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Purpose

This section describes how you use the pull list to help stage components for production. It gives an overview of the process from the calculation of the shortfall quantity to the generation of replenishment elements. In particular, this chapter explains the prerequisites that must be satisfied so that the pull list has all the necessary information on the issuing storage locations for the components to be able to trigger a transfer of stock to them.

Prerequisites

You can only use the pull list to stage components for requirements whose future storage locations in production have already been defined by material requirements planning. Therefore, you must note the following in Repetitive Manufacturing:

  • Existence of run schedule quantities assigned to a line

    A prerequisite for storage location determination is the existence of run schedule quantities, i.e. planned orders that have been assigned to a line (production version). This can be done either automatically through the planning run (alternative selection indicator or quota arrangement) or manually, in which case the planner assigns the planned orders in the planning table. Another possibility is to enter planned orders directly in the planning table as RS quantities.

  • Maintenance of master data

    The issuing storage locations for the component requirements can be determined in different ways. The issuing storage location is the storage location in production from which components used to produce an assembly are withdrawn. For example, it could be a storage location at a production line, from which all components that are used on this line are taken.

    The prerequisites for determining the issuing storage location are as follows:

    • The BOM item contains the storage location.

    • The material master for the component contains the storage location (called the production storage location in the material master).

    • The production version of the superordinate assembly contains the suggested default issuing storage location for the components. In this case, the issuing storage location is determined through inheritance from the assembly.

    • The production version contains the receiving storage location or the production storage location of the assembly.

      If you have not defined an issue storage location in the BOM item, the system uses the storage location determination strategy in the MRP group to determine which of the issuing storage locations to use to stage the components. Therefore, the above-mentioned master data does not all have to be entered simultaneously, but can be seen as alternatives.

      For more details, see Storage Location/Supply Area Determination in BOM Explosion

      This logic is also applied in the determination of a production supply area determination, which in the case of the pull list is of significance both for replenishment via kanban and replenishment via WM or EWM.

Process Flow

  1. Invoke the pull list (for example, via the assembly/production line or via the component).

  2. The system calculates the shortfall quantity by comparing the already available quantity and the quantities already triggered via the pull list with requirements within the selected period. The shortfall quantity is displayed in the pull list.

    If you invoke the pull list via the assembly, the system displays the shortfall quantities of all components. If you invoke the pull list via a component, the system displays only the shortfall quantity for this component.

  3. You can then have the system generate a replenishment proposal for one or more components.

  4. In the case of a direct stock transfer, after the generation of the replenishment proposals by the system, you must manually enter the storage location from which the component requirements are to be brought to the production storage location or complete the replenishment proposals using batch/stock determination.

  5. In the case of direct stock transfers, when you trigger component staging, the system checks that the transfer is possible, then blocks the stock at the replenishment storage location. In the case of other processes (stock transfer reservation, Kanban, WM, or EWM), the entries are simply checked.

  6. As soon as the data is saved, the system generates replenishment elements accordingly:

    • In the process with direct stock transfer, the system carries out a stock transfer.

    • In the process with a stock transfer reservation, the system generates a stock transfer reservation.

    • In the process with event-driven Kanban, the system generates kanban replenishment elements. This means that kanbans are generated and set to Empty .

    • In the process with WM, the system generates transfer requirements or transfer orders.

    • In the process with EWM, the system generates deliveries that are transferred to the SAP EWM system.