SKI P01 07 PP KUT Planning Process v1.00.pptx

Production Planning

1. PLANNING PROCESS SKI PROJECT April, 2015

2. Lembar Informasi Dokumen Nama Dokumen Nomor Dokumen Nomor Proyek Tempat Pembuatan Dokumen Tanggal Pembuatan Dokumen Penggunaan Dokumen Informasi Dokumen Versi Perubahan Tanggal 0.1 Draft awal oleh xxx 0.2 Perubahan xxx oleh xxx 1.0 Dokumen final oleh xxx Versi Dokumen

3. Agenda Memahami konsep dasar proses perencanaan produksi di module PP Pada akhir materi ini , Peserta diharapkan mampu :

4. Tujuan Memahami konsep dasar proses perencanaan produksi di module PP Memahami hubungan antara proses planning dan proses eksekusi produksi Menganalisa masalah yang mungkin timbul dan mengambil tindakan penyelesaiannya Pada akhir materi ini , Peserta diharapkan mampu :

5. RKAP Produksi ( Rencana Produksi Tahunan ) diinput sebagai Planned Independent Requirement (PIR) di SAP PP PIR diinput pada level material number PIR dapat diinput pada material Finished Goods atau Semifinished Goods sesuai kebutuhan PIR memiliki versi inactive (01,02,03,dst) dan active (00). Versi ‘01’ menggambarkan RKAP versi awal , versi ‘02’ merupakan revisinya , dst PIR dengan versi inactive paling valid akan di-copy ke versi active (Copy Inactive to Version to Active) Hanya PIR versi active ‘00’ yang akan dijadikan sebagai acuan untuk proses Material Requirement Planning (MRP) Demand Management / PIR

6. Exercise 1 MD61 – Create Planned Independent Requirement MD62 – Change Planned Independent Requirement MD63 – Display Planned Independent Requirement Exercise 2 ZPP_C02 – Upload Planned Independent Requirement Exercise 3 MS64 – Copy Inactive to Active Version Exercise: PIR

7. Fungsi LTP : ‘ Estimasi Pemakaian & Pembelian Bahan ’. Hasil run LTP untuk material pembelian dapat di-transfer ke Purchasing Info System untuk keperluan estimasi jumlah pembelian dan estimasi biaya bahan-bahan baku untuk 1 tahun ke depan . Data LTP ini juga dapat dijadikan dasar untuk negosiasi dengan Vendor tentang kontrak dan jadwal pembelian . Estimasi Capacity Mengevaluasi capacity Load dengan cara membandingkan available capacity dengan capacity requirement Long Term Planning (LTP) Long Term Planning merupakan simulasi perencanaan jangka panjang yang di-trigger oleh rencana produksi tahunan . PIR versi inactive akan dijadikan dasar perhitungan dalam Long Term Planning Run LTP akan menghasilkan perencanaan yang disebut Simulative Planning, dimana semua Planned Order yang terbentuk oleh LTP bersifat simulasi sehingga tidak dapat diubah menjadi Production Order atau Purchase Requisition.

8. Exercise 1 MS31 – Create Planning Scenario MS32 – Change Planning Scenario MS33 – Display Planning Scenario Exercise 2 MS01– Run MRP (Simulation) MS04– Stock Requirement List (LTP) Exercise 3 CM38– Evaluate Capacity LTP Exercise 4 MCB)– Evaluate Inventory Control LTP MS70– Set Up Purchasing Info Data LTP MCEC– Evaluate Purchasing LTP Exercise: LTP

9. Planning Concept Evaluate total MRP Results (MD06) MRP Run Evaluate material MRP Result (MD05) Process Order Generated Planned Order Generated Convert Planned Order to Purchase Reqs Material Master Data MRP Type: PD Material Master MRP1 MRP Result Stock Requirement List (MD04) Convert Planned Order to Process Order Purchase Reqs Generated Convert Planned Order to PR STR STR Generated STO Generated PIR

10. Planned Order / Purchase Requisition Requirements/ Demand (PIR, DepReq , OrdRes ) Supply ( seluruh elemen penerimaan yang masih open: qty open planned order, qty open process order qty open PR, qty open PO) Warehouse Stock compare Shortage Prinsip R un M RP Sistem mengkalkulasi kebutuhan (PIR/ Depreq ), lalu dibandingkan dengan ketersediaan stock (stock on-hand, open process order, open purchase order, planned order, purchase requisition) Apabila terjadi kekurangan material (kebutuhan > ketersediaan ) maka sistem secara otomatis akan membuat order proposal (supply) berupa planned order atau purchase requisition MRP Concept (1)

11. The main objective of MRP is to determine: What material is needed (material apa saja yang dibutuhkan ) How much of the material is needed ( berapa qty yang dibutuhkan ) When is the material needed ( kapan dibutuhkan ) With MRP we could: Guarantee stock availability ( Memastikan ketersediaan stok ) Get efficient inventory control system ( Mendapatkan efisiensi pengelolaan stok ) MRP Concept (2)

12. Planning Strategy: 10 10 - Make to Stock Production Logika Strategi 10: Material diproduksi berdasarkan demand program (PIR), bukan berdasarkan sales order Planned order akan dibuat secara otomatis untuk memenuhi PIR. Planned order = PIR – receipt ( open receipt element misalnya process order) – stok gudang. Planning Strategy: 10

13. Planning Strategy: 70 Logika Strategi 70: PIR di-create pada level Komponen Apabila terdapat Dependent Requirement (DepReq) / Order Reservation (OrdRes) pada level komponen akibat dari planned order/process order pada level produk, maka DepReq/OrdRes dengan PIR akan saling meniadakan (DepReq/OrdRes mengkonsumsi PIR Parameter di material master: - Strategy group 70 on the MRP screen. - Set the indicator for assembly planning, the Mixed MRP indicator, to 1 on the MRP screen. - Consumption parameters (Consumption mode, Bwd consumption, Fwd consumption on the MRP screen) to allow for consumption of planned independent requirements

14. D002 KT2 D601 WH Chemical (TAP, DAP) Netralizing Amine dll D001 KT1 Special Procurement

15. BOM Explosion

16. Planned Order Start Date Requirement Date Urea Ammonia Chemical Planned Order Purchase Requisitions DepReq: XXx Pcs DepReq DepReq Xx Kg Xx Kg Planned Delivery Time Material Time 31/07/2009 10/07/2009 05/07/2009 01/07/2009 Recipe/in house delivery time Recipe /in house delivery time MRP Backward Scheduling

17. Deterministic MRP Procurement is triggered from demand BOM will be exploded Consumption-Based MRP / Reorder Point (ROP) Procurement is triggered from stock level Start Delivery Time Date Date Reorder Point Safety Stock The system checks whether the available stock level falls bellow the reorder point defined for the material. If it does, procurement must be triggered for the amount of the lot size MRP Deterministic vs ROP

18. Alur Proses: MTS Planning (1)

19. Alur Proses: MTS Planning (2)

20. Alur Proses: MTO Planning (1)

21. Alur Proses: MTO Planning (2)

22. Process Step Planning Scope Planning Method Total planning as background job Seluruh material dalam plant Secara otomatis oleh background job Total planning online Seluruh material dalam plant Secara manual oleh MRP Controller Single item, multi-level Satu material. Sistem membaca struktur BOM hingga hirarki yang paling bawah . Secara manual oleh MRP Controller Single item, single-level Satu material. Sistem hanya membaca 1 level struktur BOM . Secara manual oleh MRP Controller Net reqmts calculation Lot size calculation Scheduling BOM explosion / determining dependent reqmts Total planning Single item - - Online / Background Plant Level Variant Scheduled Periodically Actual Online Only Material Item Level No Variant Immediately Actual / Simulation PLANNING RUN MRP Run Method

23. Procss Key Explanation NETCH MRP run only takes place for those materials which have undergone changes (sales order entry, purchase order entry) NETPL MRP run only takes place for those materials which have undergone changes (sales order entry, purchase order entry) within predefined planning horizon NEUPL Planning all materials for a plant (Regenerative Planning) This planning control parameter can control, whether you want the procurement proposal to be created as a purchase requisition rather than planned orders (Purchase requisitions are created for the externally procured materials) in the planning horizon or in the opening period**. You also have an option to have the system always create planned orders instead of purchase requisitions. ** Opening period is the number of workdays before the order start date accounted as buffer time for the MRP controller to process the planned orders in to purchase requisitions. Use Processing Key (NETCH) Control Indicator (3 ‘Planned Order’) Processing Key Creation indicator MRP Control Parameter (1)

24. This control parameter controls whether the system should create the MRP list for all the planned order or whether it should not at all create MRP lists or whether it should create MRP list only for the planned order which are in exception. Create MRP List : Use ‘1’ Planning Mode : Use ‘1’ or ‘2’ Scheduling: Use ‘2’ Create MRP List Pln. Mode Explanation Adapt Planning Whenever there is a change in requirement quantities or dates or change in lot sizing procedure, for the un-firmed planned orders, the system re-explodes the BOM for the new adjusted quantities in the MRP run. Re-explode BOM & Routing The system re-explodes BOM & Routing for all unfirmed procurement proposals Delete & Recreate the system deletes the existing procurement proposals and re-explodes the BOM and Routing for them, thereby creating new procurement proposals. Planning Mode Basic Dates Sched : Use material master in house prod time for scheduling Lead Time Sched : Use recipe data for scheduling Scheduling MRP Control Parameter (2)

25. MRP Element Keterangan Penerimaan / kebutuhan Stock Stok material pada level plant (free stock) Tersedia (+) IndReq Planned independent requirement . Rencana produksi untuk Finished Goods (RKAP/Proyeksi produksi) Kebutuhan (-) DepReq Dependent requirement . Kebutuhan yang muncul pada level komponen ( berdasarkan BOM), karena ada requirement pada material induknya Kebutuhan (-) OrdRes Dependent reservation . Reservasi komponen yang dibuat sistem secara otomatis apabila ada process order yang membutuhkan komponen tersebut . Kebutuhan (-) PldOrd Planned Order Dokumen perencanaan produksi barang in-house dan perencanaan pengadaan material out-house. Selanjutnya planned order kan dikonversi menjadi: Process order (in-house) Purchase Requisition STO (out-house another plant) Purchase Requisition (out-house vendor) Penerimaan (+) PrcOrd Process order Dokumen perintah memproduksi barang . Hasil konversi dari planned order Penerimaan (+) MRP Element (1)

26. MRP Element Keterangan Penerimaan / kebutuhan PurRqs Purchase Requisition Merupakan dokumen permintaan ke departemen Purchasing untuk membeli suatu barang. Merupakan dokumen permintaan stock transfer dari plant peminta ke supplying plant untuk menjadwalkan pengiriman. Selanjutnya purchase requisition akan dikonversi menjadi Purchase Order Penerimaan (+) PrqRel Purchase Requisition Req (Stock transfer Requisition Req) Merupakan requirement yang muncul di supplying plant akibat adanya Purchase Requisition di Delivering Plant POitem Purchase Order Dokumen perintah pembelian barang ke vendor ke Plant lain Penerimaan (+) QMlot Inspection Lot Inspection Lot. Stock yang masih berada dalam karantina karena masih diinspeksi Penerimaan (+) CusOrd Sales Order (SO) Order penjualan Kebutuhan (-) Delvr Delivery Order (DO) Surat Jalan / Perintah pengiriman Barang ke Customer Kebutuhan (-) MRP Element (2)

27. Updated at the time of the last planning run Reflect the last situation of the last executed planning Individual / Collective MRP List Stock/Requirement List Updated each time the stock/ requirement list is called up Always display the most up-to-date stock position Individual / Collective Evaluasi MRP melalui: MRP List Stock Requirements List Custom MRP Report MRP Evaluation

28. Informasi yang dibuat oleh sistem apabila terjadi keadaan yang seharusnya tidak terjadi pada kondisi normal. MRP Exception Message (1)

29. MRP Exception Message (2)

30. MRP Exception Message (2)

31. MRP Exception Message (3)

32. The list is stored in the system until it is either deleted manually or replaced by the new list from the next planning run. Materials This selection displays that new exception messages have been created for the material. An exception message is treated as 'new', it has not yet been created for an MRP element. An exception message belongs to an exception group shown at the top of the column. Each cell for each material displays the number of of exception messages that occurred for that group Exception ares displayed per Exception Group Double Clicking on one line item is possible to access the detailed item MRP list The Traffic lights represent compromised demand; Red = Compromised demand (need to order, supply in days is negative) Green = Have enough days supply stock (will remain green even if we run out of stock tomorrow) Number of days the material has been out of stock Processing status displays item as unprocessed = unprocessed = processed Collective MRP/Stock Req List

33. Exercise 1 MD01 – MRP Run: Total Planning MD02 – MRP Run: Single Item, Multilevel MD03 – MRP Run: Single Item, Single Level MDBT – MRP Run: Background Exercise 2 MD04– Stock Requirement List MD05– MRP List Exercise 3 COOISPI – Planned Order List ME5A – Purchase Requisition List MD15– Convert Planned Order to PR Exercise 4 MD12– Change Planned Order Exercise: MRP

34. Capacity Load : (Cap Req / Avl Cap) x 100% Capacity Evaluation determine of available capacity determine of capacity requirement comparison of available capacity and capacity requirement Capacity Evaluation : mengevaluasi kebutuhan kapasitas dengan kapasitas tersedia Available Capacity : jam tersedia sesuai shift sequence pada resource Capacity Requirement : jam kebutuhan produksi berasal dari planned order & process Order Capacity Evaluation

35. Alur Proses: Evaluasi Kapasitas MTS

36. Alur Proses: Evaluasi Kapasitas MTO

37. Exercise 1 CM01 – Capacity Evaluation Exercise: Capacity Evaluation

38. Static procedures Static procedures Lot- for - lot order quantity Replenishment up to maximum stock level Fixed lot size Period procedures Period procedures Daily lot size Monthly lot size Weekly lot size Flexible periods according to planning calendar Optimum procedures Optimum procedures Dynamic lot size creation Least unit cost procedure Part period procedure Groff reorder procedure Lot- Lot- sizing procedures of Lot- Sizing Procedures Entered in Material master Define Quantity Order proposal Lot Size

39. 39 Static Lot Size - Procedure

40. 40 Quantity Time Lot-for-lot order quantity (exact to the day) Receipts Reqmts EX When the lot size is “EX” or exact lot size, the system creates planned orders or procurement proposals to cover the exact shortage requirement. The lot size is the whole shortage quantity required to satisfy the demand. That is, if the requirement is for a quantity of 112 units, the proposal will be created for an exact 112 units.        Lot for lot

41. 41 On the other hand if the lot sizing procedure is “fixed lot size”, then the total requirement quantity as proposed by the system, to cover the shortages is divided in to the number of fixed quantities as included in the material master (MRP 1 view), for example, if the lot size is fixed as 100 Units and the shortage quantity is 500, then the system will create 5 planned orders to cover the shortages.      Fixed lot size FX Fixed Lot Size

42. 42 Similarly if the lot size of the material is “replenish to maximum stock level” (Lot Size – “HB” for example oil tankers or barges) then on shortages of the requirement quantities the system creates planned orders to fill it to the maximum stock level.      Replenish up to maximum stock level HB Replenish to Maximum Stock Level

43. In period lot-sizing procedures, requirements within the predefined period lengths are grouped together into one lot. The period can be defined in: days, week, month, etc TB Daily lot size WB Weekly lot size MB Monthly lot size Time Period 1 Period 2 Period 3 Period length Period length Period length Receipts Reqmts Period Lot Sizing

44. Minimum lot size Minimum procurement quantity for the material at the given plant and storage location defined For example: when the minimum lot size is 80 and the required quantity is 100, the system creates a requirement proposal for a quantity of 100 Units, to cover the shortages. Maximum lot size Maximum procurement quantity For example: If the required quantity through a demand is 120 kg, then the system will create two planned orders of 80 kg & 40 kg {if the Plant/Storage location stock for that material is Zero}   If the procurement qty is 140 kg, and the Maximum lot is 80 kg and minimum is 15 kg, then the system will create 2 planned orders of 80 kg & 60 kg. {If the Plant/Storage location stock for that material is Zero}   If the procurement qty is 85 kg, and the Maximum lot is 80 kg and minimum is 15 kg, then the system will create 2 planned orders of 80 kg & 15 kg {if the Plant/Storage location stock for that material is Zero}.   Additional Lot Size (1)

45. Rounding Values If the Rounding Value is 20 units, the procurement quantity is 70 units, and the minimum lot size is 15 units, then the system will always round up the planned order to a multiple of 20 units, specifying the rounding to a quantity of 20 Units.   You would have already noticed that the minimum lot size, in the above example, really did not play any role, but if the procurement quantity, for example, would have been 13 units, then the system would have created one planned order of 20 units, which covers both the minimum lot size and the rounding requirements.   One more example would be, if we don’t consider the Min/Max Lot size and the procurement quantity is 70, then the system would just create one planned order of 80 to round off to 20 {if the Plant/Storage location stock for that material is Zero}. Additional Lot Size (2)

46. Safety Stock specifies the quantity whose purpose is to satisfy unexpectedly high demand in the coverage period. The risk of shortfalls is reduced by having a safety stock.   The safety stock defined here for a material in terms of quantity is an additional static requirement and the system adds to this quantity as an additional requirement quantity. You can use this along with manual reorder point planning as well. Time Available quantity for planning Safety stock (not available for planning) Safety stock: To be set in material master (MRP 2) or in the MRP area segment Safety Stock

47. Thank You