5.lectureMRP（英文版）

7/31/2019IhsanOnurYilmaz,MSc1PracticalExerciseEnterpriseResourcePlanningusingSAP®R/3®7/31/2019IhsanOnurYilmaz,MSc2MaterialRequirementsPlanning(MRP)inSAPR/37/31/2019IhsanOnurYilmaz,MSc3Productionplanning-OverviewConversionProductionorderPurchasingorderproducepurchaseAvailabilitycheckSchedulingReleaseofproductionorderCapacityplanningFeedbackInvoicingProductionControlSalesplanningSalesplanforproductgroupsRough-cutplanningResourcebalancingProductionplanforproductgroupsDisaggregationPlannedprimaryrequirementsforproductsandimportantmodulesCustomerprimaryrequirementsMasterproductionschedulingMasterplanningforcriticalpartsMRPPlannedordersAvailabilitycheckSalesPlanningandProductionRoughPlanningProductionPlanning7/31/2019IhsanOnurYilmaz,MSc4MaterialRequirementsPlanningMainfunctionsofmaterialrequirementsplanning:–Guaranteeingthematerialavailability–On-timeprocurementorproductionoftherequirementsby•monitoringthestocks,•creatingofproposalsforpurchasingandproduction.MRPtriestofindtheoptimalwaybetween–best-possibleserviceleveland–minimizationofcostsandcapitallockup7/31/2019IhsanOnurYilmaz,MSc5PositionofMRPintheSupplyChain7/31/2019IhsanOnurYilmaz,MSc6ItemsofproductionplanningSales&OperationsPlanningMaterialRequirementsPlanning–Primaryrequirementsplanning–SecondaryrequirementsplanningProductionControl–Releaseofpurchasingorders–Releaseofproductionorders7/31/2019IhsanOnurYilmaz,MSc7MRPOrganizationallevel–MRPforacertainfactory–SingleplanningforamaterialMRPproceduresLot-sizingprocedures7/31/2019IhsanOnurYilmaz,MSc8MRPfunctionsThefollowingfunctionsareprovided:–Totalplanning–Single-item,single-levelplanning–Multi-level,single-itemplanning–Interactiveplanning–Multi-level,make-to-orderproduction–Individualprojectplanning7/31/2019IhsanOnurYilmaz,MSc9TotalplanningTotalplanningcoverstheplanningofallthematerialsthatarerelevantforrequirementsplanningandincludestheBOMexplosionformaterialswithaBOM.Youcanusetotalplanningforasingleplantoryoucanusethescopeofplanningtocontrolwhetherthetotalplanningrunisexecutedonamulti-plantlevel–forseveralplants,–foroneMRParea,–forseveralMRPareas,or–foracombinationofplantsandMRPareas.7/31/2019IhsanOnurYilmaz,MSc10Single-item,single-levelplanningSingle-itemplanninginvolvestheplanningofoneonlyindividualmaterial.Single-levelmeansthattheBOMisnotexplodedandthat,therefore,onlytheleveldirectlybelowthematerialisplanned.7/31/2019IhsanOnurYilmaz,MSc11Single-item,multi-levelplanningInsingle-item,multi-levelplanningtheBOMisexplodedanddependentrequirementsaregeneratedforassembliesandcomponents.Tocoverthedependentrequirements,thesecomponentsarealsoplanned.IfthecomponentsalsohaveBOMs,thesearealsoexplodedandthecomponentsareplanned.ThisprocessisrepeateduntilalllevelsoftheBOMareexplodedandplanned.IftherearecomponentsintheBOMthatareprocuredbystocktransferorproductioninanotherplant,theninsingle-item,multi-levelplanningtheotherplantisusedforfurtherplanning.7/31/2019IhsanOnurYilmaz,MSc12InteractiveplanningInteractiveplanningisasingle-levelsimulativeplanning.Itenablesyoutochecktheplanningresultparticularlycarefullyandtocarryoutfine-tuning.Itisparticularlysuitableformaterialswhichneedathroughoutcheck,e.g.formasterscheduleitems.7/31/2019IhsanOnurYilmaz,MSc13Multi-level,make-to-orderproductionWithmulti-level,salesorderplanningyoucanplanasalesorderitem,forwhichthestrategymake-to-orderproductionisenteredinthematerialmaster,overseveralproductionlevels.7/31/2019IhsanOnurYilmaz,MSc14MRPprocedures(1)MaterialRequirementsPlanning–Itisbasedonfuturesalesquantitiesthatexistintheformofplannedindependentrequirements,salesordersandmaterialreservations.MasterProductionScheduling–Partsorproductsthatgreatlyinfluencecompanyprofitsorwhichtakeupcriticalresourcesaremarkedasmasterscheduleitemsandareplannedwithextraattention.–Masterscheduleitemsmaybefinishedproducts,assemblies,orevenrawmaterials.7/31/2019IhsanOnurYilmaz,MSc15MRPprocedures(2)Consumption-BasedPlanning–Itincludessimpleandeasy-to-useproceduresformaterialsplanningwhichareusedtoachieveplannedtargetswithrelativelittleeffort.–Inconsumption-basedprocedures,historicaldataisusedasastartingpointforplanning.Futurerequirementsareforecastedusingtheinformationfromthesepastconsumptionvalues.–mainlyusedinareaswithnoin-houseproductionorforplanningBandCparts.7/31/2019IhsanOnurYilmaz,MSc16MasterProductionSchedulingDeterminationofdeliverydatesandquantitiesforfinalproductsandproductgroups(primaryrequirements)Primaryrequirements–Plannedprimaryrequirements–Customerprimaryrequirements7/31/2019IhsanOnurYilmaz,MSc17SourcesofplannedprimaryrequirementsManualinputSOPsalesplanSOPproductionplanMaterialforecastImportanotherplanMPSCriticalpartsplanning/MRP7/31/2019IhsanOnurYilmaz,MSc18SourcesofcustomerprimaryrequirementsCustomerprimaryrequirementsarecreatedautomaticallyduringcreationofcustomerorders.SAPR/3salesmoduleisnotpresentmanualinputofdata7/31/2019IhsanOnurYilmaz,MSc19Lot-sizingproceduresStaticlot-sizingproceduresPeriodlot-sizingproceduresOptimumlot-sizingprocedures7/31/2019IhsanOnurYi