Lab 7: Exercises for the MRP Module

The exercises have been designed to give you a basic idea about the working of the MRP module in SAP. At the end of the exercise, you will be able to: Create a material in the SAP system Create a BOM for the material Create Independent requirements for the material Get the MRP for the material Consider the materials that have been described in the handout. Materials A and B need to be created in the SAP system. This means that the raw materials needed for A and B also need to be created in the SAP system. 7-1 Create the Material Master Data for the 8 materials. (A,B Finished goods, C-100, C-500 Semi-finished goods, C-300, C-400, C-600, C-700 Raw materials) Menu path: Logistics Production Master Data Material Master Material Create (special) Finished Product

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Create Finished Product: Initial Screen Enter product name as A Enter the Industry sector as M (Mechanical Engineering) Click on Enter. Select views Popup screen: Select Basic Data 1, MRP1 and MRP2 views Click on Enter Organizational levels Popup screen: Enter Plant as 3000 Click on Enter

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Create Finished Product: Basic Data Screen: Material Description Product A Base Unit of measure PC Click on Enter Create Finished Product: MRP1 Screen: Enter the MRP type field as M1 Enter the Planning time fence as 100 Enter the MRP Controller as 001 Enter the lot size as EX (Lot-for-lot Order quantity) Click on Enter Create Finished Product: MRP2 Screen: Enter the Procurement type as E (In-house Production) Enter the In-house Production as 10 days Enter the Safety Stock as 0 Enter the SchedMargin Key as 000 Click on Enter Last data screen has been reached. So save your data. Click on Yes. Repeat the same procedure for Product B using the following data: Plant 3000 Material Description Product B Base Unit of measure PC MRP type field M1 Planning time fence 100 MRP Controller 001 Lot size EX Procurement type E In-house Production 15 Safety Stock 0

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SchedMarginKey 000 Save the data and exit. Go to the Create (Special) menu and choose Semi-finished Product. Repeat the above procedure for C-100 and C-500 using the following data: Plant 3000 Material Description Product C-100 (or C-500) Base Unit of Measure PC MRP type field P1 Planning time fence 100 MRP Controller 001 Lot size EX Procurement type E In-house Production 5 Safety Stock 0 SchedMarginKey 000 Save the data and exit. Go to the Create (Special) menu and choose Raw material Repeat the above procedure for C-300, C-400, C-600 and C-700 using the following data: Plant 3000 Material Description Product C-300 (or any of the other products) Base Unit of Measure PC MRP type field P1 Planning time fence 100 MRP Controller 001 Lot size FX (Fixed Order quantity) Fixed lot size 300 Procurement type F (External Procurement) Planned Delivery time 5 days SchedMarginKey 000 Save the data and exit.

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7-2 Create the BOM for the materials A, B, C-100 and C-500. Menu path: Logistics Production Master Data Bills of Material Bill of Material

Material BOM Create

Create Material BOM: Initial Screen Enter your Material Number as A Plant 3000 BOM Usage 1 (Production) Click on Enter Create Material BOM: General Material Overview Screen Go to Component Field and Enter C-100, Quantity 2, ICt L, Un PC Go to the next line and enter C-700, Quantity 1, ICt L, Un PC Click on Save to save the single-level BOM The single-level BOM is created in a similar manner for B, C-100 and C-500. The necessary information to create the BOM for these materials may be obtained from the given diagrammatic representation. View the BOM created for the various materials Menu path: Logistics Production Master Data Bills of Material Evaluation BOM Explosion Material BOM BOM (Multi-level) Explode BOM: Level by Level: Initial Screen Enter Material A Plant 3000 BOM Application PP01 (Production general) Click on Proceed (clock icon on the top left corner)

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Notice that the BOM for A has been given in 2 levels. Why is this? _________________________________________________

In order to see the graphics view of the BOM, Goto Graphics In order to exit this view, Graphics Exit Similarly, view the BOM for all the materials created.

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7-3 Create Planned Independent Requirements for materials A and B Menu Path: Logistics Production Production Planning Demand Management Planned Independent Requirements Create Create Planned Independent Requirements: Initial Screen Enter Material A Plant 3000 Version 00 Click on Enter Enter the following requirements data: Reqmts Date Planned Qty Month+3 Month+4 Month+5 Month+6 Month+7 Month+8 Month+9 Month+10 15 20 50 10 30 30 30 30

Click on Save

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7-4 Run Master Production Schedule for Materials A and B Menu Path: Logistics Production Production Planning MPS MPS SingleItem, Single-level. MRP-Single-Item, Single-level Screen: Enter Material A Plant 3000 Processing Key NETCH Create Pur. Req. 3 Deliv. Schedule 1 Create MRP list 1 Planning mode 1

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Scheduling 1 Planning date todays date Press Enter to confirm the parameters Press Enter again to complete the MPS run Similarly run the Master Production Schedule for Material B.

Analyze the results of the MRP run for all materials Menu Path: Logistics Production MRP Evaluations Stock/Reqmts. List Stock/Requirements List: Initial Screen Enter Material A Plant 3000 Press Enter

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To see the Stock/ reqmts list for any other material, Enter Material ____ and press Enter. Click on Period (Sigma button) to view S/R list in weekly periods.

Run a multi-level MRP for the other materials (C-100 and C-500) Menu Path: Logistics Production MRP Planning Single-Item, Multi-level Single-Item, Multi-level Enter Material C-100 Plant 3000

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Processing Key NETCH Create Pur. Req. 2 Deliv. Schedule 3 Create MRP list 1 Planning mode 1 Scheduling 1 Select Also plan unchanged components Select Display material list Press Enter to confirm the parameters Press Enter again to complete the MRP run Analyze the results of the MRP for all the materials. Logistics Production MRP Evaluations Stock/Reqmts list Stock/Requirements List: Initial Screen Enter Material C-100 Plant 3000 Press Enter To see the Stock/ reqmts list for any other material, Enter Material ____ and press Enter. Click on Period (Sigma button) to view S/R list in weekly periods.

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