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Chapter 1 Materials Planning: General
Information
Materials planning - complete overview
Master data
Basic information on consumption-based planning
Executing the planning run
Evaluating the planning run
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Chapter 1 b!ectives
"ou will have learned the position of materials
planning in the logistics chain and important #$P
terminolog" for materials planning
"ou will %now the master data re&uired for materials
planning
"ou will have learned the business basics of
consumption-based planning as well as the
procedure and the environment of this t"pe of
planning
"ou will %now how materials planning is carried out
and the possibilities available for evaluating the
results
B" the end of this chapter:
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Materials Planning - 'omplete verview
'onvert
Planned
order
Indep(re&mts
)epedent re&mts
#ales and
distribution
processing
Reservations
Purchasing
functions
Purchase orders
#chedule lines
Purchase
re&uisition
*arehouse
Production
order
Invoice
verification
Materials
planning
)emand
management
The main task of materials planning is to determine which material is required, the quantity required and when
it is required.
The internal planning elements of materials planning and of purchasing are the planned orders and the
purchase requisitions. Internal planning elements are known as order proposals.
The main focus of this course LO525 is external procurement.
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Purchasing Purchasing
data data
Material Master Record
General data General data
#torage location #torage location
data data
+orecast data +orecast data
'onsumption data
$ccounting $ccounting
data data
MRP data MRP data
Material number
)escription
,nit of measure
-echnical data
MRP t"pe
Planned deliver".in-house
production time
/ot si0e
MRP controller
Procurement t"pe
Purchasing group
Goods receipt
processing time
1aluation price
1aluation procedure
MRP indicator for
storage location
#pecial procurement t"pe
for storage location
The data required for consumption!ased planning is stored in the material master record at plant le"el.
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MRP Procedures
MRP procedure MRP procedure
$utomatic reorder $utomatic reorder
point planning point planning
Manual reorder Manual reorder
point planning point planning
MRP MRP
'onsumption-based 'onsumption-based
planning planning
Reorder point Reorder point
planning planning
+orecast-based +orecast-based
planning planning
-ime-phased -ime-phased
planning planning
#s opposed to $%&, consumption!ased planning procedures are !ased on material consumption.
In reorder point planning, the system checks whether the a"aila!le stock le"el falls !elow the reorder point
defined for the material. If it does, procurement must !e triggered. 'ou can determine the reorder point
manually or, it can also !e calculated automatically using the material forecast.
In forecast!ased planning, historical data is used in the material forecast to estimate future requirements. These
requirements are known as forecast requirements and are immediately a"aila!le in planning.
In timephased planned, historical data is also used in the material forecast to estimate future requirements.
(owe"er, in this procedure, the planning run is only carried out according to predefined inter"als.
)or all consumption!ased planning procedures, sales orders, planned independent requirements, reser"ations,
and so on are not rele"ant to planning.
In $%&, sales orders, planned independent requirements, reser"ations, and so on are planned directly as
requirements.
The $%& procedure is defined per material and plant. Therefore, the same material can !e planned in different
plants using different $%& procedures.
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'onsumption-Based Planning
+uture re&uirements are calculated from past
consumption values
It is assumed that the re&uirements are either
constant or linear
Irregularities in consumption are buffered b" a
safet" stoc%
*onsumption!ased planning procedures are especially useful+
for materials procured externally
for trading goods
for * materials ,#-* analysis.
for operating supplies
for goods that are not directly procured for an order, !ut are always required in large quantities
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BM Explosion for 'onsumption-Based
Materials
$ssembl"
'omponents planned b"
MRP
)ependent re&mts.
dependent reservations
Reorder point Reorder point
'omponents planned b"
consumption-based
procedures
/o dependent requirements are created for materials planned using any of the consumption!ased planning
procedures.
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'onsumption-Based Planning: Procedure and
Environment
MRP
2et re&mts calculation
/ot-si0e calculation
#cheduling
Inventor" mgmt
Material master
+orecast
$ $
Material Material
$
B B
'
B
3
3
Purchasing
)efine procurement
The main task of the planning run is to determine which material is required, how much of the material is
required and when it has to !e a"aila!le.
)or each requirement date, the system compares a"aila!le stock with requirements in the net requirements
calculation. If the requirements cannot !e co"ered !y existing stocks, the system calculates the shortage
quantity.
In the lotsi0e calculation, the system groups the net requirement quantities according to the lotsi0ing
procedure selected.
These order quantities are then scheduled.
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'arr"ing ut the Planning Run
Planning run for one plant - online 4total planning5
Planning run for one plant - bac%ground processing
4total planning5
Planning run for one material - online 4single-item planning5
$ $
Material Material
Plant
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Evaluating the Planning Result
Planning result with interactive processing options
2/6 $//*E) +R #I2G/E-I-EM P/$22I2G BE+RE #$1I2G 7
MRP lists 4individual evaluation . collective evaluation5
'urrent stoc%.re&uirements list 4individual evaluation .
collective evaluation5
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MRP /ist /a"out for 'onsumption-Based
Planning
MRP list MRP list
Material information
2umber of exception messages
Processing indicator
'onsumption values
)ate
Exception message
Receipt.Re&mt &uantit"
$vailable &uantit"
1ariable header 1ariable header
MRP elements MRP elements
Planned orders
Purchase re&uisitions
Production orders
Pruchase orders
Plant stoc%.
#torage location stoc%
'ontents 'ontents
+orecast re&uirements
Planning Planning
run run
(
(
(
#ales orders
Reservations
The $%& list displays the results of the last planning run. *hanges to receipts, issues or stocks that occur
!etween planning runs are not displayed.
In the header of the $%& list, you can display "arious data for the material using the 12etailed header3 !utton.
The system creates exception messages for the e"aluation of critical situations. 'ou can search for these
exception messages in the $%& list.
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#toc%.Re&uirements /ist /a"out
'urrent stoc%.re&uirements list 'urrent stoc%.re&uirements list
Material information
'onsumption values
)ate
Exception message
Receipt . re&mts &uantit"
$vailable &uantit"
1ariable header 1ariable header
MRP elements MRP elements
Planned orders
Purchase re&uisitions
Production orders
Purchase orders
Plant stoc% .
#torage location stoc%
'ontents 'ontents
+orecast re&uirements
(
(
(
'ontents 'ontents
re-read on re-read on
access access
#ales orders
Reservations
The current stock4requirements list always displays the uptodate situation of receipts, issues and stocks. That
is, the contents of the stock4requirements list are reread each time the list is accessed.
The layout of the list is similar to that of the $%& list.
5hen processing the stock4requirements list, you can always refresh the display.
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Evaluating the Planning Run ,sing the MRP
/ist
#election b" exception messages
#election b" MRP controller
#election b" stoc% receipt ranges of coverage
#election b" MRP date.processing date
#election b" materials with new exceptions
#election b" procurement
'ollective evaluation 'ollective evaluation
#earch function
- Exception messages
- Planning segments
- )ate of the MRP elements
Material memo
Period totals
Individual evaluation Individual evaluation
The mass e"aluation of materials is carried out using the collecti"e display of the $%& list.
# series of selection criteria is a"aila!le for selecting the desired $%& lists.
'ou can define the layout of the collecti"e display per user using the sort functions.
# search function is a"aila!le for searching for exception messages or certain dates.
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Evaluating the #toc%.Re&uirements /ist
#election b" product group
#election b" class
#election b" MRP controller
#election b" vendor
'ollective evaluation 'ollective evaluation
#earch functions
- Exception messages
- Planning segments
- )ate of the MRP elements
Material memo
Period totals
Individual evaluation Individual evaluation
The mass e"aluation of materials can also !e carried out using the collecti"e display of the current
stock4requirements list.
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Priority: if several exception messages exist for one MRP element, the system
will display the message allocated the highest priority
Creation of the MRP list depending on the exception message created
Splitting into exception gro!ps for the selection
Exception Messages
"he following settings can #e made in 'ustomi0ing:
Exceptions indicate:
2ew order proposals created in the planning r!n
$ates in the past %start, finish or opening date&
Pro#lems in BM explosion
Pro#lems in scheduling
Rescheduling
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/a"out of the Planned rder
Planned order
8eader
Material data.Plant
Procurement t"pe
#torage location
)ates
+irming
The planned order is the $%& controller3s planning tool for managing dates and quantities as well as the
procurement dates for co"ering requirements.
The system ad6usts planned orders automatically to suit changed dates or quantities.
To a"oid automatic ad6ustments, you can firm planned orders. )irm planned orders are not changed
automatically in the planning run.
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Chapter 1 Review 495
Materials planning relieves the MRP controller of routine
wor% and automaticall" plans procurement proposals to
cover material shortages(
In consumption-based planning: the s"stem uses
historical data to forecast future re&uirements(
Materials planning can be executed as a total planning run
for all materials relevant to planning 4online or in
bac%ground mode5 and as single-item planning for one
material onl"(
6ou can evaluate the planning run using the following
evaluation tools:
MRP list 4displa"s the situation at the time of the last
planning run5
current stoc%.re&uirements list 4up-to-date situation5
planning result 4interactive processing option before
saving the results of the planning run5

'hapter 9 Exercises: Executing the Planning Run
A new raw material is to #e planned in plant 1''' of the
company (or this p!rpose, the material master record is created
and the material is planned !sing the single)item planning r!n
1 Goto the main men! of the material master record:
Logistics Materials management Material master
* Create the material master record
+n the material master, select the f!nction:
Material Create (special) Raw material
,nter the material n!m#er -./*/MM)00
,nter the indicator for mechanical engineering
Select the p!sh#!tton for displaying the views and select the
following:
1asic data
P!rchasing
MRP 1 and *
Acco!nting
Select the p!sh#!tton entitled, organi2ational levels and enter
the plant 1''', the storage location '''1 and the MRP profile
-/*/
,nter the #ase !nit of meas!re PC in the 1asic $ata screen
and maintain a material description of yo!r choice
"he p!rchasing gro!p ''1 is responsi#le for p!rchasing "he
material #elongs to the material gro!p ''1
Chec3 the data on the MRP screen 4hy is it not possi#le to
overwrite the planned delivery time5
66666666666666666666666666666666666666666666666
Monthly cons!mption val!es are to #e created for this
material Starting from the MRP screen, select Extras
Consumption +n the screen that appears, enter the period
indicator M and the following cons!mption data
Previo!s month 78'
Previo!s month 1 7''
Previo!s month * 89'
Previo!s month 8 8:'
Previo!s month 7 8/'
Previo!s month / 87'
Previo!s month ; 8/'
Previo!s month : 8;'
Previo!s month < 87'
Previo!s month 9 8/'
Previo!s month 1' 87'
Ret!rn to the MRP screen #y selecting Back
+n the acco!nting screen, enter the val!ation class 8'''
Select the standard price val!ation and enter a standard price
of =1'
8 Save the material master record and then carry o!t materials
planning for the material:
Access the MRP men!:
Logistics Materials management Materials planning
MRP
"o carry o!t the planning r!n, select,
Planning run Sng-item, Sng-level
+n the planning r!n, the system is only to create planned
orders An MRP list is always to #e created for the res!lts of
the planning r!n
After the planning r!n, display the MRP list "o do this, select,
Evaluations MRP list !n"ivi"ual "ispla#
$isc!ss the res!lts of the planning r!n $isplay the detailed
header and scroll thro!gh it "o do this, select the p!sh#!tton,
$etaile" %ea"er
"hen, access the stoc3>re?!irements list "o do this, select,
Evaluations Stock&re'mts list
+ncrease the ?!antity of the planned order #y 1'' pieces "o
do this, position the c!rsor on the planned order and select,
Environment C%ange element
Change the ?!antity in the header of the planned order and
ret!rn to the stoc3>re?!irements list #y selecting, Back
"hen refresh the display of the stoc3>re?!irements list "o do
this select:
List Re(res%
@ow do yo! 3now that the planned order is firmed and what
does this mean5
66666666666666666666666666666666666666666666666
Convert the changed planned order into a p!rchase
re?!isition
"o do this, position the c!rsor on the planned order and select:
Environment Convert Pln")r" purre'
Chec3 the data in the following screen and save the p!rchase
re?!isition Ret!rn to the stoc3>re?!irements list #y selecting,
Back
After having done this, access the MRP list again 4hy can
yo! not see the changes here5
66666666666666666666666666666666666666666666666

'hapter 9 #olutions: Materials Planning in General
Executing the Planning Run
-o ;( *h" can "ou not overwrite the planned deliver"
time3
"he planned delivery time cannot #e changed as it was
defined ACannot #e overwrittenB in the MRP profile +f a
material is created !sing an MRP profile, then the val!es
that were defined ACannot #e overwrittenB can only #e
changed #y changing the MRP profile
-o <( 8ow do "ou %now that a planned order is firmed
and what does this mean3
Co! can see that an MRP element is firmed #y the D after
the n!m#er
Planned orders and p!rchase re?!isitions are internal
planning tools !sed to plan ?!antities and dates "hey can
#e changed, resched!led or deleted at any time ,very time
the planning r!n is carried o!t, the system adE!sts these
so)called proc!rement proposals to s!it the changed
stoc3>re?!irements sit!ation
"o prevent man!al changes from #eing adE!sted
a!tomatically #y the planning r!n, yo! can firm order
proposals and sched!le lines (irmed elements are no
longer changed a!tomatically @owever, they can still #e
changed man!ally, and yo! can also reset the firmed
indicator
*h" can "ou not see the changes between two
planning runs in the MRP list3
"he MRP list contains the res!lts of the last planning r!n
"his list is not !pdated !ntil the planning r!n is carried o!t
again
"he stoc3>re?!irements list is availa#le for chec3ing c!rrent
changes "he data in this list is !pdated every time it is
accessed