SAP PP Go-Live Checklist: Master Data and Cutover

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

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Material master and BOM

Every producible material has MRP 1, MRP 2, MRP 3 and work scheduling views maintainedCRITICALMRP type, MRP controller, lot size and procurement type reviewed for each material groupCRITICALIn-house production time and planned delivery time are set and plausibleSafety stock and reorder points loaded only where policy requires themBOMs exist for all produced materials with correct usage, status and validity datesCRITICALBOM quantities, units of measure and scrap percentages checked against engineering dataPhantom assemblies and alternative BOMs documented and testedProduction versions created with BOM and routing assignedCRITICAL

Routings and work centers

Every routing has valid operations, work centers and control keysCRITICALStandard values (setup, machine, labor) are loaded and reviewed with productionWork centers carry capacity, cost center and activity types for costingCRITICALShift and available capacity calendars match actual plant calendarsRouting group counters and sequences are consistent after migrationOperations that need confirmation have the right confirmation control

Configuration and MRP

Order types, number ranges and status profiles are tested for each plantCRITICALScheduling parameters and reduction strategies are configured and testedMRP run variants, planning horizon and firming rules are definedCRITICALMRP groups and exception message settings agreed with plannersBackflushing and goods movement defaults agreed with warehouseSettlement rules and costing variants tested with financeCRITICAL

Testing and cutover

End-to-end test: demand, MRP run, planned order, production order, confirmation, goods receipt, settlementCRITICALTest of subcontracting, rework and scrap scenarios if usedMigration reconciliation shows row counts and key totals match sourceCRITICALOpen production orders and planned orders have a cutover decision (close, migrate or recreate)CRITICALStock and work in process balances agreed with financeAuthorisation roles for planners, supervisors and shop floor testedRollback plan and cutover timeline signed offCRITICAL

Hypercare

Planners trained on MD04, COOIS, CO15 and COGIDaily COGI and MRP exception review assigned to a named ownerCRITICALShop floor confirmation errors have a support routeFirst MRP run reviewed line by line against expectationsCRITICALIssue log with priorities and daily review during first four weeks

Critical items should all be complete before go-live. If more than two critical items are open, treat the cutover date as at risk and review it with the project steering group.

PP master data validation

Optional: a read-only analysis of your BOM, routing and material settings with a list of exceptions.

Optional. The tool and every export work without this. No spam.

How to use the checklist

Work through the groups with the people who own each area: engineering for BOMs and routings, planning for MRP settings, finance for costing and settlement, and the shop floor for confirmation. Tick items as they are verified, not when they are promised. Items marked critical block go-live if open. Export the list to PDF or Excel and attach it to your go-live decision record.

Where PP projects go wrong

Routing and BOM data migrated from a legacy system often passes technical checks but fails practical ones: a work center without capacity, a missing production version or lead times left at zero. These do not stop the system working; they just give wrong dates and wrong shortages. A first MRP run on migrated data should be reviewed with planners, material by material for the top items.

Check that MRP actually plans the materials you expect, using MD04 on a sample.
Check scheduled dates against realistic lead times, not just that scheduling ran.
Check confirmation and goods issue end to end with a real operator.

Cutover and hypercare notes

Decide early what happens to open orders. Migrating open production orders is possible but risky; many plants complete or technically close them on the old system and recreate only the remaining work. Plan a stock count and WIP reconciliation with finance. After go-live, give planners a named support contact for the first weeks and review COGI and MRP exceptions daily.

Frequently Asked Questions

What is the most common PP go-live issue?

Missing or inconsistent master data: no production version, no routing, wrong lead times or work centers without capacity. They cause wrong planned order dates and wrong shortage lists without producing system errors, so they are found late unless checked deliberately.

Should open production orders be migrated?

Often not. Migrating open orders brings partially confirmed history and component issues with it. Many plants finish or close orders in the old system and recreate the remaining quantity in SAP. Decide with finance, because WIP values must reconcile either way.

How many MRP test runs should we do?

At least one full regenerative run on migrated data before go-live, reviewed by planners, plus a net change run after master data corrections. Compare results with the legacy system on a sample of materials to explain differences.

Does this apply to S/4HANA conversions?

Yes, but conversions add checks for simplification items, changed data models and Fiori app adoption. Use this list for the PP business checks and add your conversion project's own technical checks on top.

Netray can help you validate migrated PP master data with read-only analysis of BOMs, routings and material settings, flagging inconsistencies before the first MRP run.

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SAP PP Go-Live Checklist: Master Data, MRP and Cutover Readiness