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Author's profile photo Karunanithi Jayapal

MRP Challenges for Multiple Plants


Objective :

  • To run the MRP for multiple plants.
  • Same material involving into In-house production, External Procurement, Stock Transport Order and Subcontract process.


Plant Details:

  • Plant B (Manufacturing Plant1)
  • Plant C (Manufacturing Plant2)
  • Plant B1 (Internal Warehouse for Plant1)
  • Plant C1 (Internal Warehouse for Plant2)
  • Plant A (Distribution plant)


Material Master Settings:


Plant

Plant A

Plant B1

Plant C1

Plant B

Plant C

Material

Test 1

Test1

Test1

Test1

Test1

MRP Type

V1/V2

PD

PD

PD

PD

Reorder Point

1000

Procurement Type

F – External Procurement

F – External Procurement

F – External Procurement

E – In house Production

E – In house Production

Quota

Yes

Yes

Yes

   


For Plant A:

/wp-content/uploads/2015/01/mrp1_629788.jpg

Demand in Plant A :   


Here ROP = 1000 number is act as  demand.

When we run MRP system generates Stock transfer PR based on percentage given in Quota.

For Plant B1 and C1:


MRP2.jpg


Demand Flow from different plants:

MRP3.jpg

Total Demend in Plant (B and C) = Demand from Plant A + Demand from Plant B1 and C1


MRP Results:


When run MRP for Plant A:


Demand Created for Plant B1 and C1.

/wp-content/uploads/2015/01/mrp5_629795.jpg


When run MRP for B1 and C1:


Create stock transfer dependent requirement from Plant A and create request for Plant B.


Create stock transfer dependent requirement from Plant A and create request for Plant C.


/wp-content/uploads/2015/01/mrp6_629794.jpg

When run MRP for Plant B and C:


  • Create stock transfer dependent requirement from Plant A based on Quota and Planned order will create based on Quantity + Dependent requirement from B1 and C1.
  • If use any special procurement key for subcontract then SC PR will create based on Quota.
  • Create direct PR or Scheduling Lines.

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      10 Comments
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      Author's profile photo Former Member
      Former Member

      Nice document sharing Karunanithi.

      Thanks....

      Regards,

      Sai

      Author's profile photo Karunanithi Jayapal
      Karunanithi Jayapal
      Blog Post Author

      Thanks Sai...

      Author's profile photo Former Member
      Former Member

      It is very good document and informative for MRP newbies.....

      Author's profile photo Santosh Sharma
      Santosh Sharma

      thanks for sharing..

      Author's profile photo Ravindra Devarapalli
      Ravindra Devarapalli

      Hi,

      Is this scenario will work for MTO. Whatever you are shown MTS process but need same for  MTO process.

      example : if suppose one plant as Distribution plant , order received for  item A. For item A will manufacture at different plants..

      How we can reach this scenario.

      Author's profile photo Ravindra Devarapalli
      Ravindra Devarapalli

      Thank You for sharing valuable document.

      Author's profile photo Former Member
      Former Member

      Fantastic Post and its really useful for them who meets challenges in MRP. expecting more valuable posts from your side.

      Author's profile photo Former Member
      Former Member

      Hi Karuna,

      Good document, keep posting...

      Regards

      Vireshwar Chaturvedi

      Author's profile photo shailesh mishra
      shailesh mishra

      Hello JK,

      Cant we use here Scope of Planning of Total Planning OM0E instead of running MRP for each plans separately?

      Best regards

      Shailesh

      Author's profile photo Karunanithi Jayapal
      Karunanithi Jayapal
      Blog Post Author

      Dear Shailesh,

      I have not worked OM0E so far, I will check and let you know.

      Regards,

      Karna J