This document describes about planning material and how it can be used for capacity analysis .

The Standard SAP capacity planning does not assist a capacity availability check at the sales order; but we can check it with help of pre-planning material.


About Planning Materials?

Some of the highlight of planning material.

  • Planning materials are not produced but used for planning for non-variant/ Production parts.
  • Planning material pass
  • Planned independent requirement of ‘Planning material’ will be consumed by the Sale order of non-variant parts/Production Parts.
  • The relationship between ‘Planning Material’ and ‘Production Material’ will be maintained in ‘Conversion factor for planning material’
  • When we create Sale order for finished products availability check is not performed according to ATP logic, but instead it is based on planned independent requirements.

Example:

Let consider the below scenario:


Finished products FGP01 and FGP02 are being produced in the same production line .Here assumption is production line or Work centers are considered as ‘Planning  material ‘ and  the plant capacity are entered as Planned Independent requirement of ‘Planning material’.

Master Data Settings:

Planning Material:


Strategy      :  60

FG Material:

Strategy     : 65

Planning Material,Planning Plant and conversion factor (MRP3).

It always suggested that use same UOM between Planning material(PM) and FG. If we know correct conversion factor between the UOM of PM and FG we need to maintain it in Material master to get the accurate availability .

Step 1: Create available Plant/ Work center capacity : ( i.e Create the Planned Independent requirement for  Planning material.)

D             13.10.2014              120

D             14.10.2014              120

D             15.10.2014              120

D             16.10.2014              100 (reduced capacity)

D             17.10.2014              120

D             20.10.2014              120

D             21.10.2014              120

D             22.10.2014              120


PIR.JPG

Make sure that PIR has the below requirement type and consumption Indicator

When MRP run is take place Non-convertible Planned order will be created for Planning materials.This will be used as basis for planning dependent parts of FG.

Step 2: Sale Order processing of Finished Goods:


Create Sale order for FGP02 (one of the FG assigned with Planning material)

Qty : 150 PCs

Date : 10/10/2014

System confirm this quantity  only in two schedule as below. Reason is there is no capacity on 10/10/2014 (no PIR quantity is maintained  for Planning material)

Let say I am changing the date into 17.10.2014 and performing availability check in SO.

Since PIR quantity (Capacity) on 13 and 14 th cover this requirement  system confirm this quantity in 14-10-2014 itself.


Step 3: Capacity Reduction: ( Reduction of Planned Independent requirements)


Once sale order is created PIR of Planning material will be reduced (i.e capacity is assigned to sale order)


Here due to backward scheduling system consumed 120 qty from 14-10-2014 and 30 qty from 13-10-2014


Now if  we create sale order for the other Finished goods FGP001 which is also using same work center or production line  for the quantity 100 PC on 13-10-2014 system will only confirm 90 pcs (remaining PIR) and the 10 pcs will be confirmed on 15-10-2014 only.

Capacity utilization /load  Analysis:

We can use transaction code MD73 to analyse the capacity situation at any time.

Here 13-10-2014 capacity  of 120 PCs is fully utilized in which 100 pcs for FGP01 and 20 PCs for FGP02

On 14-10-2014 Capacity was completely  utilized by Sale order of FGP02

When MRP is carried out for  FGP01 and FGP02 system creates Planned order with type KD .

Advantages :


Available capacity in PCs or any UOM will be shown as PIR of Planning material

Capacity Utilization can be seen at any time.

Sale Orders delivery date will be calculated based on work centre capacity.

Work centers in which more than one similar products are produced ,capacity will be determined in Sale order stage itself.


Limitation:


We can not use this process for Stock transfer from other plant due to certain limitation in SAP.





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3 Comments

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  1. Mariano Cabalen

    Hi Vel,

    Interesting document!!. One question: does it only applies for make to order? because I am not seeing how you can plan future sales of FGP01 and FGP02…

    I am wondering if can this approach be used in make to stock for FGP01 and FGP02?

    Thanks in advance!

    Kind Regards,

    Mariano

    (0) 
    1. Velmurugan S Post author

      Hello Mariano,

        Thanks very much . The Idea of this process is combining Planning material logic with ATP check against PIR.We need  custom development to combine all FGs sale forecast into PIR of planning material. This will be only used for strategy 65 (MTO) requirment type.This process is usefull where many similar FGs using same production line with limited capcity and want to check the capacity at SO stage itself.For MTS I will check and let you know.

      Regards,

      Velmurugan S

      (0) 

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