Plan to Stock (PTS)

The plan to stock value stream supports the process of converting forecast and customer demand into finished goods ready for sale.  

At a high level, it encompasses demand planning, material requirements planning, capacity planning, shop floor execution, and material staging for production, whilst giving sales insight into availability dates and procurement insight into what to buy by when.

key Points:

1. The PTS value stream creates critical links between sales, service, production planning, inventory, and the shop floor.
2. PTS value stream integrates with supply chain processes to make Weir as competitive as possible.
3. Minerals SAP offers full integration between its project planning, material requirements planning (MRP), and shop floor activities.

PTS overview

Sales & Operation Planning 

• Make to order
• Make to stock
• Configure to stock
• Engineer to stock

MRP & Production Planning 

MRP automatically runs every night analyzing the demand versus stock and supply over time; creating replenishment plans to ensure all demand is covered.

MRP generates planned orders for in-house produced materials, and either planned orders or purchase requisitions for externally procured materials to meet this demand.

Generally, planned orders are 'firmed' by conversion to production orders, while purchase requisitions are 'firmed' by conversion to purchase orders.

MRPP exceptions are raised if there are any problems meeting the demand, providing planners and buyers guidance on what actions to take.

The planner responsible can then take appropriate action to ensure that the required quantity of components are available when, and where, they are needed.

After confirming component availability, Planners evaluate supply proposals against the available production capacity defined against work centers to produce an achievable production plan. 

Production Execution & Warehouse

Materials are staged in anticipation of their required date for production, based on production requirements and reservations.

Shop floor activities are executed based on the defined production operations defined in the routing master data for the produced component. 

Supporting Master Data

Master data supports the entire end-to-end process.

Material Masters provides core information for both the finished goods being produced and it's components, including MRP settings which control how MRP plans the materials 

Bill of Materials provides the 'ingredients' for production, defining the required components that are needed for semi-finished (sub-assemblies) and finished goods 

Work Centers provide machine (or group of machines) & people capacities for production, including efficiency, shift timings, capacity & scheduling parameters

Routings provide:

• the sequence of production operations and whether the operation is internally or externally executed (subcontracted)
• operations for quality management (QM) tasks
• the required work centers for each operation
• the operation time (machine, labor hours) and the inter-operation time
• component assignment for each operation
• key production events, such as automatic printing and goods receipt

Material Types:

Finished Products have a material type of Manufactured Product

Semi-Finished Products are included in a Finished Product's BOM and also have their own BOM for production

Raw Materials do not have their own BOM but are used in their own BOM