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Planning of materials SAP - how to
7 DEMAND PLANNING..........................................................................................82
7.1 Setup master data........................................................................................................................................82
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In the following chapters you will get a description when you use a method.
Please contact the service desk: servicedesk@kvernelandgroup.com if you want to change the
planning. They can also help you with setting up test scenarios.
It can happen that it gives sometimes some unwanted result therefor first test it in AS1, AS2
or AT1. Not all effect are 100% written down in this instruction, because than it will be more
than 200 pages.
With this you can give a percentage planning on the materials. This is based on the
characteristic and characteristic values used inside the KMAT.
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If you plan wheel set A for 60% and B for 40% and the highest level on stock are the rims and
tube. That means:
KMAT 5PC 10PC 20PC
Rim A 6PC 12PC 24PC
Inner tube A 6PC 12PC 24PC
Outer tube A 6PC 12PC 24PC
Rim B 4PC 8PC 16PC
Inner tube B 4PC 8PC 16PC
Outer tube B 4PC 8PC 16PC
It is only needed if the wanted delivery time from you to the customer is shorter than your
production time + the longest delivery time of your supplier(s).
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Forecast planning with product groups are working on a similar way as the Percentage
planning of the K-mat.
With this you can give a percentage planning on the materials. This is based on the
percentages in the product group.
If you plan wheel set A for 60% and B for 40% and the highest level on stock are the rims and
tube. That means:
KMAT 5PC 10PC 20PC
Rim A 6PC 12PC 24PC
Inner tube A 6PC 12PC 24PC
Outer tube A 6PC 12PC 24PC
Rim B 4PC 8PC 16PC
Inner tube B 4PC 8PC 16PC
Outer tube B 4PC 8PC 16PC
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It is only needed if the wanted delivery time from you to the customer is shorter than your
production time + the longest delivery time of your supplier(s).
This way of planning is used if you have materials that are 99% similar. So instead of
planning on 2 or more materials you just need to plan on 1 material. Be aware if you plan on 1
material and the only difference is the colour and you plan the painting you may got request to
paint the parts in the wrong colour.
With the second way you will prevent that you produce something that you dont need. The
only thing is you must maintain an extra material with BOM and routing.
It is only needed if the wanted delivery time from you to the customer is shorter than your
production time + the longest delivery time of your supplier(s).
This planning method is the basis of the last two described planning method. Also for this
method:
It is only needed if the wanted delivery time from you to the customer is shorter than your
production time + the longest delivery time of your supplier(s).
The Min Max (official: reorder point) planning can only be used on a material with a regular
consumption. The reorder point (minimum) must be setup, so that when the order goes to the
reorder point, that you will have enough stock for the consumption in the (internal/external)
delivery time of this material.
Disadvantage of reorder point planning: It is not possible to see the demands from planned
orders in the MD04. This means the demands from planned orders are not taken into account,
when you determine if the article has reached the reorder point. So it only shows the demands
from Production orders, Sales orders and delivery notes.
The easiest way of doing the planning is a demand planning. The demand planning has 1
basic. If I create a sales order. I get a requirement for that article. If I dont have it on stock the
MRP will generate a planned order or a purchase req.
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So the basic is it will try to get the stock is 0 (if no safety stock on the material) and for all
requirements I will have stock. This way of planning is also used inside the forecast planning.
Be aware before starting with 1 of the ways contact the service desk
servicedesk@kvernelandgroup.com
With external procurement you dont plan on a material. You use the signal empty bin to order
the parts at the vendor. When you receive the materials you scan the bin full. If it is scanned
full you have done the goods receipt.
With in-house production you also dont plan the material. You use the signal empty bin to
order the parts at your own production. When you receive the materials you scan the bin full.
If it is scanned full you have done the goods receipt and confirmed the production order.
With this method you can still plan on a material. You use the Kan Ban to move the stock
from 1 storage location to another storage location in your plant. Example: Move the stock
from the warehouse with a fixed quantity to the production floor.
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With this you can give a percentage planning on the materials. This is based on the
characteristic and characteristic values used inside the KMAT.
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6. Procurement type: E
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7. Leave the fields in Planning part empty. This figures are default filled with the MRP group, if you fill
it in here you will overwrite the defaults. This can make sure that it is not working anymore as
expected.
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9. Fill in the right production scheduling profile and save the material
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Check if this already exists. If not you must create it. This must be done for all planning
relevant characteristics. If all are maintained go to 2.4
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Master Data Combination
Table Create
Transaction code MDP1(MDP2 for change, MDP3 for display)
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4. Click twice on the column header Table to see the last used VT number. Choose this one by
double clicking on it.
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5. Choose the next number (this case VT9000002719 becomes VT9000002720) and continue
7. Give it a logical description and set the status to 1 (released) and click on
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8. Fill in the characteristic where this table is linked to and save it.
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Check if this already exists. If not you must create it. This must be done for all planning
relevant characteristics. If all are maintained go to 2.4
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Master Data Combination
Table Maintenance
Transaction code MDP4
3. Maintain all needed characteristic values of the characteristic in the table and save it
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3. If it is not maintained yet you will find screen below otherwise you have the screen of the next
point. Maintain in this screen a logical name and select that and click on
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If you select a table and click on you delete this table in the planning
With the tick mark behind the Characteristic value you say that one is relevant for this K-mat
If maintained completely save it.
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3. Maintain the planning figures (this can also be change by other transactions, like MC94)
Double click on the moment where you want to change the Percentage. For Example week
18.
For more info transactions please contact the service desk.
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4. Here you can maintain a percentage. You see also the total percentage use on a table in the
case below this is 121%. Based on the quantity you get some demands. Save the changes.
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A K-mat can only be used in an inactive planning. This means you cannot get any
independent requirements on the K-mat material itself. So the figures maintained in the
MD61/MD62 must be transferred to the lower level items.
To be able to do this there must be a job set up that runs the following transactions:
1. MS01 this distributes the figures from the K-mat to the lower level item (visible in
the MS04)
2. MS66 Transfer the independent requirements to the planning see the settings in next
chapter
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This must be done for all materials on the highest level on stock of the K-mat. Please dont
do it on 2 levels than you have the requirements twice!
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Master Data Material
Master Material Change Immediately
Transaction code MM02 (MM01 for create, MM03 for display)
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7. Leave the Strategy group empty. All the figures in the marked area are default filled with the MRP
group; if you fill it in here you will overwrite the defaults. The Mixed MRP = 1 makes sure that this
material gets the independent requirements
Ask service desk for determing the consumption mode and the periods backward and forewards
consumption.
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9. If it is an in-house produced part maintain production scheduling profile and save the material
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Adjust requirements
Transaction code MD74
3. Now you see the result of the job This can be exported to Excel with the
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Schedule Lines
reorganize
Transaction code MD75
3. Now you see the result of the job This can be exported to Excel with the
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Delete History
Transaction code MD76
3. Now you see the result of the job This can be exported to Excel with the
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2. Fill in the material, material type PROD (product group) and continue
3. Select the views Basic Data 1/2, MRP 1/4, Work scheduling and continue
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In several cases it is needed to transfer the demands from the higher level materials to the
lower level materials. So the figures maintained in the MC81/82 and MC75 must be
transferred to the lower level items.
To be able to do this there must be a job set up that runs the following transactions:
1. MS01 this distributes the figures from the K-mat to the lower level item (visible in
the MS04)
2. MS66 Transfer the independent requirements to the planning see the settings in next
chapter
This must be done for all materials on the highest level on stock of the K-mat. Please dont
do it on 2 levels than you have the requirements twice!
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Master Data Material
Master Material Change Immediately
Transaction code MM02 (MM01 for create, MM03 for display)
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7. Leave the Strategy group empty. All the figures in the marked area are default filled with the MRP
group; if you fill it in here you will overwrite the defaults. The Mixed MRP = 1 makes sure that this
material gets the independent requirements
Ask service desk for determing the consumption mode and the periods backward and forewards
consumption.
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9. If it is an in-house produced part maintain production scheduling profile and save the material
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Adjust requirements
Transaction code MD74
3. Now you see the result of the job This can be exported to Excel with the
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Schedule Lines
reorganize
Transaction code MD75
3. Now you see the result of the job This can be exported to Excel with the
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Delete History
Transaction code MD76
3. Now you see the result of the job This can be exported to Excel with the
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9. Fill in the right production scheduling profile for in-house produced materials and save the material
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Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Planned Independent
Requirements Create
Transaction code MD61 (MD62 for change, MD63 for display)
3. Maintain the planning figures (this can also be change by other transactions, like MC94) and
save it.
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Adjust requirements
Transaction code MD74
3. Now you see the result of the job This can be exported to Excel with the
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Schedule Lines
reorganize
Transaction code MD75
3. Now you see the result of the job This can be exported to Excel with the
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Delete History
Transaction code MD76
3. Now you see the result of the job This can be exported to Excel with the
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9. Fill in the right production scheduling profile for in-house produced materials and save the material
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Adjust requirements
Transaction code MD74
3. Now you see the result of the job This can be exported to Excel with the
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Schedule Lines
reorganize
Transaction code MD75
3. Now you see the result of the job This can be exported to Excel with the
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This must be done each month (beginning of the month.) If wanted to have it automatically
contact the service desk to set up a job.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production Production Planning
Demand Management Environment Independent
Requirements: Reorganization Delete History
Transaction code MD76
3. Now you see the result of the job This can be exported to Excel with the
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Disadvantage of reorder point planning: It is not possible to see the demands from planned
orders in the MD04. This means the demands from planned orders are not taken into account,
when you determine if the article has reached the reorder point. So it only shows the demands
from Production orders, Sales orders and delivery notes.
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6. If you fill in a safety stock, this must be lower than the Reorder Point. The advice is not to use a
safety stock with a reorder point planning.
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9. Fill in the right production scheduling profile for in-house produced materials and save the material
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7 Demand planning
Demand planning is the simplest planning method. There is a sales order created. After the
MRP run the system will suggest the needed planned orders or purchase requirements.
Convert those requirements into an order and deliver the sales order.
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9. Fill in the right production scheduling profile for in-house produced materials and save the material
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Be aware before starting with 1 of the ways contact the service desk
servicedesk@kvernelandgroup.com
For each Location where you would like to have Kan Ban on you must have a production
supply area.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production KANBAN Production
Supply Areas Maintain
Transaction code PK05 (PK06 display, PK05S fast entry)
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4. Fill in the plant, Supply Area, Supply Area description, Storage Location and Responsible MRP
controller and save
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Before you are changing a material to Kan Ban several things must be done:
Contact the supplier over the change
Count the current stock
Check on which locations it is used
Check the quantity/bin that is needed on each location
Check how many bins (minimum 2 bins) you need on each location
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4. Fill in the plant, Storage Location, Sales organization and Distribution channel which you want to
change
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5. Make sure that the item category group in NORM and continue
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6. Make sure that the MRP type is PD, Delete all lot size data (except the lot size itself) and continue
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7. Make sure that the bulk indicator is empty and a Planned delivery time is filled in and continue
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10. Make sure that the valuation class is following the table and save the material
Valuation class Material type
1100 Raw material (ROH)
8000 Semi-finished material (HALB)
9100 Finished product (FERT)
2. Fill the Material, Vendor, Purchase organization and Plant and continue
3. Make sure that the planned delivery time is the real time (most likely 7 days (every week)) and
save
3. Leave the fields Agmt, Item and MRP empty and save
4. Click on to create a control cycle This must be done for all locations individual
5. Fill in the material, plant and production supply area and continue
Before you are changing a material to Kan Ban several things must be done:
Count the current stock
Check on which locations it is used
Check the quantity/bin that is needed on each location
Check how many bins (minimum 2 bins) you need on each location
4. Fill in the plant and Storage Location which you want to change
5. Make sure that the MRP type is PD, Delete all lot size data (except the lot size itself) and continue
6. Make sure that the bulk indicator is empty and In-house production time is filled in and continue
4. Click on to create a control cycle This must be done for all locations individual and Fill in the
3. In this Kan Ban board you can see the different statuses of all Kan Ban bins
2. Select the radio button Kanban ID Number and the status (full, empty or wait) Place the cursor in
Kanban ID Number and type in or scan the Kan Ban ID and save it
For a new Kan Ban Bin you can only set them on wait or empty for the first time.
Within 10 minutes you can not change the status twice.
This transaction is used to change the status or quantity in a bin. You use this transaction.
With this transaction you can also set the status to wait. This is needed for deleting a bin for a
location.
Procedure
1. Access the transaction choosing one of the following navigation options:
SAP Menu Logistics Production KANBAN Control
Kanban Correction
Transaction code PK31
4. Make the corrections in the status and/or quantity and click on or in cases