3. May 2003 YAS Confidential
Introduction
Generic term for procedures in requirements planning which use inventory
data to plan material requirements and forecast
Tracks inventory levels
Recommends replenishment orders
Recommends rescheduling open orders
Assigns exception messages
Material Requirements Planning (MRP) Definition
MRP Functions
33
22
11
MRP Users
33
22
11 Scenario 1 (Material Control)
Scenario 2 (Workshops)
Scenario 3 (Aviation, Drilling and Projects)
44
4. May 2003 YAS Confidential
Material Control Department
MRP Users Location
Material Control Department in Dhahran area has the highest number of
MRP users (MRP Controllers)
A number of MRP users located in different areas cross the Kingdom i.e.
Riyadh, Jeddah and Yanboo
Manage the Saudi Aramco Inventory investment to ensure that the correct
materials are available when needed.
Material Control Department
22
11
5. May 2003 YAS Confidential
MRP Controller
Analyze and Reprocess Forecast Items With Errors
Analyze Material History Consumption to maintain optimized stock level
Process MRP List
Process Purchase Requisition
MRP Controller
The person responsible for a group of materials in a plant or
company
Analyze and maintain Planning Data
MRP Controller Responsibilities
55
44
33
22
11
7. May 2003 YAS Confidential
Enterprise Structure
Storage
Location
Material Service
Center MSC
Storage
Location
Customer Plant
CP
Customer Plant
CP
Customer Plant
CP
Storage
Location
Storage
Location
8. May 2003 YAS Confidential
Enterprise Structure
RABIGH AREA
SUPPORT (M004)
Material Service
Center
Rabigh Area
poject(PS04)
Customer
Plants
Project Plant Admin Plant Material Plant Maintenance Plant
Rabigh Marine
(K03B)
Rabigh R&HE
(K02C)
Rabigh
Community
(J008)
Rabigh Admin
User (AM04)
Rabigh
Refinery (C005)
Power
Distribution
( Z02J)
Transportation
(K01H)
11. May 2003 YAS Confidential
MRP Groups
The MRP group contains all the materials from
the point of view of MRP for assigning special
control parameters for the total planning run
MRP Material Master Data
MRP Types
Key that determines whether and how the
material is planned.
MRP Controller
Specifies the number of the MRP controller
or group of MRP controllers responsible for
material planning for the material.
Reorder Point
If the stock falls below this quantity, the
system flags the material for requirement
planning by creating a planning file entry.
12. May 2003 YAS Confidential
Procurement Type
Indicator that defines how the material is
procured
MRP Material Master Data
Special procurement
Indicate the supplying MSC
Planned Delivery Time
Number of days needed to obtain the
material if it is procured externally
13. May 2003 YAS Confidential
Availability Check
Specifies whether and how the system
checks availability and generates
requirements for material planning
MRP Material Master Data
Period Indicator
Indicator specifying the periods in
which the material's consumption
values and forecast values are
managed
14. May 2003 YAS Confidential
Forecast Model
Indicator that defines on which
forecast model the system bases its
calculation of future requirements of
the material
Forecast Material Master
Data
Initialization
Indicator which specifies that the
system should initialize a forecast
model
History Period
The number of historical values the
system uses for the forecast
Forecast Period
Number of period splits for which a
forecast should be created
15. May 2003 YAS Confidential
MRP
MRP Elements
Reservation
Forecast
Reorder Point
OUT-STO Open PRs
Open POs
Inventory Balance
IN-STO
Schedule
Line
Purchase
Requisition
17. May 2003 YAS Confidential
Create reservation
MB21, IW31, CN21
MRP run in CP
Purchase
Requisition CP
Process Flow
Unique Material Process
Unique Materials are planned and procured at the Customer Plant Level
Definition
Quantity Available MIGO
201,261,281
18. May 2003 YAS Confidential
Create reservation
MB21, IW31, CN21
MRP run in CP
Shared Material Process
Shared Materials are planned in the CP level, and supplied by MSC through
schedule line agreement if not available in CP
Definition
Schedule Line MRP run in MSC
Purchase
Requisition
Process Flow
Schedule
Line
19. May 2003 YAS Confidential
Create reservation
MB21, IW31, CN21 MRP run in CP
LDOR Material Process
The LDOR material are being planned and procured in the CP level
Definition
InterceptorPurchase
requisition
Process Flow
MRP
Controller
Queue List
Purchase
Requisition
released
21. May 2003 YAS Confidential
MRP Batch Jobs
MRP Daily Batch Jobs
Total MRP Planning (Midnight Batch Job)
LDOR Three Times a day
MRP Weekly Batch Jobs
MRP Update x-plant Status
MRP Monthly Batch Jobs
MRP consistency Check
Forecast Update
23. May 2003 YAS Confidential
ZMRP Requisitions Approval
M R P C o n t .
A d m i n i s t r a t o r
Y e s
Y e s
S e n i o r M R P C o n t .
Y e s
Y e s
S U P V .
$
$
$
P u r c h a s i n g
$
$
$
P u r c h a s i n g
$
$
$
P u r c h a s i n g
$
$
$
P u r c h a s i n g
S u p p l i e r s
S u p p l i e r s
S u p p l i e r s
M a n a g e r
$
$
$
P u r c h a s i n g
S u p p l i e r s
N O
N O
N O
N O
S u p p l i e r s
