SAP Planned Order to Production Order Conversion Checklist
Converting a planned order to a production order freezes decisions that MRP otherwise keeps flexible. Use this checklist to make sure the BOM, routing, materials and capacity are ready, so the shop floor does not start an order that cannot finish.
0 of 34 items complete
9 critical items still open - these are the highest-risk gaps.
Before you convert
Master data readiness
Materials and capacity
Conversion and release
After conversion
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.
Optional. The tool and every export work without this. No spam.
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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