, names of variables and parameters as well as names of installation, upgrade and database tools.
EXAMPLE Keys on the keyboard, for example, function keys (such as F2) or the ENTER TEXT key. Example text <Example text> Exact user entry. These are words or characters that you enter in the system exactly as they appear in the documentation. Variable user entry. Pointed brackets indicate that you replace these words and characters with appropriate entries.
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Contents
1 Sales & Operations Planning (SOP), Long Term Planning and Capacity Evaluation..........................6 1.1 Process Flow..............................................................................................................................6 1.2 Organizational and Master Data..................................................................................................7 1.3 Preliminary Steps........................................................................................................................8 2 Business Process Procedure.............................................................................................................9 2.1 Defining Product Group...............................................................................................................9 2.2 Creating Sales Quotation for Product Group...............................................................................9 2.3 Disaggregating Product Group (only for MTO Process).............................................................10 2.4 Transferring Production Plan to Demand Planning ...................................................................11 2.5 Long Term Planning..................................................................................................................13 2.6 Evaluating MRP .......................................................................................................................15 2.7 Evaluating Capacity .................................................................................................................16 2.8 Transferring Checked Demand Planning Version to Operative Environment.............................19 2.9 Starting MRP Run (Operative)...................................................................................................20 2.10 Evaluating MRP (Operative)....................................................................................................22 2.11 Capacity Evaluation and Leveling (Operative).........................................................................22
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Sales & Operations Planning (SOP), Long Term Planning and Capacity Evaluation
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(Note for the figure above: The number of the product groups changed from 0000XXXX to P000XXXX) To run the MTO process, create product group P00020002 according to the diagram above.
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SAP Best Practices Field name Materials Planning scenario Work centers Value H10-4000
H10: SOP, Long Term Planning and Capacity Evaluation Description Materials for MTO Planning scenarios for MTS and MTO Work centers used for capacity evaluation
Procedure
For more information about uploading the evaluation role to the system and working with roles, see to the Essential Information building block.
1.3.2 Use
You assign an individual user parameter (CY- Capacity eval.: Scenarios with production order 'X'=on) This parameter controls whether the capacity requirements for production orders are displayed when evaluating the capacity situation.
Procedure
1. Access the transaction choosing one of the following navigation options: SAP Easy Access menu Transaction code Tools Administration User Maintenance Users SU01
2. Enter the User and choose Change 3. On tab-page Parameters make the following entry: Field name Parameter ID Description User action and values CYComment
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Procedure
1. Access the transaction choosing one of the following navigation options: SAP role menu Transaction code Field name Product group Plant 3. Confirm your entries with Enter. 4. On the Change Product Group: Maintain Members (Materials), make the following entries: Field name Proportion Description User action and values Set a proportion for each material (%) Comment (Or change the values according to your requirement) Description Change Product Groups MC86
2. On the Change Product Group: Initial Screen, make the following entries: User action and values P00010000100000001 BP01 Comment
Procedure
1. Access the transaction choosing one of the following navigation options: SAP role menu Transaction code Sales and Operations Planning MC81
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2. On the Create Plan: Initial Screen, make the following entries: Field name Product group Plant Description User action and values P00010000100000001 BP01 Comment
To run the MTO process, use product group P00020002. 3. Confirm your entries with Enter.
If this is the first time you create an SOP plan, the system automatically creates a version A00 as the active version. Every subsequent time you create an SOP plan, you are required to enter a version number. This is a technical prerequisite and does not prevent you from using several product groups in SOP. It is also possible to create several versions of one product group. Enter the version number and the version description. (Preferably use the product group name). 4. On the Create Rough-Cut Plan screen make the following entries: Field name Sales Description User action and values For example current month + 12 Comment Give a value of sales quotation like 100 for each month
5. From the menu, choose Edit Create production plan Synchronous to sales. The system fills the Production line automatically (you can make manual revisions if desired). 6. Choose Save.
Result
You have created the production plan for a product group. This plan is not used in any operative planning. You use this plan as a basis for simulative or operative demand planning.
Procedure
1. Access the transaction choosing one of the following navigation options: SAP role menu Transaction code Disaggregation: Planning MC76
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2. On the Change plan: initial screen make the following entries: Field name Product Group Plant 3. Choose Inactive version. 4. Choose the version you assigned to the SOP plan for this product structure. 5. On the Change Plan: Initial Screen dialog box, make the following entries: Field name Create sales plans 6. Confirm with Enter. 7. The system displays the rough cut plan displays and shows the three planning tables for the product groups P00020002, P00020000200000001, and P00020000200000002. 8. From the menu, choose Edit create production plan synchronous to sales. 9. The system creates the production quantities for both second level product groups. 10. Choose Save. Description User action and values Set mark Comment Description User action and values P00020002 BP01 Comment
Result
You have created the production plans for the second level product groups. You can now transfer disaggregate each second level product group to demand planning. The product group that is used for the next steps does not matter, as long as you use the same one.
Procedure
1. Access the transaction choosing one of the following navigation options: SAP menu Transaction code Field name Product Group Plant Version Version of SOP Plan Description Transfer PG to Demand Management MC75
2. On the Transfer Planning data to Demand management screen make the following entries: User action and values P00010000100000001 BP01 Enter the version set for the product group previously. (For example A00 or 001) Comment
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SAP Best Practices Prod. plan for mat. or PG members as proportion of PG From..to
You do not must enter anything here unless you do not want to transfer the whole period from SOP This determines whether you want to check (and possibly change) the result of disaggregation for each material. If you set the indicator, the result is saved in background. Deselect Deselect the indicator to look at the result. Later, when you have more data, it may be advisable to set the indicator. No entry necessary if it is certain that the materials have the correct settings. YH Do not set This would make the demand plan operative
Invisible transfer
Requirements type
Version Active
3. Confirm your entries with Enter. 4. Choose Transfer Now. 5. On the the Plnd int. reqmts: planning table screen, check the result and change if required. In our example product group P00010000100000001, material H10-1000 is displayed.
(This screen displays for each material that is a member of the product group.) 6. Choose Save. The next planning table for the next material displays. (In our example, material H10-2000.) 7. Check the result, change if required, and save again. 8. Repeat for all the members in the product group. In our example, there are only two members, so the system now returns to Transfer Planning Data to Demand Management. 9. To see the whole result of the product group once more, choose one of the following navigation options: SAP role menu Change Planned Indep. Requirements
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SAP Best Practices Transaction code Field name Product Group Plant Selected Version From..to The version of demand planning Description
H10: SOP, Long Term Planning and Capacity Evaluation MD62 User action and values Set the indicator and enter P00010000100000001 BP01 Set the indicator and enter YH Comment
10. On the Change Planned Independent Requirement: Initial Screen, make the following entries:
No value necessary except you dont want to see the whole period from demand planning
You do not have to enter anything here unless you do not want to transfer the whole period from SOP
12. Now you can see all members of the product group in the planning table. You can check these and make any required changes. Choose Save.
Result
The production planning data is now disaggregated and transferred to demand management. The planning table for each single material now contains the quantity resulting from the proportion (and any manual changes). These planning tables will only be used in long term planning for simulation.
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However, the capacity evaluation can use all operative planned orders without the risk that there are capacity requirements in simulation and operative environment based on the same demand. Scenario 002: By regarding operative sales orders and work orders, and copying firmed planned orders, you get the most detailed simulated situation possible. In this case you evaluate the capacity situation by using the operative data as well. You cannot consider operative planned orders in long term planning because they are either copied (firm planned orders) or long term planning creates its own planned orders that are also effective in the operative environment. This can potentially cause the problem that if there are any planned orders required by demand planning in the operative environment these are not taken into account by capacity evaluation.
Choose scenario 001 if the risk of relevant imbalance is insignificant (due to a low number of sales orders). It is however important to take into account all the operative planned orders (those required by operative demand planning (independent requirement planning) by capacity evaluation. Choose scenario 002 if an imbalance is not allowed (for example due to a large number of sales orders) and if it is unimportant if some capacity requirements are missing (if there are only a few or no planned orders relevant for demand planning in operative environment). The version YH (demand planning) is used automatically in both scenarios.
Procedure
1. Access the transaction choosing one of the following navigation options: SAP role menu Transaction code Field name Planning Scenario Material Plant Product group Processing key Create MRP list Planning mode Scheduling Include firm planned orders 3. Choose Enter twice. 4. If the Next Stopping Point dialog box displays, choose Continue. The MRP run starts. Long-term plng: single-itm, mult-lvl MS02 Description User action and values 001 or 002 P00010000100000001 BP01 Set mark NETCH 1 1 2 1 Important for getting capacity requirements Comment
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5. Once the MRP run is finished, a statistical list displays. There you can see information about the MRP run, for example how many materials are planned.
Result
The MRP run, within the long term planning environment, has created planned orders across the whole BOM structure. As a result the system created corresponding capacity requirements. You can now evaluate the planning situation in terms of materials and capacity.
2. On the Long-Term Planning: Stock/Requirements List: Initial Screen, make the following entries:
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H10: SOP, Long Term Planning and Capacity Evaluation BP01 SAPSOP Set indicator In the Compare with section
4. The system displays an aggregated view of the planning situation of the product group. To view more details of the MRP elements, select the relevant row (issues and/or receipts), and choose Expand Subtree. 5. To view the disaggregated view of each material, select the relevant MRP element and choose Product Group View.
Procedure
1. Access the transaction choosing one of the following navigation options: SAP menu Transaction code Capacity leveling L-T planning CM38
2. Select from the menu: Planning Profiles Overall profile scroll down to find the YHH10_PLAN and select it. 3. On the Capacity Planning: Selection screen, make the following entries: Field name Planning Scenario Long Term Pl Description User action and values 001 or 002 Comment Operator: Set <= if using 001 (So that the operative plant orders are also selected) If using 002 do not make any entry Work Center Capacity Planner Group Plant E1011 or E1013 No entry necessary BP01 To see a particular work center. To see all, do not enter anything.
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H10: SOP, Long Term Planning and Capacity Evaluation No entry necessary For example H10-1000 Entry only necessary if using more than one capacity category for each work center. To see all work centers used for a material, choose materials that are members of the product group, or any other material from the BOM.
4. Choose Standard overview, Detailed cap. list or Variable overview. You should choose Variable overview first. This displays the capacity requirements split by work orders, planned orders, operative and scenario related planned orders. 5. Double-click in the line of the period and the column for which you want to see details of the requirements. 6. Return to the selection list. 7. Choose Standard overview to view a list of the capacity requirements by work center. 8. This table displays an overview of the weekly periods condensed. 9. Select the period you want to see in detail and choose Cap. Details/period. The screen Capacity Planning: Standard Overview: Detail shows you which order is responsible for the requirement.
2.7.1 Use
Capacity Leveling
Capacity leveling lets you check individual work centers for overloads and, if necessary, dispatch planned orders at other times or with other quantities. If you are checking the demand planning of the year, it is not generally important to change single planned orders. Normally you would evaluate the capacity situation in greater scope, so if you identify problems (overload) in a period, you must either change the planning greatly, change the sales planning (SOP: product group quantity), or change the demand planning data of a single material. Regardless of this aspect you can change each order easily by branching directly to the order from the detail list. The evaluation of the capacity allows you to check how the capacity situation will be depending on the demand planning during the planning period. You can quickly identify if there is an overload situation. If there is an overload situation, you can identify the responsible requirement and change the demand planning or the SOP planning. You then must repeat the steps and check the new evaluation. Alternately, you can change the availability of the work center.
Procedure
1. Access the transaction choosing one of the following navigation options: SAP menu Transaction code Capacity leveling L-T planning CM38
2. From the menu bar, choose Planning Profiles Overall profile scroll down to find the YHH10_PLAN and select it.
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3. The screen Capacity Planning: Standard overview: Detail shows which order is responsible for the requirement.
To get a better overview of the planning situation of a material, open another session in parallel and access transaction MS04 (stock/reqmts list). In transaction MS04 you can easily change every MRP element (including the demand planning table) and start a new MRP run. You can also jump to MS04 in the same modus by choose from the menu bar Environment Stock/reqmts list. 4. Use one of the following options:
Option 1: Change single orders directly (enter MS04 in a separate session) To change one single order, select the relevant row and choose Order header. Alternately, double-click PeggedReqmt number. You branch to the order and can change it (time, quantity or both). If you change a planned order it will be fixed. If you are changing several planned orders you must later transfer them to the operative environment. If you only change the requirements, you must only copy the version of the demand planning table. The right planned orders will be created by the MRP run in the operative environment.
Option 2 (Recommended): Change demand planning table It is better to change the responsible requirement. To do this, open transaction MS04 in another session. Double-click the MRP element IndReq. You can now change the quantities and/or the periods of the demand planning. Save (you will automatically go back to MS04), and choose You can now see the changes to the demand planning. Refresh.
5. Execute a new MRP run to assimilate the planned orders and therefore the capacity requirement. To do this, choose Sng-item, multi-lvl on the Long Term Planning: Stock/Requirements List screen. 6. On the Long-Term Planning: single-item, Multi Level screen, make the following entries: Field name Planning scenario Material scope of planning plant Processing key Create MRP list Planning mode Description R/O/C R R R R R R R User action and values 001 or 002 Example H101000 BP01 BP01 NETCH 1 1 Comment
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H10: SOP, Long Term Planning and Capacity Evaluation R R 2 1 Refresh. The Important for getting capacity requirements
7. Go to the Capacity Planning: Overview screen (in the other session) and choose system displays the new capacity situation.
Result
You have leveled the capacity by changing single orders, the demand planning table, and/or changing the capacity availability. You have checked these changes by repeating the MRP run and evaluating the capacities again. You may have done this repeatedly until the situation is balanced.
Procedure
1. Access the transaction choosing one of the following navigation options: SAP role menu Transaction code Field name Plant Material Source version Target version Target version active History No database changes YH 00 Set indicator Set indicator Do not set indicator Set the indicator if you first only want to see the result list without creating a new version Description User action and values BP01 If you only want copy a particular material Copy Version MS64 Comment
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H10: SOP, Long Term Planning and Capacity Evaluation Set indicator Set indicator on detailed list You can check if all the data is copied
4. Choose Execute. The system displays the statistical result list. 5. Choose Back. 6. Check if the copy is correct. To view the result of the product group once more, access the activity using one of the following navigation options: SAP role menu Transaction code Field name Product Group Plant Selected Version Prod. plan for material or PG members as proportion of PG From..to No value necessary except you dont want to see the whole period from demand planning You do not have to enter anything here unless you do not want to transfer the whole period from SOP Description Display Planned Indep. Requirements MD63 User action and values Set indicator and enter P00010000100000001 BP01 Set indicator and enter 00 The operative and active version Comment
7. On the Change Planned independent requirement: initial screen, make the following entries:
Result
You have executed the copy of the version with database changes, and the system has created a new version (00) of all materials in the scenario (if you have not limited by selecting a special material). This new demand planned table is now active and integrated in the operative environment.
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2. On the Single-item, multi-level screen make the following entries: Field name Material Description User action and values P00010000100000001 or P00010000100000002 Plant Product group Processing key Create purchase req. Delivery schedules Create MRP list BP01 Set indicator NETCH 1 1 1 Comment
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H10: SOP, Long Term Planning and Capacity Evaluation 1 2 Important for getting capacity requirements
4. When the MRP run is finished, a statistical list displays with information about the MPR run (including, for example, how many materials are planned). 5. Choose Back.
Procedure
1. Access activity using one of the following navigation options (for evaluation each material ): SAP role menu Transaction code Current Material Overview MD07 To select the whole product group
To select a single material from the product group, use transaction MD04. 2. On the Stock/Requirements List: initial Screen, make following entries: Field name Plant Product group 3. Choose Enter. 4. The Stock/Requirements List: Material list is displayed (showing the members of the product group). 5. Select all the lines and double-click the first line. You branch to the single Stock/Requirements List of the material (as you would see if using transaction code MD04). Description User action and values Set indicator and enter BP01 Set indicator and enter P00010000100000001 or P00010000100000002 Comment
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Procedure
1. Access the activity using one of the following navigation options: SAP role menu Transaction code Cap. planning, work center load CM01
2. From the menu bar select Planning Profiles Overall profile and select YHH10_OPER. 3. On the Capacity Planning: Selection screen, make the following entries: Field name Work center Capacity Planner group Plant Capacity category Material For example H10-1000 BP01 You only need to make an entry here if you are using more than one capacity category each work center. To see all work centers used for a material, choose materials that are members of the product group, or any other material from the BOM. Description User action and values E1011 or E1013 Comment To see a particular work center. To see all work centers leave the field blank. No entry necessary
4. Choose Standard overview, Detailed cap. List or Variable overview. In the operative environment, you would normally want to display work centers, so choose Standard overview. The variable list only gives you information about how many capacity requirements depend on work orders or planned orders. 5. Double-click the line of period and the section of a work center for which you want to see details of the requirements. 6. In a separate session, access transaction MD04 and enter the material that is responsible for the capacity requirement you want to change. 7. Check that changing the order is ok (taking into account the whole planning situation of the material). 8. Return to the capacity detail screen and double-click the order you want to change. You branch to the order screen. 9. Make the required changes (for example, reduce the quantity) and save your changes. 10. Go back to the capacity detail screen. Choose Refresh to see the changes to the capacity list. 11. Return to the overview. You can now see the new capacity overview. 12. Return to the stock/requirement list and refresh it. You can see the result of the changing the MRP planning situation.
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