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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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