This document is a training guide for SAP users, focusing on the Material Requirements Planning (MRP) process within the SAP ERP system. MRP in SAP is a systematic approach that calculates material requirements based on production demands, existing inventory, and procurement needs, ensuring on-time availability of materials. The document details the steps from production plan preparation and pre-MRP run activities to executing MRP and understanding related master data objects.
Key topics covered in the document are:
- Production Plan Preparation: Customer schedules are gathered and production plans are manually entered into SAP, utilizing product groups for categorized planning data. This involves defining product groups to organize planning.
- Pre-MRP Run Preparations: Before executing MRP, several preparatory steps are crucial to clear out old and irrelevant data. This includes deleting old purchase requisitions, closing open purchase orders, managing scheduling agreement lines, technically completing old production orders, deleting planned orders, and reorganizing independent requirements. Deleting planned independent requirements is also performed, often using predefined product groups.
- Planned Independent Requirements (PIR) Creation: Production plans are entered into SAP as Planned Independent Requirements. This is the step where the actual demand figures are input for planning purposes.
- MRP Run Execution: The core MRP run is executed to analyze material requirements. This process examines demand from PIRs, current inventory, and existing procurement proposals. Based on this analysis, the system generates procurement proposals such as planned orders or purchase requisitions.
- Stock/Requirements List Review: The Stock/Requirements List is reviewed to analyze MRP results. This provides a consolidated view of demand and supply elements, allowing users to assess the planning outcome and make adjustments if needed.
- Master Data Maintenance: Maintaining accurate master data is essential, especially in the Material Master. Key views like MRP related views, Accounting, Purchasing, and Work Scheduling are important. Production Versions within the Material Master are used to manage different BOM and routing combinations for the same material.
- Master Data Objects Configuration: Creating and managing master data objects is described, including Bills of Materials (BOMs), Routings, Work Centers, Reference Operation Sets, and Production Resource Tools (PRTs). The document outlines how these objects are configured and how they relate to each other within production planning. Trigger Points for automating functions are also covered.
- Scrap and Rework Handling: The process for managing scrap and rework within production orders is outlined. This includes confirming production quantities, managing rework quantities, and handling scrap postings against production orders.
- BOM Update in Production Orders: Instructions are provided on how to update the Bill of Materials in existing production orders to incorporate engineering changes made to BOMs after production orders are created.
This training material guides users through the MRP process in SAP, from initial planning data entry and pre-processing to running MRP and managing key production master data, providing practical knowledge for effective material planning.