5.lectureMRP（英文版）1566.pptx

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1、Practical Exercise Enterprise Resource Planning using SAP R/35/10/20231Dipl.-Wirtsch.-Ing.Ferdinand BlmerMaterial Requirements Planning(MRP)in SAP R/35/10/20232Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScProduction planning-OverviewProduction planning-Overview5/10/20233Dipl.-Wirtsch.-Ing.Ferdinand BlmerMSc

2、Material Requirements PlanningMaterial Requirements PlanninglMain functions of material requirements Main functions of material requirements planning:planning:Guaranteeing the material availability Guaranteeing the material availability On-time procurement or production of the On-time procurement or

3、 production of the requirements byrequirements by monitoring the stocks,monitoring the stocks,creating of proposals for purchasing and production.creating of proposals for purchasing and production.lMRP tries to find the optimal way betweenMRP tries to find the optimal way between best-possible serv

4、ice level andbest-possible service level and minimization of costs and capital lockupminimization of costs and capital lockup5/10/20234Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScPosition of MRP in the Supply ChainPosition of MRP in the Supply Chain5/10/20235Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScItems of pr

5、oduction planningItems of production planninglSales&Operations PlanninglMaterial Requirements PlanningPrimary requirements planningPrimary requirements planningSecondary requirements planningSecondary requirements planninglProduction ControlRelease of purchasing ordersRelease of purchasing ordersRel

6、ease of production orders Release of production orders 5/10/20236Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScMRPMRPlOrganizational level MRP for a certain factory MRP for a certain factory Single planning for a material Single planning for a material lMRP procedureslLot-sizing procedures5/10/20237Dipl.-Wir

7、tsch.-Ing.Ferdinand BlmerMScMRP functionsMRP functionslThe following functions are provided:Total planning Total planning Single-item,single-level planning Single-item,single-level planning Multi-level,single-item planning Multi-level,single-item planning Interactive planning Interactive planning Mu

8、lti-level,make-to-order production Multi-level,make-to-order production Individual project planningIndividual project planning5/10/20238Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScTotal planningTotal planninglTotal planning covers the planning of all Total planning covers the planning of all the materials

9、that are relevant for the materials that are relevant for requirements planning and includes the requirements planning and includes the BOM explosion for materials with a BOM.BOM explosion for materials with a BOM.lYou can use total planning for a single You can use total planning for a single plant

10、 or you can use the scope of planning plant or you can use the scope of planning to control whether the total planning run is to control whether the total planning run is executed on a multi-plant level executed on a multi-plant level for several plants,for several plants,for one MRP area,for one MR

11、P area,for several MRP areas,or for several MRP areas,or for a combination of plants and MRP areas.for a combination of plants and MRP areas.5/10/20239Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScSingle-item,single-level planningSingle-item,single-level planninglSingle-item planning involves the planning of

12、 one only individual material.lSingle-level means that the BOM is not exploded and that,therefore,only the level directly below the material is planned.5/10/202310Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScSingle-item,multi-level planningSingle-item,multi-level planningl lIn single-item,multi-level planni

13、ng the BOM is In single-item,multi-level planning the BOM is exploded and dependent requirements are exploded and dependent requirements are generated for assemblies and components.generated for assemblies and components.l lTo cover the dependent requirements,these To cover the dependent requirement

14、s,these components are also ponents are also planned.l lIf the components also have BOMs,these are If the components also have BOMs,these are also exploded and the components are planned.also exploded and the components are planned.l lThis process is repeated until all levels of the This process is

15、repeated until all levels of the BOM are exploded and planned.BOM are exploded and planned.l lIf there are components in the BOM that are If there are components in the BOM that are procured by stock transfer or production in procured by stock transfer or production in another plant,then in single-i

16、tem,multi-level another plant,then in single-item,multi-level planning the other plant is used for further planning the other plant is used for further planning.planning.5/10/202311Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScInteractive planningInteractive planninglInteractive planning is a single-level si

17、mulative planning.lIt enables you to check the planning result particularly carefully and to carry out fine-tuning.lIt is particularly suitable for materials which need a throughout check,e.g.for master schedule items.5/10/202312Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScMulti-level,make-to-order producti

18、onMulti-level,make-to-order productionlWith multi-level,sales order planning you can plan a sales order item,for which the strategy make-to-order production is entered in the material master,over several production levels.5/10/202313Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScMRP procedures(1)MRP procedure

19、s(1)lMaterial Requirements PlanningMaterial Requirements PlanningIt is based on future sales quantities It is based on future sales quantities that exist in the form of planned that exist in the form of planned independent requirements,sales orders independent requirements,sales orders and material

20、reservations.and material reservations.lMaster Production SchedulingMaster Production SchedulingParts or products that greatly influence Parts or products that greatly influence company profits or which take up company profits or which take up critical resources are marked as master critical resourc

21、es are marked as master schedule items and are planned with schedule items and are planned with extra attention.extra attention.Master schedule items may be finished Master schedule items may be finished products,assemblies,or even raw products,assemblies,or even raw materials.materials.5/10/202314D

22、ipl.-Wirtsch.-Ing.Ferdinand BlmerMScMRP procedures(2)MRP procedures(2)lConsumption-Based PlanningConsumption-Based PlanningIt includes simple and easy-to-use It includes simple and easy-to-use procedures for materials planning procedures for materials planning which are used to achieve planned which

23、 are used to achieve planned targets with relative little effort.targets with relative little effort.In consumption-based procedures,In consumption-based procedures,historical data is used as a starting historical data is used as a starting point for planning.Future requirements point for planning.F

24、uture requirements are forecasted using the information are forecasted using the information from these past consumption values.from these past consumption values.mainly used in areas with no in-house mainly used in areas with no in-house production or for planning B and C production or for planning

25、 B and C parts.parts.5/10/202315Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScMaster Production SchedulingMaster Production SchedulinglDetermination of delivery dates and quantities for final products and product groups(primary requirements)lPrimary requirementsPlanned primary requirementsPlanned primary req

26、uirementsCustomer primary requirementsCustomer primary requirements5/10/202316Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScSources of planned primary Sources of planned primary requirementsrequirementsManual Manual inputinputSOP sales SOP sales planplanSOP SOP production production planplanMaterial Material

27、 forecastforecastImport another Import another planplanMPSMPSCritical parts planning/MRPCritical parts planning/MRP5/10/202317Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScSources of customer primary Sources of customer primary requirementsrequirementslCustomer primary requirements are created automatically

28、during creation of customer orders.lSAP R/3 sales module is not present manual input of data5/10/202318Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScLot-sizing proceduresLot-sizing procedureslStatic lot-sizing proceduresStatic lot-sizing procedureslPeriod lot-sizing proceduresPeriod lot-sizing procedureslOpt

29、imum lot-sizing proceduresOptimum lot-sizing procedures5/10/202319Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScStatic lot-sizing proceduresStatic lot-sizing proceduresThe lot size is calculated exclusively by means of the quantity specifications entered in the material master record.The lot size can be calc

30、ulated according to three different criteria:Lot for lot order quantityLot for lot order quantityFixed lot sizeFixed lot sizeReplenish up to maximum stock levelReplenish up to maximum stock level5/10/202320Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScPeriod lot-sizing procedures(1)Period lot-sizing procedur

31、es(1)lThe requirement quantities from one or The requirement quantities from one or several periods are grouped together to several periods are grouped together to form a lot.The SAP System supports form a lot.The SAP System supports various periods.various periods.lYou can determine the number of p

32、eriods You can determine the number of periods which are to be grouped together into a which are to be grouped together into a purchase order proposal.purchase order proposal.5/10/202321Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScPeriod lot-sizing procedures(2)Period lot-sizing procedures(2)lYou have the c

33、hoice of:You have the choice of:Daily lot sizeDaily lot size Weekly lot sizeWeekly lot size Monthly lot sizeMonthly lot size Lot size according to flexible period lengths Lot size according to flexible period lengths(based on accounting periods)(based on accounting periods)Lot size according to a pl

34、anning calendar Lot size according to a planning calendar(freely definable periods)(freely definable periods)5/10/202322Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScOptimum lot-sizing proceduresOptimum lot-sizing procedureslThe requirement quantities for several The requirement quantities for several period

35、s are grouped together to form a lot,periods are grouped together to form a lot,whereby an optimum cost ratio is whereby an optimum cost ratio is determined between lot size independent determined between lot size independent costs and storage costs.costs and storage costs.lThe only differences betw

36、een the various The only differences between the various optimization procedures are the cost optimization procedures are the cost criteria.criteria.lSAP supports the following procedures:SAP supports the following procedures:Part period balancingPart period balancing Least unit cost procedureLeast

37、unit cost procedure Dynamic lot size creationDynamic lot size creation Groff reorder procedure Groff reorder procedure 5/10/202323Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScHomework:Case studyMRP5/10/202324Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScCase study“IDES AG”(1)Case study“IDES AG”(1)lScenario The mater

38、ials requirement planning for the months July The materials requirement planning for the months July to December has to be executed for the office chair to December has to be executed for the office chair created in the SAP R/3 system.created in the SAP R/3 system.In addition,a merchandising scheme

39、was given by the In addition,a merchandising scheme was given by the management in the context of a market study for the management in the context of a market study for the next half year:next half year:5/10/202325Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScCase study“IDES AG”(2)Case study“IDES AG”(2)lSeco

40、ndary conditions Please use the material numbers for the Please use the material numbers for the finished office chair from the first case studyfinished office chair from the first case study5/10/202326Dipl.-Wirtsch.-Ing.Ferdinand BlmerMSclTasks Maintenance of the sales scheme of the office Maintena

41、nce of the sales scheme of the office chair.chair.Creation of a sales-synchronous production Creation of a sales-synchronous production plan(primary requirements).plan(primary requirements).Transfer of the primary requirements to the Transfer of the primary requirements to the demand planning.demand

42、 planning.Disaggregation of the monthly requirements to Disaggregation of the monthly requirements to daily requirementsdaily requirements Execution of the MRPExecution of the MRPCase study“IDES AG”(2)Case study“IDES AG”(2)5/10/202327Dipl.-Wirtsch.-Ing.Ferdinand BlmerMScPractical ExercisePractical Exercise5/10/202328Dipl.-Wirtsch.-Ing.Ferdinand BlmerMSc