SAP Production Planning and Control
Frequently Asked Question
Bills Of Material
Q: We have a BOM - 'A' with two
packing materials 'X' and 'Y'. For 1000 units of 'A', 1 packing material
of 'X' is required and for 50 units of 'A', 1 packing material of 'Y' is
required. Base quantity of 'A' is defined
as 1000. How can I define 'X' & 'Y' or in fact 'A'?
A: Make the base quantity of 'A' as 5000. The resulting component
quantities would be 5 of 'X' and 100 of 'Y'.
Q: Can we have more than 6 standard
values in standard value key?
A: One way
to achieve this is to create another operation step using the same work
center. However this shall be with a control key that is not a milestone.
When the milestone operation is confirmed, the previous operations up to
the next milestone are automatically confirmed. To get the desired number
of standard values , all the 'non milestone' steps can be built depending
on the need.
Q: Can we use same routing for materials
undergoing the same process/operations? Can we avoid
separate routing for each and every material produced?
A1: Presume that there are 50 products
and the fabrication shop uses a set of 10 machines. If all these products
use the same settings of the machines, Reference Operation Sets (task list
type S) can be setup for common processes that use the same work centers.
However costing, scheduling and capacity will be affected if each product
has different setup time and Reference Operation sets can not be used.
A routing for each material number ( type N or R) has to be set up
and within that routing, the Reference Operation Set can be used.
However you can by try utilizing the KMAT material and product variants
invariant configuration to avoid separate routing for each material.
A2: You may create a routing group. Go into routing creation
and enter the plant and the group name. If you want you may name the group
, else name is assigned by internal counter). Create the routing with the
work centers, operation times, etc. Go to the "Header overview" screen
and click on the "Mat Alloc" screen. Fill in the blanks with all the material
masters that use this routing.
Q: Scheduling times can be defined
in the material master record by;
# entering the in-house production time. This value can be updated
from the routing by the system.
# entering the setup, tear down, processing, and interoperation times.
If these values are maintained, the system determines the in-house production
time on the basis of lot size.
How do you get the system to update this
from the routing?
A: In routing, carry out scheduling. Go into the routing operation
overview and follow Extras -> Scheduling -> Results. The pop-up window
displays the scheduling data. At the bottom there is a pushbutton to copy
the scheduling data to the material master Check this push button to update
Q: We have deleted a group key in an operation in routing and
the same does not appear for this routing (CA02). But we noticed that entries
are maintained in table PLPO and the deletion indicator is not set. How
does the system remember this deletion of group key?
A: You may look at the tables PLKO, MAPL and PLAS.
Sales & Operations
Q: We defined SOP in months. However
during SOP transfer
to demand management, our independent requirements are appearing
in weeks. How can we correct this from weeks into
A: Check transaction OMPA for
general split. OMPS - based on the MRP group. Ensure that MRP group assigned
to the material. Delete any allocations in these tables. Then periods will
be transferred to Demand Management with the same splits as in SOP. Also
check whether the value of period is set as "month" at your plant level
in Transaction 'OMP7'
Q: Sales quantities in SOP for certain
days are transferred into Demand Management and are shown as planned independent
requirements. We need to keep the settings in SOP and change the periods
in Demand Management? We would like to have a rolling
horizon, for ex: the following 4 weeks on a daily basis, after that
on a monthly basis. What is the best way to do this?
A: Use the automatic period split
M R P
Q: We have a lot size procedure here
which is creating more order proposals. How do you set the limit
value for maximum number of MRP
order proposals per date in IMG?
A: Under customization, try materials
management->consumption based planning->maintain all plants
Q: What is the difference
between "planned consumption" and "Unplanned consumption"?
Can safety stock calculation be done on either of these?
A: While customizing movement types (OMJJ)
it is defined as to which set of consumption values gets posted during
the material movement. For some it may always be the total consumption
and for some it is always the unplanned one and for some it is dependent
on whether the issues were done with reference to a reservation ie., a
planned consumption. The way these consumption values are taken into account
in MRP is defined in the customizing of MRP types.
For Reorder point planning (VM) the total consumption
is used to calculate the safety stock and the reorder point.
For Forecast based planning (VV) the total consumption
is used to build the forecast which will be used to compile the order proposals.
For Deterministic MRP (PD) the unplanned consumption
is used to calculate the forecast which in turn is added to the actual
Q: We want the system to run a single level MRP automatically
on receipt of sales order. How to configure triggering event based MRP?
A: This can only be run if material master has planning strategy
41 (made-to-order) in the MRP2 view. We need to run for other MRP types.
We have to create a user exit in the sales order processing (VA01) to start
MRP based on data from our sales transaction.
Q: We have an assembly 'A' using a subassembly 'B'. 'B' in turn
uses raw material 'C'. Item 'A' is an MPS and is duly marked in Material
Master. Item 'B' and 'C' are marked as 'PD'. When demand for 'A' is entered
and MPS is run , upto which level the requirements are taken care of?
A: MRP can be run depending on your requirement. For example:
Without marking the checkbox " Process MRP materials" is like case
( 1) above and with the checkbox marked is like case (2 ).
Single Item / Single Level from MPS - Transaction Code MD42 - Only the
top MPS item ( 'A' in this case) is planned and dependent requirements
will be passed to MRP item ( 'B' ) . Run MRP, Transaction MD02 on 'B' to
plan it and all MRP items below .
Single Item / Multi Level from MPS - Transaction Code MD41 - All levels
are planned - A , B & C
Total Planning from MPS online or background - Transaction Code MD40 or
Q: We get an
message "Control parameters for scheduling not defined" while creating
test production Orders. Why?
A: Before you attempt creating Production
orders, configure your
Order types- Transaction Code OPHJ
Order type Dependent parameters - Transaction Code OPL8
Backorder Scheduling - Transaction Code OMIH
Scheduling Levels - Transaction Code OMIF
Q: We are trying to create Purchase
Requisition from MRP run. We have material , info Record, Source list ,
Demand in place. MRP is always creating plan order.
A: Check the procurement type in
MRP view of material master. Check 'Create Purchase requisition' indicator
while running MRP. If you want purchase requisitions to be created in the
opening period, select the for MRP control parameter 'create purchase requisitions'
Q: what is the option "Documented
goods movements" on Selection of Individual Object Lists (transaction
A: Use Transaction code OPL8 to
customize by choosing the order type, select all the checkbox under "Documentation
of goods movements" at the bottom of the page. Create a new Production
order, make GI to it, and run the report.
Q: We would like to have a report/inquiry
that would indicate variances (materials, material quantities) between
material recipe and actual process orders. We tried ME2M but this gives
us a list of purchasing documents and not the consumption deviation. Where
can I get such consumption deviation (master recipe
Vs. Process> Orders)?
A: Do a data collection first.
Menu Path - Accounting->Controlling->Product cost acctg->Process mfg->Information
system->Cost object hierarchy->data collection
(If you are using order hierarchy you would select order hierarchy
in place of cost object hierarchy in the menu path.)
Accounting->Controlling->Product Cost Accounting->Order Related Production->Information
Choose Report Period Costing - Target/Actual production variance
Q: We have two components ( 'X' & 'Y' ) in a production order
in a process oriented production process. When 50 numbers of component
'X' are issued, we need the system to automatically issue
100 numbers of component 'Y' based on ratio of 1
to 2. Where do I specify these ratios?
A: You can define the ratio in BOM and material may be issued
with reference to BOM.
Q: We have two storage locations are '0001' and '0600'. Default
storage location in Process order is always '0001' What determines
this default location?
A: Look into OSS notes: 100757, 63493, 96262, 87843, 82033,
The Storage location as configured in the Supply area has the highest
Q: We need to do GI of components
to production order using Back-flush. The component stock is managed in
Batches. The Batch to be back-flushed is selected
by FIFO from the issue storage location. How can we set this up?
A: With the following settings, the batches are selected the
moment the production order is released.
1: Set up batch determination the way that the batches in batch selection
are sorted the right way. e.g. sorted by expiry date
2: Use automatic batch selection in disp view.
3: Ensure that the components are allowed to be back-flushed (material
master / work center)
Q: We want to report on several status
combinations like each order that has status 'Not deleted' and 'Not
technically completed'. What set up is required?
A: Check transaction CO28. In the selection screen note the
possible selection 'System Status' . You can select TECO for technically
complete an DLT for deleted from the list. Select the Excl. indicator also.
You may also try transaction CO26 (Logistics -> Production -> Production
control -> Control -> Information systems -> Order Info System -> Object
overview). Before executing the transaction report, combinations of statuses
can be selected or exclude them.
Q: How can we shut
off the "automatic costing indicator" and the "automatic scheduling indicator"
which go on when the production order is released?
A: For "no automatic costing" follow
the IMG path
Production -> Production orders ->Master data -> Order - >Define order
type dependent parameters
Select the order type for which u automatic costing is not required.
In the controlling settings, select "no automatic costing"
For "no automatic scheduling" , follow the IMG path :
Production ->Operations - >Scheduling -> Define control parameters
Select the order type and go to details. Deselect " automatic dates
Alternatively, you can find indicators in the control key, which is
in the routing. Transaction OPL8 gives you costing indicators (Order type
dependent parameters), and OPJU (control table for scheduling) gives some
Q: How can
I use variable size items?
A: For example, consider an item A with 'kg' as base Unit Of
Measurement(UOM) and 'm3' as stock keeping/issue unit. Conversion factor
is 1kg = 2.4 m3.
In the BOM of 'B' ,number of A required are specified (say 5).
Specify the 3 variable dimensions i.e. length, width & thickness-
say 2000mm X 3000mm X 4mm = 0.024 m3
As per BOM - 'B' , the quantity of A required is 0.024 X 5 = 0.120
If a production Order is released for 15 numbers of 'B' , the quantity
of variable size unit will be 1.20 m3.
You can change the length, width or thickness in the production order
& check the resulting variable size item quantity. At the same time
this requirement can be seen in 'kg' in stock/requirement list.
Q: How to configure
the planning calendar for the ATP calculation where goods
are shipped every other working day?
A: Use Transaction MD25 and define calculation rule for every
other working day. Check the lot size settings in OMI4 and maintain relevant
data in MMR.
Q: We have two different production lines with different operations.
One production line works 5 days a week and the other 7 days a week. The
factory calendar is assigned to the plant for 5 days a week. This calendar
is checked when MRP is run. How can we assign
5 day a week and 7 days a week against a factory
calendar to the related resources? Is it possible to have two types
A: Assign factory calendars to the work centers.
Q: What is the difference between by-product
and co-product and how do you differentiate
in a BOM?
A: In case of Co-product costs are settled with a apportionment
structure. In case of By-product the price of this by-product is credited
to the order or the material stock account of the lead material being manufactured.
Co-Product as well as by-product are defined as BOM Components/Items. Both
of them have negative quantities. ( Not all negative quantity items fall
under these categories!). When BOM is created for FERT , you can see one
indicator in COMPONENT DETAILS screen for co-product. You need to define
the co-products with this special indicator .
Q: What are some important tables
used in PP ?
A: For orders:
AFPO - Order item
CUAFVD dialog structure for order headers and items
AFFLD Order: Dialog table for order sequences (AFFL)
MOPER Operation for production order
KBED Capacity requirements
AFRU Order completion confirmations
RESB Reservation/Dependent Requirements
AFFHD Structure of PRT's in orders
SAFRU Sub-operation confirmations
SKBED Capacity requirements for sub-operation
MRP table is MDTB.
CAUFV - AFVC Operation within an order
AFFT Order Process Instructions
AFFV Order process instruction values
Some other tables of interest:
PLKO, MAPL , PLAS.
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