PP Training Presentation M&M
PP Training Presentation M&M
PP Training Presentation M&M
Mangesh Landge
30.01.2010
Agenda
Topics:
Delta changes
PP master data
Material data changes
Views,MRP 1/2/3/4,Work scheduling
Bill of Materials
Work Centers
Routing
Production Version
Product Cost Collector
Agenda
Topics:
SOP-Sales and Operation planning
Demand management
MTS-Consumption
MTO
MRP
Planned orders
Order firming
LTP-Long Term Planning
Declaration
Agenda
Topics:
Finish product quality
ECN
Tool Room/Kitting-Dekitting/Die shop
Reports/Tcodes
Data cleansing and cut over stratergy.
Delta changes
Area
Sub area
Action
Material
Master
MRP
controller
Old vs new
Material
Master
Purchasing
group
Old vs new
Material
Master
REM Profile
Old vs new
Material
Master
Old vs new
Material
Master
Storage
locations
Old vs new
Material
Master
Equipment
master
Table
maintain ce
Transaction
MFBF
MFBF screen
Order
Business area
No Business
Remark
PP Master Data
Master
Master data
data
Material Master
Record
BOM
Routing
Item
10
20
30
Operation
10
20
30
Work centre
Basic Data
MRP
Stocks in plant/
storage location
Accounting
Storage
Costing
Purchasing
The
The material
material master
master is
is aa
central
central data object for all
material
material types
types e.g.
raw
raw materials
materials
semi-finished products
products
finished products
Sales
Work
scheduling
Quality
management
Forecasting
Classification
Each
Each user
user function
function has
has its
its own
own view
view of
of the
the material
material master
master
which
which permits
permits easy
easy access
access and
and maintenance
maintenance of
of data.
data.
Engineering
Production
??
Engineering
Materials
Materials Management
Management
Purchasing
??
Finance
Purchasing
Cost
Accounting
Cost Accounting
AAbill
billofofmaterial
materialisisaacomplete,
complete,formally
formallystructured
structuredlist
list
ofofthe
components
of
a
product
or
assembly.
A
bill
of
the components of a product or assembly. A bill of
material
materialcontains
containsthe
thedescription
descriptionand
andobject
objectnumber
numberofof
each
eachcomponent,
component,the
thequantity
quantityand
andunit
unitofofmeasure.
measure.
Multi-level BOM
Motorcycle
Power Train
Motor
Gear
Exhaust
Chassis
Front
Wheel
Rear
Wheel
Frame
Combining
Combiningsingle-level
single-levelBOMs
BOMscreates
creates
aacomplete
multi-level
structure.
complete multi-level structure.
Brake
System
Standard values
for routing
Basic data
Default values
Capacity data
Capacity
Scheduling data
Scheduling
Costing data
and
HR data
Scheduling basis
Queue and move times
Formula key
Assignment
Cost centre
Activity types
Formula keys
Available capacity
Formula key
Work
Work centres
centres contain
contain data
data stored
stored in
in several
several screens.
screens.
This
This figure
figure shows
shows some
some of
of the
the important
important data
data stored
stored in
in work
work centres.
centres.
Routings
Routing group
Operation 20
Operation 10
Work centre
Texts
Control data
Times
Material components
Production Version
The production version determines the
different production techniques that
can be used to manufacture a material.
A material may have several bills of
material (BOMs) and / or routings
corresponding to the different
production techniques. Each
combination constitutes a production
version.
SOP
Budgeted plan=>Quarterly plan for vendors=>monthly plan for actual
procurements=>weekly plan for sequencing-All levels should system
driven with version maintainance.Mannual interventions will be captured
as well as plan adherence calculation should be their.
Abstract of SOP: Budgeted and long term plan is used to decide the strategy of the business.
Budgeted plan prepare by collecting input from SSG/past trends for 5 years in
which 1 year firma and 4 years tentative.
Capacity utilization / capacity expansion is decided by referring SOP.
Plan prepared accordance with considering the capacities/targets.
Budgeted plan converted into quarterly plan in which 1 month firm and three
month tentative by considering all constraints.
Quarterly plan used for procurement proposals.
Same/modified plan converted into weekly plan for sequencing.
SOP-Process Flow
Demand Management
Function
The function of Demand Management is to determine requirement
quantities and delivery dates for finished products and important
assemblies. The result of Demand Management is the demand program.
Prerequisites
To create the demand program, you must define the planning strategy for a
product. Planning strategies represent the methods of production for
planning and manufacturing or procuring a product.
Result.
The demand program is created in the form of planned independent
requirements. Demand Management uses planned independent
requirements and customer requirements. Customer requirements are
created in sales order management.
Backward/Forward Consumption
Planned
independent
requirements
Backward/forward consumption
1
Time
Sales Orders
Backward
period
Forward
period
InInbackward/forward
backward/forwardconsumption
consumptionwhen
whenaasales
salesorder
orderisiscreated,
created,ititisisfirst
firstallocated
allocatedtotothe
the
independent
requirement
in
the
most
recent
past.
If
the
order
is
larger
than
the
independent
independent requirement in the most recent past. If the order is larger than the independent
requirement,
requirement,the
thesales
salesorder
orderisisallocated
allocatedtotothe
thenext
nextindependent
independentrequirement
requirementthat
thatlies
liesininthe
the
past
until
all
independent
requirements
have
been
consumed
within
the
defined
consumption
past until all independent requirements have been consumed within the defined consumption
period.
period. Once
Onceall
allofofthe
thepast
pastindependent
independentrequirements
requirementshave
havebeen
beenconsumed,
consumed,the
thesales
salesorder
order
isisallocated
to
the
first
independent
requirement
in
the
future.
allocated to the first independent requirement in the future.
Demand Management
Demand Management involves management of,
Planned Independent Requirements (PIR)
Customer Requirements (CR)
Strategy determines
Requirement types i.e. attributes of the requirements
How PIR are consumed by CR
Demand Management
Copy from
Sales Plan
Copy from
Prodn Plan
Copy from
Forecast
Copy from
Orig Plan
Demand Management
Demand Program + Strategy
MRP
MRP OVERVIEW
Line
Assignment
Sequencing
/ Scheduling
Matl. Staging
REM
Backflush
Deterministic
Deterministic
MRP
MRP
Consumption-Based
Consumption-Based
Planning
Planning
Forecast-Based
Forecast-Based
Planning
Planning
Reorder
ReorderPoint
Point
Planning
Planning
Automatic
Automatic
Reorder
ReorderPoint
Point
Manual
Manual
Reorder
ReorderPoint
Point
MRP Types
Commonly Used:
PD - Deterministic Planning
MRP produces order proposal(s) to match the exact quantity of the
requirements based on independent and dependent demands
VB - Manual Reorder Point Planning:
MRP produces order proposals when stock falls below a reorder
point. The reorder point and safety stock levels are entered
manually
Net Change Planning only items which have undergone a change to the
supply/demand balance, such as warehouse receipts and issues, are re-planned.
It is common to run net change MRP daily.
MRP Steps
Net Requirement Calculation:
In MRP, the system compares available stock or the scheduled receipts from
purchasing and production with planned independent requirements, material
reservations and incoming sales orders during the net requirements calculation.
In the case of a material shortage the system creates an order proposal.
Lot Sizing:
It calculates the quantity recorded in the order proposal according to the lot
sizing procedure specified.
Scheduling:
The order proposal is scheduled. For external procurement delivery and release
dates are determined and for in house production the production dates are
calculated.
Planned Orders / Purchase Requisition:
During MRP run planned orders / purchase requisitions are created for in house
production / external procurement.
Exception messages
Exception groups
"CANCEL OPERATION"
"DISPLACE OPERATION"
"FINISH DATE IN
THE PAST"
Selection of the MRP lists according to exception group "Exception during rescheduling"
Material A
"BRING FORWARD
OPERATION"
"CANCEL OPERATION"
Material B
Long-Term Planning
Long-Term Planning
Material Staging
Declaration
Serialized product have unique
equipment master contain unique
serial number with active status
management.
Equipment category-E for Engine and J
for vehicle
ECN
Engineering change number
With approval
Handle through status management
Without approval
Tool Room/Kitting/Dekitting/Die
shop
With material
Without material
Labor and Machine utilization for
order
Confirmation and settlement
Non valuated material
Cost report
Reports/Tcodes
Old vs new Tcodes
Old vs new important tables
Thank you