Capacity Planning in MPS andMRPRelease
Capacity Planning in MPS and MRP SAP AGCopyright© Copyright 2001 SAP AG. All rights part of this publication may be reproduced or transmitted in any form or for any purposewithout the express permission of SAP AG. The information contained herein may be changedwithout prior software products marketed by SAP AG and its distributors contain proprietary softwarecomponents of other software vendors.®®®®®® ®Microsoft, WINDOWS, NT, EXCEL, Word, PowerPointand SQL Server are registeredtrademarks ofMicrosoft Corporation.®®®®®®®®®IBM, DB2, OS/2, DB2/6000, Parallel Sysplex, MVS/ESA, RS/6000, AIX, S/390,®®®AS/400, OS/390, and OS/400 are registered trademarks of IBM Corporation.®ORACLE is a registered trademark of ORACLE ®®INFORMIX-OnLine for SAP and Informix Dynamic Server are registered trademarks ofInformix Software Incorporated.®®®®UNIX, X/Open, OSF/1, and Motif are registered trademarks of the Open Group.®HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C, World WideWeb Consortium,Massachusetts Institute of Technology. ®JAVA is a registered trademark of Sun Microsystems, Inc. ®JAVASCRIPT is a registered trademark of Sun Microsystems, Inc., used under license fortechnology invented and implemented by Netscape. SAP, SAP Logo, R/2, RIVA, R/3, ABAP, SAP ArchiveLink, SAP Business Workflow, WebFlow,SAP EarlyWatch, BAPI, SAPPHIRE, Management Cockpit, Logo and trademarks or registered trademarks of SAP AG in Germany and in several other countriesall over the world. All other products mentioned are trademarks or registered trademarks of theirrespective 2001
SAP AGCapacity Planning in MPS and MRPIconsIconMeaningCautionExampleNoteRecommendationSyntaxApril 20013
Capacity Planning in MPS and MRP SAP AGContentsCapacity Planning in MPS and MRP.................................................................5Capacity Leveling in MPS and MRP............................................................................................6Determining Basic Dates.................................................................................................................7Lead Time Scheduling.....................................................................................................................8Carrying out Capacity Planning (MPS/MRP)..............................................................................9Capacity Leveling or Capacity Situation........................................................................................10Executing Single-Item Planning...............................................................................................13Executing Interactive Single-item Planning..............................................................................14Planned Order Processing.......................................................................................................15Current Stock/Requirements List.............................................................................................16Calling up Capacity Leveling....................................................................................................17Executing Capacity Leveling from the Material View..........................................................18Executing Capacity Leveling from the Order View.............................................................19Functions in Capacity Leveling................................................................................................20Selecting Capacities...........................................................................................................21Executing the Overload Check...........................................................................................22Displaying the Maximum Load and Selection of the Overload Periods..............................23Displaying the Scheduling Data..........................................................................................24Displaying Pegged Requirements in Detail........................................................................25Displaying all the Planned Orders for a Material................................................................26Displaying Capacity Planning in the Material View.............................................................27Capacity Planning in the Order View..................................................................................28Calling up the Capacity Situation........................................................................................29Functions in the Capacity Situation..........................................................................................30The Capacity Check......................................................................................................................31Executing the Capacity Check.................................................................................................32Capacity Planning Table...............................................................................................................33Branching to the Capacity Planning Table...............................................................................344April 2001
SAP AGCapacity Planning in MPS and MRPCapacity Planning in MPS and MRPCapacity Planning in MPS and MRPCapacity leveling in MPS and MRP [Page 6]Executing capacity planning (MPS/MRP) [Page 9]April 20015
Capacity Planning in MPS and MRP SAP AGCapacity Leveling in MPS and MRPCapacity Leveling in MPS and MRPThe task of material requirements planning is to guarantee material availability. The systemcalculates which materials must be procured or produced at what time and in what amounts soas to provide the quantities MPS you can carefully plan important parts or bottleneck parts in a separate planning runat the highest BOM level before the planning results have an effect on all of the production time scheduling and the calculation of capacity requirements in MRP and MPS provide thebasis for the creation of a master plan that corresponds to capacity planning. This way the MRPcontroller obtains information about possible bottlenecks and overloads. Before the master planbecomes effective and the planning results affect subordinate BOM levels, the MRP controllercan make changes that affect capacity for chosen capacity planning can take place you must create capacity requirements within lead timescheduling, that is, determine the production dates. The system only generates capacityrequirements if it executes lead time scheduling using the times specified in the in MRP and MPS determines the basic dates and the production dates for theplanned order. The basic dates define the earliest and latest dates for production. The productiondates use the times in the routing to determine the start and finish of production as well as of theindividual can find more details in:Determining basic dates [Page 7]Lead time scheduling [Page 8]6April 2001
SAP AGCapacity Planning in MPS and MRPDetermining Basic DatesDetermining Basic DatesThe system carries out a planning run that uses the requirements date to determine the basicorder dates. The basic order dates are calculated to the exact day. The system carries out backward scheduling to determine the basic dates. It starts from the finishdate and calculates backwards using the goods receipt processing time and the in-houseprocessing time maintained in the material master and thus calculates the basic start backward scheduling generates a basic date in the past then the system automatically switchesto forward scheduling and sets the current date as the basic start date. You can deactivate theautomatic switch to forward scheduling for each plant in Customizing for MRP. Then the systemexecutes backward scheduling even if a basic start date was calculated that starts in the 20017
Capacity Planning in MPS and MRP SAP AGLead Time SchedulingLead Time SchedulingLead time scheduling can be carried out in a second step. Lead time scheduling calculates theconcrete production dates. The system uses the times in the routing to carry out lead carry out scheduling and to generate capacity requirements various parameters must be setin Customizing. You can find information on settings in Customizing necessary for carrying out capacity levelingin MRP and MPS in Settings and profiles for capacity leveling [Ext.].Scope of functionsIn backward scheduling, the system first calculates backwards from the order finish date throughthe float after production to the production finish date. After this the individual operation dates arecalculated backwards, starting from the last operation finish date. The first operation start dategives the start of forward scheduling the system starts from the current date and calculates through the floatbefore production into the future. Then the individual operation dates are calculated starting fromthe first operation finish date and working forwards into the can specify whether lead time scheduling is to be carried out forwards or backwards in theparameters for detailed scheduling in Customizing for capacity planning or in Customizing lead time scheduling there are three scheduling levels available for capacity planning: Detailed scheduling Production-rate scheduling Rough-cut schedulingWith detailed scheduling you usually use the routing to carry out scheduling and capacityrequirements planning for a BOM level. The lead time is divided up into the operation segments:setup, processing and teardown. Production-rate scheduling is implemented in repetitive manufacturing. Production-ratescheduling is based on the times for the rate routing and is also carried out for a BOM -cut scheduling is based on the scheduling data in the rough-cut planning profiles and ata higher planning level (SOP) provides an initial overview of the capacity situation. The rough-cutplanning profile represents a cumulation of the overall BOM can find more information on scheduling levels, their setting in Customizing and on settingthe scheduling parameters in Parameters for scheduling and calculating capacity requirements[Ext.].You will find more information in the document PP - Material Requirements 2001
SAP AGCapacity Planning in MPS and MRPCarrying out Capacity Planning (MPS/MRP)Carrying out Capacity Planning (MPS/MRP)You can carry out capacity planning in three different ways, depending on the function called up: From within planning as capacity leveling From the evaluation “current stock/requirements list” as the capacity situation From within planned order processing as the capacity checkCapacity leveling makes it possible to check individual work centers for overloads and ifnecessary to dispatch planned orders at other times or with other capacity situation also provides an overview of available capacity and the load for theindividual work centers, but you cannot dispatch planned orders differently from within thecapacity situation. The capacity check from within planned order processing checks whether overloads may occurfor the work center(s) selected, which might endanger production of the planned order. It is only ifthere are overloads that the system branches to capacity leveling to make changes in planned order processing is only possible when creating or changing an order. Whendisplaying the planned order the system branches to the capacity the capacity planning table you can dispatch the capacity requirements for detailed planningcontinuously through time and for specific operations. You can find out from which functions you can call up capacity leveling, the capacity situation, thecapacity check or the planning table in: Capacity leveling or capacity situation [Page 10]Capacity check [Page 31]Capacity planning table [Page 33]You can find more details in: Calling up capacity leveling [Page 17]Calling up capacity situation [Page 29]Carrying out capacity check [Page 32]April 20019
Capacity Planning in MPS and MRP SAP AGCapacity Leveling or Capacity SituationCapacity Leveling or Capacity SituationIn MRP or MPS data is displayed in two lists in which the planning periods are shown on avertical axis. Capacity leveling Capacity situationThe capacities are displayed in the same way in both lists. However, whereas you can changedata in the capacity leveling list and carry out capacity leveling, you can only display data in thecapacity can call up the capacity situation or capacity leveling for all planned orders for one materialor just for a single planned order. In the following graphic the capacity situation was called up forone planned following data is displayed for a work center for specific periods: Available capacity at the work center in a period Total capacity load at the work center caused by all planned- /production orders in aperiod Capacity requirements in a period for the material for which a planning run has beencarried outIf the capacity situation or capacity leveling has been called up for a planned order then thecapacity requirements for the planned order in a period is also 2001
SAP AGCapacity Planning in MPS and MRPCapacity Leveling or Capacity SituationWork centerPLATZWork U of quantity100, per %Material%%,0710,0310,710,0310,70,000,,3362,6753,462,6753,40,000,,3373,0062,973,0062,911,139,,33100,2892,3100,2892,355,6547,,3368,4258,368,4258,358,0949,,3362,6753,462,6753,40,000,,3362,6753,462,6753,40,000,,3362,6753,462,6753,40,000,,3362,6753,462,6753,40,000,,3362,6753,462,6753,40,000,,3362,6753,462,6753,40,000,,3352,6344,952,6344,90,000,,070,000,00,000,00,000,0Load per periodOrderOrder -MKI50,,13PlanA7571JS-MKI50,,50PlanA7572JS-MKI100,,65If the material is processed at several work centers then you can display the data for the variouswork centers sequentially. By changing the order quantity and the basic finish date you can reduce under- and overloads ata given work can call up capacity leveling or the capacity situation from within the following functions: Master production scheduling: from the planning result of single-item planning from the planning result of interactive planning from planned order processing from the stock/requirements list Material requirements planning: from the planning result of single-item planningApril 200111
Capacity Planning in MPS and MRP SAP AGCapacity Leveling or Capacity Situation from planned order processing from the current stock/requirements list Long-term planning from the planning result of single-item planning from the current stock/requirements listYou can find information on accessing functions, from which you can carry out capacity levelingor check the capacity situation, inCarrying out single-item planning [Page 13]Carrying out interactive single-item planning [Page 14]Planned order processing [Page 15]Current stock/requirements list [Page 16]12April 2001
SAP AGCapacity Planning in MPS and MRPExecuting Single-Item PlanningExecuting Single-Item PlanningFor single-item planning, proceed as follows:1. In the initial screen for planning specify the indicator for lead time scheduling andcapacity planning in the field Scheduling. 2. Select the field Display result. 3. Press ENTER, and check the input . Press reach the results screen of single-item from the results screen you can carry out capacity planning with 200113
Capacity Planning in MPS and MRP SAP AGExecuting Interactive Single-item PlanningExecuting Interactive Single-item PlanningFor interactive single-item planning proceed as follows:1. In the initial screen for planning specify the indicator for lead time scheduling andcapacity planning in the field . Press ENTER and check the input . Press reach the initial screen for interactive single-item . Carry out planning. Choose Planning Execute planning from the results screen you can carry out capacity planning with 2001
SAP AGCapacity Planning in MPS and MRPPlanned Order ProcessingPlanned Order ProcessingIn planned order processing starting from the MRP or MPS menu, choose Planned order Create or Planned order Change or Planned order reach the header of the planned order. From here, either when creating or changing, youcan carry out a capacity check or, if necessary, capacity leveling. In display mode you can alsocarry out a capacity check. If there is an overload then the system branches to the capacitysituation, that means that you cannot carry out any 200115
Capacity Planning in MPS and MRP SAP AGCurrent Stock/Requirements ListCurrent Stock/Requirements ListFor the current stock/requirements list, proceed as follows:Choose... Starting from the menu for requirements planning: Evaluations Stock/reqmts list or Starting from the menu MPS: Evaluations Stock/reqmts list or Starting from the menu Long-term planning: Evaluations Stock/reqmts reach the current list of the MRP elements for the chosen can call up the capacity situation from here, if lead time scheduling is being carriedout in the planning run for the material in 2001
SAP AGCapacity Planning in MPS and MRPCalling up Capacity LevelingCalling up Capacity LevelingCapacity leveling gives you an overview of available capacity and the capacity load either fromthe point of view of the material in question or specifically for individual planned orders. Incapacity leveling planned orders can be changed both in terms of dates and quantities. Firstly, you can choose from within the planning result, whether capacity leveling is to be calledup from a material-related point of view, that means for all dispatched planned orders or for aspecific planned order as the order , you can carry out capacity leveling in planned order processing directly for theselected planned order. Here the order view is called material view displays a list of the periods when capacity requirements arose with theavailable capacity for these periods and the requirements from a material view. You are able tochange individual planned orders after the capacity order view adds the capacity requirements of the individual planned orders to the materialview. The order view is carried out for one specific planned order so that this planned order canbe shifted if can find more details in: Executing capacity leveling for the material view [Page 18]Executing capacity leveling for the order view [Page 19]Functions in capacity leveling [Page 20]April 200117
Capacity Planning in MPS and MRP SAP AGExecuting Capacity Leveling from the Material ViewExecuting Capacity Leveling from the Material View1. In the screen displaying the results of single-item planning or interactive single-itemplanning, choose Goto Capacity planning Capacity leveling For reach the dialog box Settings for capacity planning, if you have not previouslyspecified parameters for capacity . Select the desired planning type and the period type for capacity planning. Choose aview period, if necessary. Press the function key Continue. The system determines the work centers and the capacity categories affected andschedules them according to the chosen planning . If errors arose during scheduling, you get an overview of the scheduling errors relating tothe planned order in the dialog box Scheduling errors. From here, you can directly checkthe details of the scheduling errors in the scheduling log. To do this press the functionkey . Press the function key Continue. You branch to capacity system displays the capacity situation for one work center and one capacitycategory as well as the capacity unit from the work center. Note the following: If aplanning work center is entered in the routing on the detail screen for the routing headerthen this work center is displayed first of all with the relevant capacity category,otherwise the selection takes place , the system displays the following data: material number, short text and plant of the material to be processed the available capacity the overall capacity requirements at the work center selected the capacity requirements of the materialthe system highlights periods with 2001
SAP AGCapacity Planning in MPS and MRPExecuting Capacity Leveling from the Order ViewExecuting Capacity Leveling from the Order View1. Select the planned order with a double-click on the results screen for single-itemplanning or interactive single-item planning. Choose Goto Capacity planning Capacity leveling For the header of the planned order, select Goto Capacity reach the dialog box Settings for capacity planning, if you have not previouslyspecified parameters for capacity . Select the desired planning type and the period type for capacity planning. Choose aview period, if necessary. Press the function key Continue. The system carries out scheduling using the parameters set in . If errors occur during scheduling, you get an overview of the errors relating to thoseplanned orders affected. From here, you can directly check the details of the schedulingerrors in the scheduling log. To do this press the function key . Press the function key Continue. The system displays the evaluation of the system displays the capacity situation for one work center and one capacitycategory as well as the capacity unit from the work center. Note the following: If you haveentered a planning work center (task list header) in the task list, then this work center isdisplayed first with the corresponding capacity category, otherwise the selection occursat random. The system also displays the following data: order number, order quantity and basic finish date the available capacity the overall capacity requirements at the work center selected the capacity requirements of the material the capacity requirements for the planned order selectedThe system separately marks capacity loads generated by the planned order. April 200119
Capacity Planning in MPS and MRP SAP AGFunctions in Capacity LevelingFunctions in Capacity LevelingThe following functions are available to you in capacity leveling: Selecting capacities [Page 21] Executing the overload check [Page 22] Displaying maximum load and selection of overload periods [Page 23] Displaying scheduling data [Page 24] Detail display of pegged requirements [Page 25] Displaying all planned orders for the material [Page 26] Displaying capacity planning material view [Page 27] Capacity planning order view [Page 28] Branching to the capacity planning table [Page 34]20April 2001
SAP AGCapacity Planning in MPS and MRPSelecting CapacitiesSelecting CapacitiesYou can check the capacity situation for all work centers and the capacity categories you want to display another capacity, that is another work center or another capacity category,press the function key reach the dialog box Capacities. The system lists all those work centers along with thecapacity categories maintained there, at which capacity requirements for the material havearisen. The system displays the maximum load for every capacity select another work center or another capacity category, place the cursor on the desiredcapacity category and press the function key 200121
Capacity Planning in MPS and MRP SAP AGExecuting the Overload CheckExecuting the Overload CheckTo display the overload for individual work centers (capacity categories), proceed as follows:1. Press the function key Capacities. You get to see the dialog box Capacities with a list of the work centers and capacitycategories for the material shows the maximum load for every capacity category, that means the absolute valuefor the maximum load. If the value exceeds the available capacity then it is . To check the overload(s) in detail for the capacity categories, press the function keyOverload. You reach the dialog box Capacities with Overload with a list of all the periods inwhich too many operations were dispatched for the capacity overload, that is the value as of which the availability is exceeded, is usually set at 100%. Acapacity is overloaded at a particular date if the requirements are not less than or equal to theavailable capacity. You can specify any other percentage values you like. To do this proceed asfollows:1. Press the function key Settings in the dialog box Capacities with overload. The system displays the dialog box Settings for overload . In the field “Max. capa. load” enter the desired percentage for the overload check. Youcan limit the time period for which the overload check takes place in the section “Limitperiods”.3. Press the function key system carries out the overload check using the changed values. 22April 2001
SAP AGCapacity Planning in MPS and MRPDisplaying the Maximum Load and Selection of the Overload PeriodsDisplaying the Maximum Load and Selection of theOverload PeriodsTo check the periods which have maximum load on inspection and to target them for processing,proceed as follows:1. Press the function key Capacities. The system branches to the dialog box Capacities with a list of the work centers andcapacity categories for the material shows the maximum load for every capacity category, that means the absolute valuefor the maximum load. If the value exceeds the available capacity then it is highlighted. 2. To select the precise period(s) where the maximum load was dispatched, place thecursor on the capacity category that is highlighted and press the function key branch to the overview for the selected resource; the system highlights the periodwith the maximum check the periods which can be seen to have maximum load on inspection and to target themfor processing, proceed as follows:1. Press the function key Capacities. The system branches to the dialog box Capacities with a list of the work centers andcapacity categories for the material . Press the function key Overload. You branch to the dialog box Capacities with . Place the cursor on a period and press the function key branch to the overview for the capacity selected; the system highlights the 200123
Capacity Planning in MPS and MRP SAP AGDisplaying the Scheduling DataDisplaying the Scheduling DataYou can display the scheduling data for the individual orders. You have the following options: Call up the pegged requirements in the material view. Place the cursor on the order andpress the function key Displays scheduling data. Once in the order view place the cursor in the column Order number on any period youwish for the planned order selected and select Edit Scheduling get to the screen Scheduling data and can check the basic dates and production dates thereas well as any scheduling 2001
SAP AGCapacity Planning in MPS and MRPDisplaying Pegged Requirements in DetailDisplaying Pegged Requirements in DetailYou can get the system to display which orders have generated the overall capacityrequirements for a period. To do this place the cursor in the column Total req. on the appropriateperiod and press the function key Pegged requirements. If you only want to display the orders generating the requirements, place the cursor in the columnMaterial on the appropriate period and press the function key Pegged system displays the orders generating the requirements in the lower section of the following data is displayed: Order group Order number Material number Order quantity Base unit of measure Finish date for the order Capacity requirements for the orderIf you have maintained several operations in the routing for an order then the individualoperations are listed under the same order 200125
Capacity Planning in MPS and MRP SAP AGDisplaying all the Planned Orders for a MaterialDisplaying all the Planned Orders for a MaterialTo display all the planned orders for a material, press the function key Planned orders. The system displays the dialog box Planned orders for material with the list of all the plannedorders and the following data: Planned order number Planning plant Material number Order quantity Unit of measure Basic start date Basic finish 2001
SAP AGCapacity Planning in MPS and MRPDisplaying Capacity Planning in the Material ViewDisplaying Capacity Planning in the Material ViewIn the material view you can change the quantity or date of all planned do this press the key Planned orders. You get a dialog box Plnd orders for mat. with a list of allthe planned the cursor on the desired planned order and press the function key system displays the selected planned order in the screen section “Planned order” with thefollowing fields: Planned order number Material number Planning plant Order quantity Production version Basic start date Basic finish dateThe order quantity, basic finish date and production version can be 200127
Capacity Planning in MPS and MRP SAP AGCapacity Planning in the Order ViewCapacity Planning in the Order ViewIn the order view you can only change the dates or quantities of the selected planned system displays the selected planned order on the screen section Planned order: Planned order number Material number Planning plant Order quantity Production version Order start date Order finish dateThe order quantity, basic finish date and production version can be 2001
SAP AGCapacity Planning in MPS and MRPCalling up the Capacity SituationCalling up the Capacity SituationThe capacity situation is a display function in the current stock/requirements list. It provides anoverview of the available capacity and the load of individual work centers. You cannot dispatchplanned orders in any other capacity situation is called up as the material . In the current stock/requirements list: Choose Goto Capacity planning reach the dialog box Settings for capacity planning, if you have not previouslyspecified parameters for capacity . Select the desired planning type and the period type for capacity planning. Choose aview period, if necessary. Press the function key Continue. The system reads the work centers and capacity categories branch to the capacity capacity situation relates to one work center and one capacity category as well asthe unit of capacity from the work center. Note the following: If you have entered aplanning work center (task list header) in the task list, then this work center is displayedfirst with the corresponding capacity category, otherwise the selection occurs at system also displays the following data: material number, short text and plant of the material to be processed the available capacity the overall capacity requirements at the work center selected the capacity requirements of the materialthe system highlights periods with overload. You can find more details in: Functions in the capacity situation [Page 30]April 200129
Capacity Planning in MPS and MRP SAP AGFunctions in the Capacity SituationFunctions in the Capacity SituationThe following functions are available in the capacity situation: Overload check Displaying the maximum load and select overload periods Displaying scheduling data Displaying Pegged Requirements in Detail Selecting Capacities Displaying all the planned orders for the material Branching to the planning tableYou can find a description of the functions in Functions in capacity leveling [Page 20].30April 2001
SAP AGCapacity Planning in MPS and MRPThe Capacity CheckThe Capacity CheckThe capacity check can be called up from the following functions: MPS: from planned order processing MRP: from planned order processingYou can find information on accessing planned order processing in:Planned order processing [Page 15]April 200131
Capacity Planning in MPS and MRP SAP AGExecuting the Capacity CheckExecuting the Capacity CheckWhen creating or changing a planned order you can check the available capacity. The plannedorder must already have been scheduled. For every operation the system checks whether thereis sufficient capacity at the appropriate date for the requirements of the operation at the workcenter where the operation is to be processed. The capacity requirements of other orders oroperations at this work center are taken into account call up the capacity check in planned order processing for an individual planned from the planned order header select the menu options Edit Capacity check. Thesystem checks for the planned order selected whether there is an overload situation. If this is notthe case then the check is terminated. You get the message: “Capacity checked. No overloadfound”.If there is an overload situation, then the system displays a dialog box in which the overloadedcapacities are displayed per period. From there the system branches to capacity leveling inchange or display mode so rescheduling can be carried out there if necessary. In display modethe system branches to the capacity situation in the case of an overload 2001
SAP AGCapacity Planning in MPS and MRPCapacity Planning TableCapacity Planning TableYou can call up the capacity planning table from the following functions: Master production scheduling: from the planning result of single-item planning (material view) from the planning result of interactive planning (material view) from the current stock/requirements list MRP: from the planning result of single-item planning (material view) from the current stock/requirements list Long-term planning from the planning result of single-item planning (material view) from the current stock/requirements listYou can find information on accessing functions from which you can branch to the capacityplanning table:Carrying out single-item planning [Page 13]Carrying out interactive single-item planning [Page 14]Current stock/requirements list [Page 16]April 200133
Capacity Planning in MPS and MRP SAP AGBranching to the Capacity Planning TableBranching to the Capacity Planning TableThe capacity planning table allows you to dispatch call up the capacity planning table choose Goto Capacity planning Ca pacity system displays the planning table. The functions on the capacity planning table aredescribed in the section Functions in the capacity planning table [Ext.].The changes that you make from the current stock/requirements list are copied to the evaluationwhen you save the capacity planning changes that you make starting from the planning result only take effect when you save theplanning 2001
