Replenishment Planning Based On Sap Ecc Optimization Model And System Implementation

SAP is the most world-wide ERP system. The basic principle of MRP is to turn market demand into MPS. Plan order or purchase plan is built according to MPS, inventory, route and BOM. There is an issue that replenishment plan fluctuates when demand is not smooth.This issue is obvious in vehicle industry. Chinese vehicle markrt demand is fluctuating and hard to forecast accurately. With the wave of market demand, vehicle plant's MPS (master production schedule) is fluctuating and need adjustment frequently. On the orther hand, strong foreign parts vendor ask Chinese vehicle plant to provide smooth replenishment plan and proper purchase order which should be in a certain range around former replenishment plan. According to the principle of MRP, market demand fluctuation causes MPS to fluctuate, then it has the same effect on MRP, So traditional MRP can't cope with the conflict of Chinese vehicle industry replenishment plan. The key of the problem is the conflict between conflicting market demand and smooth replenishment. Change of damand leads to adjustment of replenishment, or it leads to lack of stock or over stock.Considering the special replenishment plan requirement of Chinese vehicle industry, the concept of demand leveling and variation control is issued which can be helpful to get smooth replenishment plan and control the variation between forecast plan and actual purchase order. Based on SAP ECC, replenishment optimization model is issued, integrated with variation control and demand leveling. It helps to meet the requirement of safety stock while it also helps domestic vehicle industry to meet the special requirement. It solves the special problem of traditional MRP.With B/S Struts, replenishment plan system is designed and built based on SAP ECC. C++ realizes the core principle. Work flow, user interface and database are designed. Interface between SAP ECC and replenishment plan is analysed to make sure to get base data from SAP ECC. The result of test and application of this system shows that this system makes good effect on demand leveling and variation control. It helps to solve the MRP problem of domestic vehicle industry.