Material requirements planning [rev]

Prerequisites

Planning concept
MRP areas

FAQ
185599 - Special procurement keys in MRP area

Planning process

BOM Explosion and Determining Dependent Requirements

Material classification for setting MRP parameters
MRP types
Lot Sizing Procedures ~ generate an order proposal with that optimal lot size
Rounding
Scrap calculation
Scheduling
Running Material Requirements Planning
Demand-driven replenishment
MRP on S4/HANA
FAQ

MD04: Use ( 24.09.2021 )
457110 - FAQ: Source determination in purchasing
1567876 - Planned order conversion: MRP relevance
634038 - MRP: Returns order and delivery
2980392 - OPPR: Reduced number of parameters maintainable for MRP groups in S4
23922 - MRP: Creation indicator, purchase requisition or planned order
1975704 - Evaluating the material masters for MRP live
2640949 - How Single Discontinuation Works
2659649 - How Parallel Discontinuation Works
944616 - planning Mode 2: Some/All components lost in BOM Explosion
2047547 - MD04, MD05: Dependent requirement without planned order
819617 - MD04: Inspection lots not displayed for handling units
Rescheduling (04.10.2021)
How to check possible causes if MRP does not create any proposals (04.10.2021)
Automatic assignment of Storage Location MRP Area to Material Master (05.11.2021)

Prerequisites

Planning file entry concept

The planning run and the scope of the planning run (which materials are planned in which planning run) are controlled by the planning file. Entry in the planning file is deleted (checkbox is reset) immediately after MRP run. Entry in the planning file is again activated when there is a change to material with respect to MRP.

It is not possible to create an overview over all actions in which the planning flag is set as this concerns far more than 50 actions, the list would become constantly larger and some calls occur only dynamically.
If you do not change either quantities nor dates or storage locations during the conversion of a planned order into a production order, the situation did not change for the materials planning and no planning flag is set.

Create a planning file for a material ( Transaction MD20 )

Net change planning (NETCH): Determines that the material is taken into account in the net change planning run.
Plng file entry NETPL: Means that the material is taken into account in the short-term planning horizon during the next net change planning run.
Reset ord. proposals: Controls that existing procurement proposals (planned orders, purchase order requisitions and schedule lines) from the last planning run are deleted and recreated.
Re-explode BOM: Controls the re-explosion of BOMs for existing procurement proposals (planned orders, purchase requisitions, delivery schedules) that came from the last planning run.
Planning date: Date for planning.

MDAB - Mass change in the planning file

MRP evaluation

Stock Requirement List: It is a dynamic list, which shows the current status of requirements & sources for that material. So any changes in the procurements or needs will be shown in this list.
MRP List: It is a static list, which shows the status of requirements & sources just after the MRP run. This list is not updated till the next MRP run.

Common questions

Planning file entries are not created automatically for MRP area

The requirement class of the sales order has MRP indicator (NODIS) 1 or 2 - No relevant to MRP.
To determine the storage location, use user exit USEREXIT_SOURCE_DETERMINATION (MV45AFZB). If the storage location is filled here, the system can fill the MRP area correctly, that is, depending on the storage location.

MRP area

185599 - Special procurement keys in MRP area

MRP areas are activated at client level.
Materials are assigned to storage location MRP areas.
A special procurement key "Phantom assembly"
or "Withdrawal from an alternative plant" is maintained
in the plant material master segment.
A special procurement key is maintained in
the MRP area segment of the material master.

Reason:

For special procurement keys that are entered in the MRP area segment, material requirements planning for the MRP area takes into account only the settings that refer to an actual special procurement, such as stock transfer or subcontracting.
Special procurement keys with settings that refer to the control of the BOM explosion, such as "Phantom assembly", are not taken into account if they are entered in the MRP area segment. In material requirements planning, these special procurement keys are used only from the plant material master.
However, the system does not issue an error message.

FAQ

1. Does the material requirements planning support stock transfers between MRP areas?

Answer: It supports the stock transfer from plant MRP area to storage location MRP area or subcontractor MRP area via stock transfer reservation or stock transfer requisitions by default.

Additional information especially for S/4HANA: The planning for separately planned storage locations or storage locations that are excluded from materials planning is no longer supported. Instead, in the planning at storage location level S4/HANA is supported only in connection with MRP areas. More detailed information is available in SAP Note 2227579.

2. Can I assign my factory calendar to an MRP area?

Answer: No, the factory calendar can only be assigned to the plant.

3. Can I use the make-to-order production or engineer-to-order planning strategies in MRP areas?

Answer:

The strategies of the make-to-order planning can be used only in the plant MRP area. Therefore, individual customer segments are always in the plant MRP area even if a storage location that refers to a storage location MRP area is assigned in the sales order. You cannot plan individual customer segments in the MRP area.

As of SAP Enhancement Package 3 for SAP ERP 6.0, you can use the business function OPS_PS_CI_1 in the project system to achieve a work breakdown structure (WBS) account assignment on MRP area level. Restriction: Note that to procure project account-assigned requirements from MRP, you can only create purchase requisitions or stock transfer requisitions. For technical reasons, you cannot use stock transfer reservations for the procurement.

4. Can I delete a material assignment for the MRP area again?

Answer: Yes, for this you must set the deletion flag in the overview screen of the material master assignments for the corresponding MRP area (transaction MM02). To reorganize materials in MRP areas (among others, the physical deletion of material master segments for MRP areas) a report can be provided on request (Note 545444).

5. Can I maintain my own goods receipt processing time in the MRP area material?

Answer: No, the goods receipt processing time can only be maintained at plant level.

6. Can I deactivate the planning with MRP areas?

Answer: No, the material requirements planning with MRP areas cannot be undone.

7. Can I use the quota arrangement in MRP areas?

Answer: A quota arrangement in the storage location or subcontractor MRP area is not possible. However, quota arrangements are supported in the plant MRP area.

The above restriction is due to the fact that the quota arrangement master data can only be defined at plant level. A quota arrangement at storage location or SC MRP area level would update the quota quantities at plant level. This would lead to incomprehensible results for the procurement proposals (quota quantity at plant level affects the quota arrangement calculation at storage location or SC MRP area level).

In principle, you can also use the MRP areas function if you were using the quota arrangement up to now (before activating the MRP areas). When you use the function with MRP areas, bear in mind that a quota arrangement can only occur in the plant MRP area.

If you must use quota arrangements in the storage location or SC MRP area, Development Support may provide a modification proposal on request. However, before implementing such a modification, you must consider the conflicts and side effects concerning the quota quantities that are not updated separately for the different MRP areas.

8. Does the system write change documents for the MRP area data when changes are carried out in the material master?

Answer:

As of Release 4.6A, the system logs these changes in the same way as changes to the material master itself.

9. The maintenance of the MRP area data is integrated in the material master. Are the Customizing options of the material master also relevant for the MRP area?

Answer: No, the following options are not implemented:

Field attribute control using the field selection (transaction OMSR). In Customizing (SPRO) under Logistics General -> Material Master -> Field Selection.

View selection per material type as set in the material type attributes (transaction OMS2).

Planning process

BOM Explosion and Determining Dependent Requirements

The BOM is exploded and the dependent requirements are determined within MRP during the planning run, after the system has performed the procurement quantity calculation, lot-size calculation and scheduling.

Prerequisites

You have created a BOM that has a valid period and area (see Period/Area of Validity of BOMs ).
The BOM status is set to active for MRP (see BOM Status ).
The BOM components are relevant for production (see BOM Items Relevant for Production ).
You have maintained a selection ID for the priority of the BOM in Customizing for Bills of Material, in the IMG activity Define order of priority for BOM usages .

Process Flow

The system determines the valid BOM that is to be used for the explosion and for determining the dependent requirements.
Alternative items and discontinued parts are taken into account within the valid BOM=
Special cases:

If you work with variant configuration and you have created a super BOM for the standard product, the system plans the components of the configurable product when the BOM is exploded in the planning run
Phantom assemblies are also taken into account when the BOM is exploded
You can define for products with a high number of components that total requirements are to be generated when determining the dependent requirements. You can thus improve system performance during the planning run

The system determines the date for the dependent requirements on which the components are to be available for the production .
The system can determine the issue storage location for the components when the BOM is exploded. The system then displays this issue storage location in the component list for the planned order .
Direct procurement and direct production of components are also triggered in the BOM explosion of the planning run .
If necessary, existing revision levels are taken into account in the BOM explosion

Determining the Valid BOM

Process Flow

The system checks which BOM usage in the plant has the highest priority
For this usage, the system then checks whether there is a valid BOM for the explosion date. The explosion date is the planned start date of the planned order.
If, for a particular production unit, you want to ensure that the total BOM structure is always exploded using the same explosion date and have assigned a BOM explosion number and fixed key date to the sales order, the planned independent requirement, or the planned order, the system chooses the BOM that is valid for this date (Fixed Key Date) .
The system checks, whether the chosen BOM has the status active for MRP .
If a multiple BOM exists, the system checks which alternative BOM corresponds to the preconditions of the alternative selection .

Determining the Valid BOM Items

Process Flow

When the valid BOM is determined, the system checks the items to see if they require the creation of secondary requirements:
If you have maintained alternative items, the dependent requirements of the alternatives are calculated according to the usage probabilities
The system checks whether a BOM item is a discontinued material and, if necessary, diverts the requirements to a follow-up material
In the planning run, dependent requirements are only created for BOM items that are relevant for production . The system copies only these items to the planned order (
For variant configuration, the BOM that corresponds to the configuration of the sales order is exploded. Thus, the system only plans those components that are to be used in production as specified by the configuration from the super BOM
If a BOM item is a phantom assembly , the dependent requirements of the higher-level assembly are directly passed on to the components of the phantom assembly. The phantom assembly itself is still not taken into account

The task of MRP when discontinuing parts is to reassign the dependent requirements for the component to be discontinued to the follow-up material , once the stock of the part to be discontinued has completely been used up.

The system differentiates whether

exactly one material is to be replaced by one follow-up material ( simple discontinuation ), or
a group of materials is to be replaced by another group of materials ( parallel discontinuation ).

During the planning run, the system checks the discontinuation indicator and the effective-out date in the material master and reassigns the materials correspondingly. The system reassigns the requirements during the planning run for the discontinued material and not during the BOM explosion. The system reassigns only dependent requirements and dependent reservations.

If a BOM item is a phantom assembly , the dependent requirements of the higher-level assembly are directly passed on to the components of the phantom assembly . The phantom assembly itself is still not taken into account.

Calculating the Dependent Requirements Date

As the components and the assemblies are needed for the production of a higher-level planned order, they must be available by the order start date of this higher-level planned order.

If no lead-time offset has been maintained, the system uses the order start date for the source planned order as the dependent requirements date for the components.

Storage Location Determination in BOM Explosion ( PP )

In order for the system to find the issue storage location for components in a BOM explosion in MRP or in a backflush in repetitive manufacturing, you can make the appropriate settings according to the assignment of storage locations in the plant.

Prerequisites:

In the BOM for the assembly or for the finished product, you have defined the production storage location for the component in the BOM item.
If you have not defined a production storage location in the BOM item, you can define in Customizing for MRP or in Customizing for Repetitive Manufacturing which strategy the system is to use to find the issue storage location and from which location the components are to be withdrawn in the BOM explosion. You do this in the IMG activity Define stor.loc./supply area determination for BOM explosion

#1 Production Storage Location in the BOM Item

If you have defined a production storage location in the BOM item for the withdrawal of the components, the system finds it during the BOM explosion and adopts it in the planning run. You can check it in the component overview for the planned order.

#2 No Customizing Strategy, No Production Storage Location in the BOM Item

If you have not entered a production storage location in the BOM item nor defined a strategy in Customizing, the system checks whether the production storage location has been maintained in the material master for the component and uses it as the issue storage location in the BOM explosion.

#3 Customizing Strategy, No Production Storage Location in the BOM Item

If you have determined a strategy in Customizing and if no storage location has been defined, the system reads the MRP group for the assembly and determines the strategy for the storage location determination. The following strategies are available:

If you set indicator 1 Only components (or no indicator) in Customizing, the system checks to see whether the production storage location has been maintained in the material master of the components and uses this as the issue storage location.
If you set indicator 2 Only assembly , the system checks to see whether the proposal issue storage location has been maintained in the production version of the assembly or finished product. If this has been maintained, the system uses this issue storage location for all components of the BOM for the assembly or finished product.

SPRO --> Production --> Repetitive Manufacturing --> Cross-Process Settings --> Define Storage Location and Supply Area Determination in BOM Explosion

If no proposal issue storage location has been maintained, the system adopts the receiving storage location of the assembly or finished product. The system then uses the receiving storage location as the issue storage location for the components.

FAQ

How to debug MD04?

The stock/requirements list (transaction MD04) displays all the MRP relevant documents and is builded with information from many different tables, belonging to different application areas (PP, MM, SD, QM, etc).

The starting point to analyze MD04 in debug is function module AUFBAUEN_MDPSX_ANZEIGEN. Here, all the customizing, master data and planning elements are read from the database, therefore, we should set a break point o the beginning of this function module.

Initially, system reads the material master settings and MRP customizing (both methods of BAdI MD_MRP_PARAMETERS are called here).

After that, for each kind of planning element there is an specific SELECT form, like SELECT_PLAF, SELECT VBBE, etc…

When a record is found on the database, a PRUEFEN form (PRUEFEN_PLAF, PRUEFEN_VBBE, PRUEFEN_RESB…) is called to validate, check and adjust the record. If this record is relevant to MRP, it will be inserted into the internal table MDPSX at the end of the PRUEFEN form. BAdI MD_CHANGE_MRP data is also called here, to make a possible adjustment of this planning element.

After all the SELECT forms, there is the code related to forecast, sorting and PIR consumption. Note that BAdI MD_ADD_ELEMENTS is called here.

At the end of this function module, MDPSX will contain all the MRP elements that will be displayed on MD04.

Besides AUFBAUEN_MDPSX_ANZEIGEN, the following function modules may also be useful:

MD_GET_KUND: Read customer information for sales orders;
MD_GET_LIEF – Read vendor information;
MDEZX_AUFBAUEN – Build the MRP elements texts, as they are displayed on the screen;
MDSUX_AUFBAUEN – Build the MD04 period totals;

S4 /

Besides those changes, the code logic behind MD04 is still the same: The same function module AUFBAUEN_MDPSX_ANZEIGEN is called to read the planning elements from the database and the planning elements relevant for MRP will fill the internal table MDPSX.

The difference starts within the function module AUFBAEN_MDPSX_ANZEIGEN. Here, there is a new piece of code that checks if the system should use the classic logic or if should trigger the new selection built specifically for the HANA database.

When the new logic is selected, method GET_MAT_WERKS_S4H of class CL_PPH_MDPSX_SELECTION will be triggered, and here is where the magic will happen. Firstly, method EXECUTE_PROCEDURES_S4H will be executed, where the whole database selection will be triggered.

EXECUTE_PROCEDURE_S4H (CL_PPH_HANA_ACCESS); Class CL_PPH_READ_CLASSIC.

This data selection logic happens in HANA and we would have to access HANA Studio to be able to debug this step, so we cannot see the actual selection in the ABAP debugger. We can see, however, that the database selection results will be stored in the internal table LT_MDPS, so if there if a planning element is already missing here, it means it was not selected from the database and the problem is most likely related to the database selection in the HANA stored procedure.

1825187 - MD04/MD05: Incorrect quantity for an MRP element

The available quantity for a planning element is empty in the stock-requirements list (transaction MD04) or in the MRP List (transaction MD05).

Open transaction MD04 or MD05 for a material and check that the available quantity is empty, as shown in the screenshot below.

Cause

The available quantity may not be affected by planning elements in the following situations:

A purchase order or stock transfer order has stock type blocked.
A purchase order or purchase requisition for a value-updated material has an account assignment.
A planned independent requirement is within the period of adjustment.
Material has a forecast-based MRP type (such as MRP type VV).
You have an active implementation of BAdI MD_CHANGE_MRP_DATA.
Dependent requirements are defined as not relevant to MRP on the material master.
The sales order requirement class/type is not relevant to MRP.

Resolution

A purchase order with stock type blocked will only affect the available quantity if the blocked stock is defined as available for planning. You can find this setting on the customizing transaction OPPI.
A purchase order or requisition with an account assignment for a value-updated material should not affect the available quantity. The value update customizing for the material type can be found on transaction OMS2.
A PIR within the period of adjustment should not generate any replenishment proposal and it is displayed only for information purposes. You can change the period of adjustment in the customizing transaction OMPG.
For a material planned using forecast-based planning, MRP only considers the forecast requirements. Other requirements are displayed but do not influence the available quantity. You should use a different MRP type if other requirements should be considered.
With BAdI MD_CHANGE_MRP_DATA is possible to define if a planning element will affect the available quantity or not. If you have an active implementation of this BAdI, check your custom code accordingly.
On the material master tab MRP 4 you can find the field MRP relevancy for dependent requirements (MARC-AHDIS). If this field is set to 1, dependent requirements will not affect the available quantity.
Check the setting defined for the field NO MRP for the sales order requirement class/type customizing on transaction OVZG.

The MRP user exit M61X0001 implemented to exclude certain materials in MRP

Please go to transaction SMOD or CMOD to check if the user exit is implemented.

Some BADIs are implemented to exclude the MRP requirements

The BADI MD_CHANGE_MRP_DATA contains many methods that can change or exclude the data read for net requirements calculation, e.g. the reservation, dependent requirements, planned independent requirements etc. Please go to transaction SE18, input the BADI MD_CHANGE_MRP_DATA into the field 'BADI Name', and click 'Display', go to menu 'Implementation' > 'Overview' to check if there are your own implementations, if yes, double click that to check the source code of relevant methods.

Sales documents are not considered in MRP

In the example above, sales order 14144 is displayed but is not considered in MRP (No quantity is reflected in column 'Available Qty'.

It happens because the field 'No MRP' has value 1 'Requirement not planned, but displayed' in customization transaction OVZG as above for the required class of the sales document.
If that is blank, the sales document can be planned by MRP. If that has value 2, the sales document doesn't appear in transaction MD04.
To get the required class of sales document, check the requirement type in field BEDAE of table VBAP, go to customization transaction OVZH as following to find the requirement class by requirement type.

Then, the class, e.g. 030 in this example, can be checked in transaction OVZG.

In addition, the sales order is not considered in MRP if the schedule line category which doesn't allow MRP is set in the order even though field 'No MRP' is set to consider it in transaction OVZG for requirement class. In screen shot below, CP is the one allows MRP, CN doesn't.

The dependent requirements are not considered in MRP

There is dependent requirements (Order Reservations in this case) with quantity 100 in the screen below, but no proposal is created.

After checking, it is turned out that the value 1 'Materials for dependent requirements are not planned' in the field 'MRP dep.requirements' of MRP 4 view of the material master as below.

Resetting the field can create the proposals by MRP.

No proposals are created for the requirement of PIR (Planned independent requirement)

The PIR exists as below in MD04, but proposals, e.g. planned orders, are not created after running MRP.

In this case, please check if the MRP group is maintained for the material, if yes, then go to the customization below to check if the PIRs lie in the period of Adjustment.
SPRO > Production > Production Planning > Demand Management > Planned Independnet Requirements > Maintain consumption mode and period of adjustment.
Double click the line for the plant and MRP group, the screen below is displayed.

The 'Adjustment: Planned Ind. Reqmts' value 1 means that the period is calculated forward from today, and the field 'Adjustment Period: PIRs' is the period by working days.
E.g. Today is 29.09.2011, plus 7 working days forward it goes to 10.10.2011. Since the PIRs lie before this date they are not included in the MRP calculation and no proposals can be created for them.

There is a requirement from safety stock

There is a requirement from safety stock in MD04 but this is not considered in MRP as the screen below.

If the material has a material group in the material master, please go to the customization transaction OPPR.

Input the plant and MRP group, then click the button 'Safety Stock', then the screen below is displayed.

If there is a value in the field 'Share SStk' as above, this means that the percentage of the safety stock can be used to cover the requirement.

e.g. there is a requirement of safety stock 100, and the 'Share SStk' has the value 100 in the OPPR, then the quantity 100 * 100% = 100 will be used to cover its requirement. Since this can cover the safety stock itself no proposals are needed.

SAP Note: 1890440 - Materials are not planned by MRP

When the user run the total planning of MRP with the parameter NEUPL the system only runs the materials whose planning file entries exist (In this case, the NETCH indicator is not checked.). When the total planning of MRP is done with parameter NETCH, only the materials whose planning file entries exist with indicator NETCH are planned. But if you run MD03, the system does not check the planning file entry since the system is told what material should be run.

Please create the planning file entry in MD20 or make some changes of MRP related object in order to set the flag. Running the transaction MDAB can automatically detect the missing planning file entries and create them but this does not set the NETCH indicators for the existing planning file entries.

Normally the planning file entry will be created automatically while the material is created or set the flag automatically when user makes changes of MRP related.

The following note provides more details about the planning file entry:

1920439 - How are the subcontracting requirements displayed in transaction codes MD04 and MD05?

In the subcontracting process, the necessary materials for making subcontracting assembly need to be purchased by ordering company, then transfer to a subcontracting vendor.

E.g. some subcontracting requirements appear in both the plant segment and subcontracting vendor segment but some others are only in the subcontracting vendor segment.

The subcontracting requirements of transaction codes MD04 and MD05 are displayed as the following example in 2 segments generally, one is the plant segment which represents the ordering company, another one is the subcontracting segment for the subcontracting vendor.

The requirements can appear in both segments or only in the subcontracting segment according to the stock situation of the subcontracting vendor.

If the MRP area is created, the proposals are created in the MRP area segment and doesn't transfer the requirements to plant.

Basics

Material classification for setting MRP parameters

The most important parameters are set directly to a material master at Plant or MRP area levels. Therefore it is important to classify it correctly. Here are some advises for that:

Prepare a comprehensive list of all materials
Segregate the materials to plan from those that aren’t worth the time, effort, or cost involved in planning
Segregate them further by classifying them as A, B, or C types (ABC analysis)
Analyze A-materials:

What should the safety stock of this material be?
How many days of planning window do I need so that the system doesn’t make any automatic changes to my production (or procurement) plan?
When there is a requirement for material, how much should I plan (exact quantity, minimum quantity, maximum quantity, etc.)?
How should the incoming sales orders consume my planning figures?
Is this material make-to-stock (MTS) or make-to-order (MTO)?
Do I need to produce this material for a specific project?
Is this assembly produced in-house or at another plant of the company?
How much scrap (percentage) does the production of a material generate for a product or subassembly, so I can incorporate that in planning?
Should I also first forecast material requirements by using a forecasting tool and adjust forecast values before proceeding with material planning?

Evaluate raw and packing materials

What is the planned delivery time of this material?
What is the receipt of the goods (GR) processing time?
How much under-delivery and over-delivery of material is allowed?
Is there a scheduling agreement or a contract (quantity or value) with a vendor for a material?
Is there a quota arrangement in place, in the case of multiple vendors for the same material?

For B- and C-type materials, consider using consumption-based planning or stochastic replenishment procedures

These questions can be expanded to the most common functions available in the SAP MRP component.

Transaction WPDTC can provide a comparison between the information that you’ve entered in the material master and the actual planned delivery time that the system recorded for each delivery.

Material requirements planning

Deterministic repl. procedure (MRP): PD, P1-4, and D1,M0-M4..

No BOM explosion
Master schedule line
Consumption-based planning

Re-order point

Forecast based
Time phased planning

MRP types

PD

PD may also include a forecast on unplanned consumption. PD looks at demand in the future and covers it with a procurement proposal that has a delivery date just before the demand occurs.

Plant stock + Scheduled receipts from production and purchase – All of the demands

(e.g., from sales orders, material reservations, and PIRs).

P1, P2, P3, and P4

Business example: for the next five days starting from today, the production plan shall not be changed, not even if there are new sales orders.

Options:

Firming methods of existing procurement proposals (within the planning time fence)
Firming methods of new order proposals (within the planning time fence)

The system firms the existing procurement proposals as these are within the defined planning time fence and it creates new supply proposals only when it is a shortage of material within the same planning time fence.

Delete firm planned orders ( if they are not converted during a period of time ) option from the Roll forward.
It is set in MRP Group or in the material master.

VB Manual reorder point planning

Сalculate and set the reorder point manually and maintain it in the Reorder Point field in the material master. it’s recommended to maintain safety stock when using this MRP type.

Thу lead time should be maintained in the MRP 2 screen of the material master record (Planned Delivery Time + GR Proc.Time + Purchasing Time) fields.

The reorder point quantity is your estimated consumption within the TRLT plus the safety stock quantity.

The more often exception message 96 appears, the more likely the reorder point is too low.

VM Automatic reorder point plng

Calculate the Re-order point based on forecast data.

V1 Manual reord.point w. ext.reqs

MRP type V1 acts exactly like VB, except that it takes external requirements into consideration.

V2

It calculates safety stock and reorder point automatically using the Forecasting screen in the material
master record.

VV

In MRP type configuration, you can choose the type of historical consumption of material for planning whether the system uses total consumption or unplanned consumption. You can also choose the reduction method for forecast requirements.

Constant model (D)
Trend model (T)
Seasonal model (S)
Seasonal trend model (X)
Moving average (G)

use Transaction MP30 to run Forecast calculation.

R1 Time-phased planning & R2 Time-phased w.auto.reord.point

This is determined by the planning cycle in which the MRP run is only triggered on

specific days of a week.

Lot Sizing Procedures ~ generate an order proposal with that optimal lot size

After performing a net requirements calculation, when the system determines a material shortage, it looks to information maintained in the Lot-Sizing Procedure field in the MRP 1 view of the material master.

It proposes a balanced quantity and considers other information, such as safety stock, maximum or minimum lot size, static or dynamic safety stock, scrap percentage, and rounding value.

Static lot-sizing procedures

Lot Size: EX (Exact Lot Sizing)
Lot Size: FX (Fixed Lot Sizing)

if the lot size is 10 and req. is 90, then 9 proposals are generated

Lot Size: FS (Fixed Lot Sizing with Splitting)

Lot size is 10 and rounding is 20, then 5 proposals; takt time is to delay the start date for each proposal

Lot Size: HB (Replenish to Maximum Stock Level)

define the maximum stock level. It will check demands and adds req. to a proposal to have the stock in the max, qty.

Periodic lot-sizing procedures: D, W, M

aggregate demands for a period

Optimum lot-sizing procedures

fixed lot size costs, such as setup costs for machines or PO costs and variable costs: Variable costs = Requirement × Price × Storage costs [%] × Storage duration ÷ 365

Rounding

Transaction OWD1.The system offers static and dynamic rounding profiles.

Scrap calculation

Based on historical data or practical experience, you can maintain assembly and

component scrap as master data

Assembly scrap

MRP1: Assembly scrap (%)

The system considers it during scrap calculation by correspondingly increasing the production order quantity.

Component scrap

MRP 4 view, Operations and Component Scraps in Bill of Materials

Safety Stock

The safety stock must always be available to cover for unforeseen material shortages or unexpected high demand.

Two types of safety stocks: absolute safety stock and safety days’ supply. The absolute safety stock enables the system to subtract it from material availability calculations (net requirements calculations). The safety stock must always be available to cover for unforeseen material shortages or unexpected high demand.

static (i.e., absolute) safety stock

The Stock/Requirements List in Transaction MD04 subtracts that safety stock in the first line and then works without.

To avoid the unnecessary creation of planned orders for a smaller quantity, which can otherwise be covered by the safety stock, you can define the percentage (share) of safety stock.

To define the safety stock parameters, use configuration (Transaction SPRO) menu path, Logistics > Production > Material Requirements Planning > Planning > MRP Calculation > Stocks > Define Safety Stock Availability.

dynamic safety stock by use of the Range of Coverage profile ( Transaction OMIA )

Dynamic safety stock = Requirements in the specified periods ÷ Number of days in the total period length× Range of coverage

Safety time

For days’ supply/safety time, the system plans the goods receipt in advance by the period specified as safety time. Thus, planned days’ supply of the stock, in fact, corresponds to the number of days specified as safety time. The system shifts backs the date of the receipts by the number of working days and also takes the factory calendar into account.

To consider the safety time, you need to set the Safety time ind. to “1” (for independent requirements) or “2” (for all requirements), and then also give the Safety time/act.cov. in days. Further, you can define deviations from the constant safety time using a safety time period profile (STime period profile field).

Example: If you define that a 10% safety stock can be used to account for smaller shortages, which for this example means that 4 PC come from safety stock, then the system can cater to this small requirement or shortage of 2 PC from the 4 PC available from safety stock and no longer creates a procurement proposal.

Scheduling

Scheduling In-House Production

Basic date determination ( based on the production time defined in the material master )

The scheduling margin key (SMK) is the float consisting of the number of days it takes to release a production order and the number of days before and after production when the material finally becomes available.
Quantity-Independent In-House Production Time or Quantity-Dependent In-House Production Time ( => In-house production time = Setup + (Order quantity ÷ Base quantity) × Processing time + Interoperation time )

Lead time scheduling ( on the information in the routing (or master recipe) ) + perform capacity planning, sequencing, leveling, and scheduling with planned orders

Scheduling External Procurement

The Planned Deliv. Time information in the material master or from the purchasing info record

Opening period
Purchasing department processing time (Plant parameters)
Planned delivery time
GR processing time

Procurement Proposals

The Procurement type in the MRP 2 view of the material

master defines which of the alternatives applies to the material in the plant

If both in-house production and external procurement are allowed,

MRP assumes in-house production by default

Planned order

Planned orders contain an order quantity, a start date, and a finish date. The start and finish dates are the result of the scheduling process and are based on the factory calendar.

The availability date can occur after the finish date if a GR processing time has been maintained.

Create a planned order

While remaining in the stock/requirements list (Transaction MD04) By using Transaction MD11, which is the planned order creation transaction

You can carry out interactive planning by specifically creating planned orders using

Transaction MD11 or by using interactive MRP for material and plant via Transaction

MD43. In the latter case, the system displays the current requirement and stock situation.

manually created planned order is

always firmed.

PR

Configuration Settings for Material Requirements Planning

Activation: Transaction OMDU
SAP IMG/Production / Material Requirements Planning / Planning / Define Scope of Planning for Total Planning
Plant parameters
MRP groups
Material master (MRP views)

Running Material Requirements Planning

Check the planning file to avoid planning materials that aren’t needed.
Determine the material shortage quantity (or surplus quantity) by carrying out a
net requirements calculation.
Calculate the procurement quantity to include lot sizes for planned orders or purchase
requisitions.
Schedule basic dates or lead time (for in-house production only).
Select the source of supply by determining the procurement proposal.
Determine the requirement of subordinate parts on the basis of the bill of materials
(BOM) explosion by carrying out a dependent requirements determination.

Demand-driven replenishment

MRP on S4/HANA

Classic MRP
Live MRP

Stored procedures on SAP HANA
The most important key differences between MRP live and classic MRP are mentioned below:

MRP Live on HANA cannot plan materials that are included in supersession chains. In this case, the system also does not automatically plan the material using classic MRP. Use transaction MD_MRP_FORCE_CLASSIC to make sure that the material is planned using classic MRP.
Customer can use classic MRP for Direct production since it is not yet supported by MRP Live on HANA
Characteristics-based forecasting is not supported in MRP Live on HANA.
Currently, MRP live does not write MRP lists
Multi-level, make-to-order planning (transaction MD50) is not optimized for HANA.
Individual project planning (transaction MD51) is not optimized for HANA.
The creation indicator for purchase requisitions is not available in MRP Live. MRP Live always creates purchase requisitions if the material is procured externally.
The creation indicator for delivery schedule lines is not available in MRP Live. MRP Live always creates delivery schedule lines if a valid delivery schedule exists.
MD01N (MRP Live) is a standard SAP transaction code optimized for SAP HANA available to use with SAP S/4HANA system.
Long Term Planning (LTP) is not supported by any HANA optimizations. That means it is neither possible to plan LTP scenarios in the context of MRP live nor SAP provide optimized database accesses when reading LTP data for the classic LTP transactions as we do it for appropriate MRP transactions. So there are no special LTP features at all in a HANA environment.

MRP live

it’s not possible to replace multilevel, make-to-order (MTO) planning (Transaction MD50) and the individual project planning (Transaction MD51) with MRP Live.

Besides changes related to the transaction design, there are some changes to the MRP

process that must be considered:

 Total requirements aren’t supported on MRP Live.

Just like the classic MRP transactions, total dependent and sales requirements

aren’t supported on MRP Live.

 Subcontracting on MRP Live is only supported with MRP areas.

In classic MRP transactions, a separated planning segment is created for each vendor

on a subcontracting scenario. In MRP Live, however, this functionality is no

longer available. This means that the subcontracting scenario must be mapped

with MRP areas. Therefore, you need to create an MRP area for each vendor in Customizing

and assign this MRP area to the materials that will use the subcontracting

scenario. See Section 13.4 for more on MRP planning areas.

 Replenishment proposals aren’t reusable.

In classic MRP transactions, unfirmed planned orders and purchase requisitions

weren’t necessarily changed during the MRP run in the case of a quantity or date

change. Now, in MRP Live, if the date or quantity of a replenishment proposal must

be changed by MRP, the replenishment proposal is deleted and a new one is created.

Basically, this means that the number of existing planned orders and purchase requisitions

may be changed more frequently in MRP Live than in the classic MRP.

a complete overview of those restrictions can be found in SAP Note 1914010.

Requirement lists

The red, yellow, and green traffic lights in both Transaction MD06 and Transaction MD07 in Figure 13.12 give a quick indication in the list view of potential overstocking or understocking:

Transaction MD04 to display the dynamically created stock requirements situations for an individual material. Transaction MD05 to display the MRP list, a snapshot from the time when the MRP run last planned the material. Transaction MD06 to display a collective list of materials with their respective MRP lists. Transaction MD07 to display a collective list of materials with their respective stock/requirements situations.

Additional information

1567876 - Planned order conversion: MRP relevance

In Customizing for the order type-dependent parameters for process orders or production orders, you have set the indicator for the MRP relevance (Reservation Relevance/Generation of Purchase Requisition) to 2 "From release".

You then use this order type to convert a planned order to a production order or a process order. In the planned order, reservations are always MRP-relevant.

After the planned order is converted, these reservations remain MRP-relevant unless you have changed the message type for the system message C2 280 as described in Note 569984.

You do not want the reservations to lose their MRP relevance during the planned order conversion, so you do not make any settings for system message C2 280. However, you also do not want purchase requisitions to be created until the order is released.

634038 - MRP: Returns order and delivery

You work with returns orders:

Either by stock transfer of plant to plant ('Plant return' or 'Store return'), or returns back to the vendor ('Return to vendor').

You create a delivery for a returns order.

The processing of the delivery and the purchase order within the materials planning is not clear or results in undesired effects; for example, both the purchase order and the delivery are relevant for the materials planning relevant in case of a return to the vendor so that the available quantity is reduced twice.

The control occurs via several steps:

Customizing of the returns order (Allocation of the delivery type, in the Standard system NLR for the stock transfer case and RL for the return to vendor)
Item category determination in the Customizing of the delivery (in the Standard system NLRN for delivery type NLR and RLN for delivery type RL)
By means of the allocation of the requirements type to the activity, you must make sure in case of a stock transfer that you select a requirements type in such a way that by the assigned requirements class a requirement is generated which is relevant for the materials planning.
For the problematic nature of the ATP (visibly in CO09), consider question 4 from Note 606282 after the creation of the delivery.
For the return to vendor, a requirements type must be selected in case of which the assigned requirements class does not result in a requirement that is relevant for the materials planning.
If you desire a delivery relevant for requirements for the return to the vendor from reasons of the ATP and if the Customizing is correspondingly prepared, as a consequence both the purchase returns and the delivery are regarded as a relevant requirement. This behavior cannot be avoided in the R/3 standard system(see Note 606282, question 6) and can be avoided only via a modification within the MRP.

2980392 - OPPR: Reduced number of parameters maintainable for MRP groups in S4

The following parameters are not available anymore in S4:

Strategy Group (T438M-STRGR)
Planning Horizon (T438M-PLAHZ)
Direct Procurement Indicator (T438M-KZDRB)

#Planning Horizon

The planning horizon will not be supported anymore in S4. All planning runs in MRP live and the classic MRP will always plan the complete planning horizon. There is no differentiation in S4 between changes inside and outside the planning horizon when updating the planning file entries (see note 2268088 ). The processing key NETPL is still available for the classic MRP, but acts internally in the same way as the processing key NETCH.

#Direct Procurement Indicator

The direct procurement indicator on plant and MRP group level (T399D-KZDBR, T438M-KZDRB) has been introduced in early R/3 releases to control whether the MRP should already initiate procurement processes for components to be produced directly (direct production/collective order) or purchased directly (e.g. procurement of non-stockable items directly for an order). The meaning of this indicator has been reduced over the years. The control of direct production processes has been eliminated at all already in later R/3 and ECC releases.

As a lot of process enhancements have been done for an external direct procurement process as well (e.g. like the introduction of special procurement keys and planning segments for external direct procurement), there seem to be no needs anymore to postpone the initiation of these procurement processes to the production execution. Especially the differentiation on MRP group level seems to be irrelevant as this could leed to non-uniform planning behavior of concerned requirements based on different MRP group assignments on assembly level. If such a non-unique planning behavior is really required, this has to be modelled accordingly using BOM features like item specific special procurement keys or explosion types.

The general recommendation is to maintain and allow direct procurement on plant level.

Planning Strategy

The purpose of the MRP group is to specify the planning and process behavoir of materials during the MRP and subsequent processes (like conversion of planned orders etc.). In this context MRP groups usually refine settings maintained on plant level for certain materials or activate some special features or variations of the standard process behavior. The planning strategy does not really fit into this concept as this value is used as fallback if no planning strategy is maintained at material master level. As this fallback logic is not really transparent to the user, often questions occur why certain requirements types have been chosen or denied by concerned applications.

Generally it is not the idea of the MRP group to simplify the material master data maintenance. For that purpose other means like MRP profiles, mass changes etc. are available. Therefore the opportunity to maintain strategy groups has been removed from transaction OPPR. But the field is still available on MRP group level and will be furthermore evaluated. If it is still required to maintain the strategy group for MRP groups, transaction OMD1 can be used to realize this (called either directly or by using the 'Overview' feature of transaction OPP

23922 - MRP: Creation indicator, purchase requisition or planned order

During the planning run of material requirements planning (MD01/MDBT or MS01/MSBT) or during master production scheduling (MD40/MDBS), the control parameters of materials planning that were entered on the initial screen of the transaction (creation indicator "Create purchase req.", "Schedules lines", "Create MRP list" or "Display list") appear to have no effect.

As a result, the single-item planning for a material may return a different result from total planning even if the indicators on the initial screen are the same.

Single-item planning and total planning follow a different logic in relation to the creation indicators.

This is also described in the documentation for production planning/material requirements planning (Chapter 4, Section 2) and in the Implementation Guide (IMG).

Single-item planning:

The specified creation indicators apply in general.

Total planning:

The specified creation indicators are default values.

For materials with an MRP group, the values from the MRP group apply (if they exist).

The creation indicator for schedule lines can be determined additionally for each plant. This is used if nothing is determined using the MRP group.

Therefore, the priority is as follows:

MRP group
Plant
Initial screen

Check the settings in Customizing for MRP:

Planning -> Creation Indicator
Planning -> Procurement Proposals -> Define External Procurement -> Plant:
Creation of delivery schedules.
Planning -> Activate Runtime Statistics

1975704 - Evaluating the material masters for MRP live

You want to find out which materials can be planned with MRP Live on SAP HANA and which materials still need to be planned on ABAP. This provides the basis for estimating the possible performance improvements of MRP on SAP HANA.

After this, report PPH_CHECK_MRP_ON_HANA is available. This report performs a material master evaluation and identifies which materials cannot currently be planned with MRP Live on SAP HANA. For each low-level code, the results list returns an overview showing the number of materials that cannot be planned on SAP HANA (and also the reason why not) and the number of materials that can be planned on SAP HANA. The more detailed version of the output list provides a specific evaluation per material.

2659649 - How Parallel Discontinuation Works

In parallel discontinuation, the discontinued group items(material ZJL-DISCON-PL-1 and ZJL-DISCON-PL-2) are replaced by follow-up group items(material ZJL-FOLLOW-PL-1 and ZJL-FOLLOW-PL-2).

Configuration:

Set up follow-up materials and discontinued materials. Follow-up material is as normal. Set discontinuation fields for discontinued materials.
Set "Discontinue indicator" as 1 for main discontinued material in the group, and "effective date" and "follow-up material".

Set "Discontinue indicator" as 3 for dependent discontinued materials in the group, "effective date" and "follow-up material" is initial.

Configure discontinuation data in BOM. From Item details screen, menu -> Extras -> discontinuation data.

Notice: Discont. group must have same character string as Follow-up group.

Test:

Confirm the stock for discontinued material(qty=0) and follow up material(qty=100).
Run MRP for header material in T-code MD02.
Check the planned order generated and switch to Component Overview. The requirement qty is transferred from Discontinued materials to Follow up materials.
Result: Requirements for discontinued materials are transferred to follow-up materials.

Function:

Parallel discontinuation transfers requirements for both materials in discontinuation group to follow-up material in follow-up group, only if stock is missing for the discontinued material with discontinued indicator "1". Discontinued material with discontinued indicator "3" is just dependent mateiral in the parallel discontinuation.

2640949 - How Single Discontinuation Works

Configuration:

Create follow up material.
Create discontinued material and assign follow up material to it.
Configure discontinued material in BOM of Header material.

Function:

Simple discontinuation is a 1:1 replacement of the discontinued part by the follow-up part at a particular date. It can be considered as a simple replacement of the material number only (MATNR). All other characteristics are inherited from the discontinued part. Based on that both materials should have the same characteristics from planning point of view.

Test:

Confirm the stock for discontinued material(qty=0) and follow up material(qty=100).
Run MRP for header material in T-code MD02.
Check the planned order generated and switch to Component Overview. The requirement qty is transferred from Discontinued material to Follow up material.
Notice: All other settings are inherited from the discontinued material, e.g. component Scrap 20% etc.

944616 - planning Mode 2: Some/All components lost in BOM Explosion

MRP Run with Planning Mode 2 (Re-explode BOM and routing) , deletes some or all the components for the subcontracting schedule line. Whereas MRP run with planning mode 3 (Delete and recreate planning data) , restores them back correctly. This happens when you have the following constellation.

the requirements element (Example sales order) has got configuration(CUOBJ) or parameter Effectivity(TECHS) attached to it.
The BOM is using ECM(with Parameter Effectivity) or Object dependencies.
Subcontracting Schedule lines are configured as procurement elements for the requirements.

SAP has the following suggestions to avoid this problem:

When using subcontracting with schedule lines , do not use the BOM having parameter effectivity or object dependency .
If you want to use parameter effectivity or object dependency then have the purchase requisition/Purchase order as the procurement element.

2047547 - MD04, MD05: Dependent requirement without planned order

Stock/requirements list (MD04), MRP list (MD05): The system displays dependent requirements for which there are no planned orders. That means that the planned order has already been deleted.

Case A: In the detailed information for the dependent requirement, the system displays no planned order number. In this case, there is a postprocessing record from the confirmation (MFBF/repetitive manufacturing) and not an inconsistency (see explanatory note 61144).

Case B: In the detailed information for the dependent requirement, the system displays a planned order number. However, this planned order does not exist in the database in the table PLAF-> inconsistency.

The incorrect requirements can be found and deleted using the attached report ZCHECKRESB1. The report considers no inconsistencies in connection with subcontractor requirements (RESB-BDART = BB). Before you run the report, at least one other person should check that it has been copied correctly. SAP assumes no responsibility for damage that arises as a result of incorrect copying or modifications of the report.

819617 - MD04: Inspection lots not displayed for handling units

Inspection lots with handling units are not displayed in transaction MD04 while inspection lots without handling units are displayed as the MRP element "QM-lot". Thus, inspection lots with handling units are not taken into account in the ATP check.

When we designed the "Handling Unit Management" module, we decided that not only can you make a transfer posting for inspection lots with inspection stock handling units using inspection lots (the usage decision) but also using other transactions such as HUMO, VLMOVE, etc.
The direct result of this is that inspection lots cannot be taken into account in transaction MD04.

457110 - FAQ: Source determination in purchasing

1. Question:

Why does the system propose a contract twice (several times) with different purchasing organizations as possible sources of supply?

Answer:

The contract is created for a reference purchasing organization. In Customizing "Assign purch. organization to reference purch. organization", you can specify that contract release orders of the reference purchasing organization are allowed for a purchasing organization that is assigned to the reference purchasing organization.

As a result, the contract appears in the list of possible sources of supply with the reference purchasing organization, and once more with the purchasing organization that is assigned to the reference purchasing organization.

--------------------------

2. Question:

When you use transaction ME51N to create a purchase requisition (PReq), the system does not determine a source of supply even though the "Source Determination" indicator is set.

Answer:

You have already entered part of the source of supply in the item, such as the purchasing organization. However, the source determination is started automatically only if none of the corresponding fields (Vendor, Purchasing Organization, Supplying Plant, Info Record, Outline Agreement, Material Number Corresponding to Manufacturer Part Number, and so on) are filled yet.

--------------------------

3. Question:

Why does the system propose an info record as a possible source of supply even though the requirement quantity is lower than the first scale value of a base scale?

Answer:

At the time of the source determination, a check of valid or existing prices is not carried out. The price is first determined when the PReq is converted to a purchase order.

--------------------------

4. Question:

The runtime of the source determination (for material groups, for example) is very poor. How can this be improved?

Answer:

A large number of contracts or contract items that are possible sources of supply may cause the runtime of the source determination to be poor. To improve this, you should set the deletion indicator for contract items that are no longer relevant and you should archive documents.

See SAP Notes 32375, 148623, and 354178.

--------------------------

5. Question:

An entry in the source list is blocked. Why does the system also issue error message 06 723, "Source of supply blocked (according to source list)", when you change a purchase order?

Answer:

This is the program design and it cannot be changed. To change the purchase order, you should reverse the block in the source list temporarily.

--------------------------

6. Question:

A purchase requisition contains a desired vendor. Why is this not taken into account during the source determination?

Answer:

This is caused by a missing function. However, you can use the user exit (EXIT_SAPLMEQR_001) to control the system behavior.

You can call the user exit in the function module ME_SEARCH_SOURCE_OF_SUPPLY. The desired vendor is in the field COMIM-LIFNR; all of the info records or contracts that are determined by the source determination are in the internal table LORD.

It would be conceivable to use a LOOP through the table LORD within the user exit to check whether there is an entry for the desired vendor and to select it if this is the case.

--------------------------

7. Question:

Why does the system propose an info record with several units of measure in the dialog box of the possible sources of supply?

Answer:

See SAP Note 445239.

--------------------------

8. Question:

One contract and one or several info records exist as possible sources of supply. Why is the contract still assigned automatically?

Answer:

See SAP Note 433774.

--------------------------

9. Question:

Why is specific data from the source of supply not transferred to the purchase requisition?

Answer:

See SAP Note 311174.

--------------------------

10. Question:

Why does the system not take into account a contract that is valid for the delivery date but is not valid for the current date during the source determination?

Answer:

See SAP Note 44368.

--------------------------

11. Question:

Why does the source determination during the MRP run behave differently to the source determination in purchasing?

Answer:

See SAP Note 206684 regarding necessary prerequisites for a successful source determination during the MRP run.

During a source determination in purchasing, many other checks are carried out (the vendor must not be deleted, an info record must exist, and so on). In this case, a source of supply may be assigned to a purchase requisition during the MRP run; however, a different source of supply may be assigned when you create a purchase requisition manually.

Basically, the source determination in purchasing and the source determination in MRP are very different in terms of various checks, and can therefore not be directly compared to each other.

--------------------------

12. Question:

When you create a purchase order with reference to a contract, why does the system not issue error message 06 722 ("Source not included in list despite source list requirement") even though there is a source list requirement for the material, but the contract is not included in the source list?

Answer:

Check whether the 'exclusion indicator' is set for the source list for the contract item on the additional data screen.

A contract for which the exclusion indicator is set cannot be and does not have to be in the source list when there is a source list requirement. As a result, you are allowed to create a purchase order item with reference to this contract item.

--------------------------

13. Question:

Why can you assign a PReq for which the indicator for a subcontracting vendor is set or a PReq with receiving vendors to a contract in which this data is not maintained, but you cannot do the same in reverse?

Answer:

It is assumed that the contract exists before the purchase requisition and that the contract is normally less specific than the purchase requisition.

For this reason, the data of the PReq is weighted more strongly during source determination, that is, it should not be possible to assign a contract containing this data to a PReq for which the indicator for a subcontracting vendor is not set or to a PReq that has no receiving vendors.

However, the opposite case (a purchase requisition for which the indicator "subcontracting vendor" is set or a purchase requisition with receiving vendors, contract without this data) is supported.

See SAP Note 408432.

--------------------------

14. Question:

You want to assign a source of supply to a PReq with material. One or several info records and several material group contracts exist. You do not know how the system selects the possible sources of supply.

Answer:

- If several info records and several material group contracts exist, then the system proposes all of them for the selection.

- If an info record exists for vendor A and material group contracts exist for the vendors B and C, then the info record is assigned as the source of supply.

- If an info record exists for the vendor A and material group contracts exist for the vendors A, B, and C, then the system proposes the info record and the material group contract for vendor A for selection.

--------------------------

15. Question:

The source determination uses the source list to determine the source of supply. The relevant source list entry contains a supplying plant. An info record exists.

Why does the source determination not determine the info record?

Answer:

The info record is determined if the source determination is carried out using transactions ME51N/ME52N or ME56/ME57 (scope of list "ALV").

When you use transaction ME51/ME52 or ME56/ME57 (scope of list "A"), the info record is not determined.

The basic principle is: In all cases, the info record is NOT determined in the source determination (function module ME_SEARCH_SOURCE_OF_SUPPLY) due to SAP Note 208138. When you use the single-screen transactions or the scope of list 'ALV' for ME56/ME57, the info record is subsequently determined.

Therefore, we recommend that you use the single-screen transactions or the scope of list "ALV" for ME56/ME57.

(The scope of list 'ALV' is provided for the transactions ME56/ME57 as of Release 4.70.)

--------------------------

16. Question:

Are deleted info records taken into account during the source determination?

Answer:

No. If, for example, an info record is deleted, and it is already assigned for existing purchase requisition items, this link is not deleted automatically.

The info record is taken into account during the conversion to the purchase order.

The system then issues message 06 718

("Purchasing info record & & & & flagged for deletion").

When a new source determination is triggered, a new determination is carried out and the existing assignment may be removed completely; for example, if no other source of supply apart from the deleted info record is maintained.

For example, if you delete the plant-specific info record but there is still a cross-plant record that is not deleted, this is taken into account as a possible source of supply.

--------------------------

17. Question:

Why does the result of source determination for the report RM06BZ10 differ from the report RM06BZ00 or transaction ME56 or ME52N?

Answer:

If a source list has not been maintained for the material but there are several valid sources of supply, the system automatically assigns the first valid source of supply when you use the report RM06BZ10.

If source determination is started manually and a purchasing info record as well as a master contract exists, the user can select the source of supply.

Supply source determination can be influenced using the source list.

MD04 Use

Set a manual firming date

‘Edit’ > ‘Set Firming Date’.

Receipts lying before the firming date are firmed (an asterisk is added to the MRP element)and won’t be changed by MRP running.

Receipts lying before the firming date are firmed (an asterisk is added to the MRP element)and won’t be changed by MRP running. For example, if you increase the PIR quantity to 10 and run MRP again, the firmed proposal (schedule line in this case) within 12.12.2014 is not changed. A new proposal is created to cover the requirement on the manual firming date.

Additional navigation buttons

Navigation profile

Sorting and filter

OM0J - Declaration Display Filter
OM0I - Declaration Selection Rule

Der Unterschied zwischen Filter- und Auswahlregeln liegt in der Berechnung. Selektionsregeln kann sich auf die verfügbare berechnete Menge auswirken (!) .

Material Grouping and Cross-Plant View
Business function LOG_PP_LMAN

Only when the material exists in product group, or exists in multiple plants, “Production Group” or “Cross-Plant View” appears. You should set corresponding customizing. The path is OPP1 -> Evaluation -> Display Material Groupings. Function Filter and Selection Rule can be used together.

In t-code MC84, create a product group
Then in t-code MD04, “Product Group” tab appears. You can view the stock/requirement situation for multiple materials there. Also, you can decide if it is displayed in aggregated form or not by clicking the aggregation icon.

Material ZJLTEST-1 exists in plant 1000 and plant 1100. You can check the stock/requirement in all plants for material ZJLTEST-1 in “Cross-Plant view”. You can choose display form using aggregation icon.

Rescheduling

Whenever the MRP finds a requirement, it checks if this requirement can be covered for an existing fixed receipt (within the rescheduling horizon), before creating a new replenishment element (planned order). This procedure is called “rescheduling check”.

If a fixed replenishment element is found, an exception message is created, suggesting the user to reschedule this fixed element in order to cover the shortage.

System first searches for fixed elements before the requirement date. If a fixed element is found before the requirement date, then this receipt is not needed until later. In this case, the exception message “15 – Postpone process” is displayed for the element.

If the fixed element is after the requirement date, within the rescheduling horizon and this type of fixed element is included on the rescheduling check, according to the customizing, exception message “10 - Bring process forward” is displayed for the element.

#1 Exception 15

#2 Exception 10

#3 Exception 01

#4 Exception 20

Find the rescheduling customizing on transaction OMDW

Rescheduling horizon: It is the number of day for which the system checks whether the fixed replenishment elements should be rescheduled. The rescheduling horizon is calculated in working days, according to the plant factory calendar and it starts on the end of the replenishment lead time.

Firmed elements: You can define which specific elements will be included on the rescheduling check. If the flag is unchecked, MRP will not consider the element during the rescheduling check.

Dependent reservations with positive sign (by-products or co-products) are not considered during the rescheduling check on the standard system. The system behavior can be changed with the implementation of the modification note 203151.

Comparison values: If the difference between the requirement date and the firmed receipt element is less than the tolerance value, system will not display an exception message.

The rescheduling horizon and the firmed elements can also be defined at MRP Group level.

It is also possible to reach the rescheduling customizing for the plant through transaction OPPQ and for the MRP group through transaction OPPR.

At last, even if there is no MRP group assigned to the material master, the settings defined at MRP group level will be consider if the MRP Group key is equal to the material type (see note 34013 for more details). For example, if the material type is ZPRD and there is an MRP Group ZPRD, the settings from this MRP group will be considered by MRP if the field MRP Group is empty on the material master.

1745312 - MRP creates redundant proposals though there are fixed future receipts which can cover the requirements

A new proposal (planned order, purchase requisition, schedule line etc.) is created to meet the requirement after running MRP though a fixed future receipt element exists already (firmed planned order, firmed purchase requisition, firmed schedule line, production order, purchase order etc.) at the date later than the requirement on the time axis. As a consequence, the exception message 20 (Cancel process) appears in MD04/MD05 for the fixed element,

he fixed future receipt lies out of the rescheduling horizon or it is not selected for rescheduling.

It is only considered for rescheduling when it lies in the rescheduling horizon and it is selected to be considered for rescheduling in the customization.

- The rescheduling horizon is the sum of the days below for external procurement and in-house production.

External procurement.

- Purchasing processing time. (Maintained in the customization transaction OMDT for plant, working days.)

- Planned delivery time. (Maintained in the material master, calendar days.)

- GR processing time. (Maintained in the material master, working days.)

- The horizon maintained in customization for plant or MRP group.

(Maintained in the customization transaction OMDW for MRP group or plant, they are working days. If the MRP group is entered in the material master and the rescheduling horizon is maintained for

MRP group in OMDW it has higher priority than the one of plant. If the MRP group is entered in the material master but there is no value in OMDW for MRP group then the horizon for plant

maintained is read.)

In-house production.

- In-house production time. (Maintained in the material master, working days.)

- GR processing time. (Maintained in the material master, working days.)

- The horizon maintained in customization for plant or MRP group the same as external procurement.

- The customization for which fixed future receipt elements can be selected for rescheduling is maintained in the transaction OMDW for plant.

Here is a screenshot of an example after running MRP, there is a requirement of reservation on the date 26.07.2012 and a purchase order which can meet it (Reservation quantity 16 - Stock quantity 8 - Purchase order quantity 8 = 0.) exists on the later date 10.08.2012 but a new purchase requisition is created after running MRP.

Here is the screenshot of transaction OMDT where the purchase processing time is maintained as 1 working day now.

25388 - MD01, MD02, MD03: Rescheduling proposals: Documentation

Symptom

1. Requirements planning creates a new order proposal (planned orders, order requirements, or delivery schedules) although sufficient firmed receipt elements (firm planned orders, purchase requisitions, or schedule lines, production orders, shipping notifications, and purchase orders) exist.

2. In the requirements planning run, a new order proposal was created for a particular date, even though a firmed receipt element with the same quantity already exists on this date. However, this firmed receipt element has been given a reversal proposal in the planning run.

3. A requirement that cannot be covered by the current warehouse stock exists in the past. A firmed receipt that covers this material shortage also exists in the past. However, the receipt occurs after the material shortage. Materials planning responds as follows in this case: Cancellation proposal for the firmed receipt element and creation of a new order proposal which has a start date in the past.

4. You have a balanced stock/requirements situation. That is, for every requirement there is an appropriate receipt element. The receipt elements at the start of the time axis are firmed receipts; for example, production orders, purchase orders, firm planned orders, purchase requisitions, or schedule lines. Now, a new larger requirement is added at the start of the time axis. As a result, new order proposals are created at the end of the time axis. The entire lot size determination is disrupted. Suddenly, there are more receipt elements than requirements for a lot-for-lot order quantity.

5. At the start of the time axis, there is a requirement that is not covered by an order proposal from materials planning. Although the material was planned using MD01 or MD02, you cannot find a receipt element near the requirement which would be suitable to cover this requirement. Negative quantities are also displayed in MD05/MD06 for the available quantity.

6. The MRP controllers use exception groups (Customizing exception groups) in transaction MD05/MD06 to search for materials with exceptions in order to intervene manually if necessary. In this case, they are flooded by materials with rescheduling proposals. In most cases, the requirements date and receipt date are only one or two days apart.

These rescheduling proposals are often viewed as unnecessary. How can you prevent these rescheduling proposals from appearing to reduce the worklist of the MRP controllers?

7. A requirement could be covered by a receipt reservation that lies further in the future. However, the system creates a new order proposal instead. The receipt reservation does not therefore participate in the rescheduling check.

8. A rescheduling proposal 10 is created without a date for a firmed receipt element at the start of the time axis. However, a rescheduling proposal 10 (move forward) is created with a date for a later firmed receipt element.

How can a situation occur in which the effect of both rescheduling proposals might cancel each other out?

9. You procure a material with an assembly order and create an assembly order directly from a sales order. However, material requirements planning still creates a planned order for the sales order.

The problem can occur if the material is planned using material requirements planning. This may also be useful for materials which are obtained using assembly orders, for example to consider different requirements (no sales orders).

10. You use a distribution key for receipts (for example, planned orders). A planned order of 100 pieces is distributed as a result (for example, Monday to Friday 20 pieces in each case). If you now firm the planned order, a subsequent planning run creates additional receipts.

11. The rescheduling horizon is set too short or not at all, or the firmed receipt element is set in Customizing in such a way that it does not participate in the rescheduling check. The rescheduling data of the receipt elements in MD04 and MD05 differ from each other.

Solution

1. Enter a longer rescheduling horizon for the MRP group of the material. A default value can be entered in the plant parameters for requirements planning.

2. Use a longer rescheduling horizon. For period lot-sizing procedures with the availability date at the end of the period, this horizon should be at least so long so that all requirements lie within it.

3. In the Customizing of plant data, it is best to activate the rescheduling check for all firmed receipt elements.

4. This behavior is intentional. There is no solution. Pay attention to the rescheduling proposals. These can provide valuable information on when a manual intervention is necessary.

5. Try to firm the receipt element or generate firmed receipts as late as possible. This ensures that materials planning adjusts the receipt elements to the current requirements each over a long period of time. It also prevents materials planning from trying to cover requirements with firmed receipts that are too far in the past or future.

You firm an order proposal by making manual changes. For planned orders, a simple "posting" is sufficient without having to change any data.

For firm order proposals, "/*" is displayed at the end of the planned order number or purchase requisition number in MD05 or MD06, as well as in MD04.

If special company-internal reasons make it necessary to firm a receipt element early, or to create a firm receipt element, try to do this in a separate planning section (individual customer requirements).

You can set the rescheduling horizon in the Customizing of the planning group table. Default values can be set in the Customizing of plant data. Firm receipts outside the rescheduling horizon do not participate in the rescheduling check. This also prevents rescheduling proposals over a long period. If, however, the firmed receipt moves into the rescheduling horizon, then materials planning immediately covers the first requirement that is not covered by earlier firmed receipts.

6. Set suitable comparison values in the Customizing of the planning group table or plant data.

7. After you implement the modification from SAP Note 203151, dependent reservations are taken into account during the rescheduling check.

8. There is no solution.

9. If you process assembly orders and you plan the material requirements, make sure that the rescheduling horizon is long enough.

10. Use a rescheduling horizon and, in Customizing, specify that the firmed receipts participate in scheduling.

11. See point 10.

1794796 - Planning calendar is not considered in rescheduling check of MD04

Planning calendar planning is not considered by the rescheduling check on MD04.
In MD04, the rescheduling date of the receipt element is based on the requirement date.
The logic in form CHECK_VWVER of program SAPLM61R is passing the requirement date to rescheduling date directly without checking the planning calendar.

How to check possible causes if MRP does not create any proposals

MRP sometimes does not create any proposals, e.g. planned order, purchase requisition, schedule lines, even though there is shortage for requirements. The root causes are not so clear.

Here are some cases can be checked one by one.

Case 1: The total planning of MRP cannot generate any proposals

If you ran the total planning of MRP, e.g. MD01 or MDBT and no proposals were generated, please run MD03 for the material/plant, if this can create it means that the planning file entries of the materials are missing or the corresponding planning indicator, e.g. NETCH is missing in the planning file entry. Please go to the transaction MD21to check if the planning file entry exist, if there is not or no NETCH indicator is set then the system may not run the material in the total planning of MRP.
When the user run the total planning of MRP with the parameter NEUPL the system only runs the materials whose planning file entries exist (In this case, the NETCH indicator is not checked.). When the total planning of MRP is done with parameter NETCH, only the materials whose planning file entries exist with indicator NETCH are planned. But if you run MD03, the system does not check planning file entry since the system is told what material should be run.

Please create the planning file entry in MD20 or make some changes of MRP related object in order to set the flag. Running the transaction MDAB can automatically detect the missing planning file entries and create them but this does not set the NETCH indicators for the existing planning file entries.

Normally the planning file entry will be created automatically while the material is created or set the flag automatically when user make changes of MRP related.

The following note provides more details about the planning file entry:

SAP Note: 1890440 - Materials are not planned by MRP

Case 2: There is a requirement from safety stock in MD04 but this is not considered in MRP as the screen below

The material has a material group in the material master, please go to the customization transaction OPPR.
Input the plant and MRP group, then click the button 'Safety Stock', then the screen below is displayed.

Case 3: No proposals are created for the requirement of PIR (Planned independent requirement)

The PIR exist as below in MD04, but proposales, e.g. planned orders, are not created after running MRP.

In this case, please check if the MRP group is maintained for the material, if yes, then go to the customization below to check if the PIRs lie in the period of Adjustment.

SPRO > Production > Production Planning > Demand Management > Planned Independnet Requirements > Maintain consumption mode and period of adjustment.

Double clikc the line for the plant and MRP goup, the screen below is displayed.

The 'Adjustment: Planned Ind. Reqmts' value 1 means that the period is calculated forward from today, and the field 'Adjustment Period: PIRs' is the period by working days.
E.g. Today is 29.09.2011, plus 7 working days forward it goes to 10.10.2011. Since the PIRs lie before this date they are not included in the MRP calculation and no proposals can be created for them.

Case 4: The dependent requirements are not considered in MRP

After checking, it is turned out that the value 1 'Materials for dependent requirements are not planned' in the field 'MRP dep.requirements' of MRP 4 view of the material master as below.

Case 5. Sales documents are not considered in MRP

It happens because the field 'No MRP' has value 1 'Requirement not planned, but displayed' in customization transaction OVZG as above for the requirement class of the sales document.
If that is blank, the sales document can be planned by MRP. If that has value 2, the sales document doesn't appear in transaction MD04.
To get the requirement class of sales document, check requirement type in field BEDAE of table VBAP, go to customization transaction OVZH as following to find the requirement class by requirement type.

Case 6. The MRP user exit M61X0001 implemented to exclude certain materials in MRP.

Please go to transaction SMOD or CMOD to check if the user exit is implemented.

Case 7. Some BADIs are implemented to exclude the MRP requirements.

The BADI MD_CHANGE_MRP_DATA contains many methods which can change or exclude the data read for net requirements calculation, e.g. the reservation, dependent requirements, planned independent requirements etc. Please go to transaction SE18, input the BADI MD_CHANGE_MRP_DATA into the field 'BADI Name', and click 'Dispaly', go to menu 'Implementation' > 'Overview' to check if there are your own implementations, if yes, double click that to check the source code of relevant methods.

Automatic assignment of Storage Location MRP Area to Material Master

In S/4HANA 2020, it is possible to automatically assign a storage location MRP Area to a material when extending this storage location to a material, and have default values for the MRP fields in the MRP area. This feature allows a storage location to be automatically excluded from MRP or planned separately whenever it is extended for a material.

In the MRP Area Profile we will define default values for the MRP fields under the MRP Area. These values will be used when extending the storage location assigned to the storage location to the material master, if the feature is active for the MRP Area. By setting the flag Copy Field, the value defined at the material master at plant level will be copied to the MRP Area.
After the profile creation, we need to check the flag Assign Materials Automatically and assign the profile to the MRP Area in the MRP Area customizing (transaction OMIZ).

With this setting in place, whenever we extend storage location 0004 (which is the storage location assigned to the MRP Area) to a new material, it will automatically create the assignment to the MRP Area, with the field values proposed on the profile.