SAP Planned Order Conversion Checklist (Free)

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9 critical items still open - these are the highest-risk gaps.

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Before you convert

Confirm the MRP run completed and the planned order is currentCRITICALCheck the demand is still valid (sales order, forecast or independent requirement)CRITICALReview the order quantity against lot size, minimum and rounding rulesConfirm the order start and finish dates are inside your conversion horizonCheck no open change number is affecting the BOM or routingVerify the planned order is not already firmed by another plannerConfirm the correct plant, MRP area and procurement type (in-house)CRITICAL

Master data readiness

BOM exists, is active and uses the right alternative for this orderCRITICALRouting exists, is released and has valid work centers and control keysCRITICALProduction version is valid for the order date and quantityComponent item categories are correct (stock versus non-stock)Phantom assemblies and special procurement keys behave as intendedStorage location and production supply area are maintained for componentsBatch management and serial number profiles are set where required

Materials and capacity

Run the availability check on components and note shortages (CO24 after creation)CRITICALCheck long lead and purchased components have confirmed supplyReview subcontracted operations and external processing lead timesCheck capacity load on key work centers for the production week (CM01 or CM02)CRITICALCheck tools, fixtures and gauges are available if tracked as production resourcesCheck inspection lot settings and quality hold requirementsConfirm packaging and kanban requirements for the finished goods

Conversion and release

Convert with MD04 for one order or CO40 for a selection, using the correct order typeCRITICALVerify the order type, number range and costing variant defaultsCheck the converted order has the right dates, components and operationsRelease only when materials and capacity allow, or accept a controlled shortagePrint or issue shop papers after releaseConfirm the goods issue method (backflush or manual) for componentsRecord the conversion and exceptions in the daily MRP worklist

After conversion

Re-check MD04 so the planned order is replaced by the production order and no duplicate remainsCRITICALCheck dependent requirements moved to order reservationsReview MRP exception messages that appear after conversionInform the shop floor supervisor of priority and expected startUpdate customer promise dates if the converted order movedCheck the order appears in COOIS with the expected status

Items marked critical should be checked before conversion. If any critical item is open, hold the order and resolve the issue first.

Automate readiness checks before conversion

Optional: an expert review of how to flag shortages and missing master data before orders are converted.

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How to use the checklist

Go through the groups in order for each batch of planned orders. Tick items as you confirm them and mark exceptions. Critical items should be done before you convert. Export the checked list to PDF as a record of what was reviewed, or share it with the shift supervisor so they know why an order was held. Use it for new products and after master data changes, as well as for routine weekly conversion.

Do critical items first
Use CO40 for batches, MD04 for single orders
Keep the exported PDF with the week's plan

What conversion actually does

Converting a planned order creates a production order from the same material, quantity and dates, explodes the BOM into reservations and copies the routing into operations. The planned order is replaced and dependent requirements become order reservations. Costs and statuses start with the order type. Because BOM and routing are read at conversion, changes made later may need a re-explosion or manual update.

When to convert and when to wait

Convert inside the horizon where you can actually build, usually close to the start date. Converting too early locks quantities and dates, and MRP can no longer adjust them when demand changes. Converting too late leaves no time for shortage resolution and capacity leveling. Many plants use a rolling conversion horizon of a few days to a couple of weeks, based on lead times and supplier reliability.

Common mistakes

Converting before checking component availability sends orders to the floor that cannot complete. Releasing everything at once overloads work centers. Ignoring changes to BOM or routing after conversion leaves orders with outdated data.

Check shortages after creation with CO24
Stagger release by capacity
Review open orders after engineering changes

Frequently Asked Questions

How do I convert a planned order in SAP?

Open the planned order in MD04 or MD12 and use the convert to production order function, or use CO40 to convert a selection of planned orders. Check the order type and the resulting dates and components afterwards.

What happens to the planned order after conversion?

The planned order is replaced by the production order, and the dependent requirements for components become reservations on the new order. MD04 should show the production order as the receipt element and no duplicate planned order.

Can I convert a firmed planned order?

Yes. Firming only stops MRP from changing the order, and conversion is the next step. Many planners firm an order inside the time fence and convert when materials and capacity are ready.

Should I release the order immediately after conversion?

Not always. Release when materials are available or shortages are accepted and capacity exists. Releasing too early creates a backlog on the floor and can trigger confirmations on orders that are blocked.

If planners lose hours checking readiness order by order, we can build a read only assistant that flags shortages, missing routings and overloaded work centers before conversion, with approval kept human.

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SAP Planned Order to Production Order Conversion Checklist