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MAN Production Planning (PP)

Dependent requirement reduction after reporting point backflush

Purpose

Explain how planned order dependent requirements are reduced in repetitive manufacturing if reporting point backflush is used for production. This document refers to the explanation and example described in SAP Note 459960.

This document is also a continuation of the document Reporting point backflush in REM process.

Master data setting

See master data settings in the document Reporting point backflush in REM process

Only the following settings are changed:

  1. MM01 : Create one more component material NG_REM_RAW2.  Refer to the material NG_REM_RAW.
  2. CS02 : Add it to the BOM of assembly material NG_REM_FERT.
  3. CA22 : Assign the component NG_REM_RAW2 to operation 0020.

Preparation

  1. MD61 : Create 2 PIRs with qty = 100 and 50 for assembly NG_REM_FERT.
  2. MB1C : Post GR with movement type 561 for material NG_REM_RAW and NG_REM_RAW2, qty = 100.
  3. MD02 : Run MRP for material NG_REM_FERT.
  4. MD04 : Check the MRP result. 2 planned orders with order type PE (Run Schedule Quantity) are created.
    Planned order 40725 : qty = 100   << referred as PO1
    Planned order 40726 : qty = 50     << referred as PO2

MFBF Posting steps and results

  1. Backflush: Reporting point 10: PO1: 10 pcs

    Result :
    Component NG_REM_RAW of PO1 is reduced by qty = 10.
    Check MD13  of planned order 47025:
  2. Backflush: Reporting point 20: PO1: 5 pcs
    Result :
    Component NG_REM_RAW2 of PO1 is reduced by qty = 5.
    Check MD13 of planned order 47025:

    Check MF26 :
  3. Backflush: Reporting point 10: PO2: 5 pcs

    Result:

    Component NG_REM_RAW and NG_REM_RAW2 of PO1 is no longer reduced.
    Component NG_REM_RAW of PO2 is reduced by qty = 15.
    Component NG_REM_RAW2 of PO2 is reduced by qty = 5.
    Check MD13 of planned order 47026:
  4. Backflush: Reporting point 10: PO2: 45 pcs
    Result:
    Component NG_REM_RAW of PO1 is reduced by qty = 10.
    Component NG_REM_RAW of PO1 is reduced by qty = 0.
    Component NG_REM_RAW of PO2 is reduced by qty = 50.
    Component NG_REM_RAW2 of PO2 is reduced by qty = 5.

For more explanation of the results, see SAP Note 459960.

Cancellation and redistribution of dependent requirements

SAP Note 423771 explains the dependent requirements are not adjusted after reversing a reporting point backflush.

There are 2 options to re-distribute the dependent requirements:

  • During the next reporting point backflush for the same material, the dependent requirements with the reporting point stocks and the planned order are compared and adjusted if necessary.
  • With report RMSERI35 you can explicitely check and adjust the dependent requirements, without having to carry out a reporting point backflush.


As an example, try to cancel the last reporting point confirmation in step 4.
Check MF12:

Check table CEZP:

Check MF26: (Adjusted)

Check table RESB : (Not changed)

Re-distribute dependent requirements by report RMSERI35:


Check table RESB again: (Adjusted)

Conclusion:


After a cancellation of reporting point backflush, if you don't carry out a new backflush or re-distribute dependent requirements by report RMSERI35, dependent requirements could be wrongly reduced compared with the real production.  Field RESB-ENMNG could be wrong compared to CEZP-LMVRG and WIP quantities.

You should follow the rules listed in SAP Note 423771 to avoid wrong production in the system.

Modification of the reduction logic

As explained above, the withdrawal quantities of all dependent requirements are initialized completely for all planned orders that can be taken into account according to the offsetting logic of the repetitive manufacturing profile and are set up again according to the cumulated reporting point quantities after the confirmation. Dependent requirements which are already reduced may be initialized after a new reporting point backflush.  To prevent it the modification SAP Note 543590 provides the posibility to prevent the re-distribution of dependent requirements.

As an example let's compare it with last backflush in step 4.

Before posting step 4, Table RESB:

Standard design after posting step 4, Table RESB: (Reduction of PO1 dependent requirements is changed)

Change the parameter AM61B_DREQ_REDISTRIBUTE to '1' or '2', post step 4, Table RESB:(Reduction of PO1 dependent requirements is NOT changed)

For more details about the parameter AM61B_DREQ_REDISTRIBUTE, see note 543590.

Reduction period calculation

You can set what planned orders are considerd and the reduction period in the REM profile, t-code OSP2.

The reduction period calculation logic is described in the following blog post and SAP KBA 1932420.

Reduction Period for planned orders in REM

Related coding


Where dependent requirements are reduced:

     Program  LBARMFE1

     FORM PLAF_REDUCTION_GR_GI

Where reduction period is calculated:

     Program LBARMF0E

     Form    READ_PLAFZ

Related notes

459960     -     Explanation: Dep. requirmnts after reporting point backflush

423771     -     Depend. requirem. and reversal of reporting point backflush

543590     -     Reprtng point backflush:New distribtn of dependnt requirmnts

1932420   -     Reduction Period for planned orders in REM