1) Attaching document as an item in the item overview: …go to the `General Item Overview' screen …select the tab page `Document' …enter item category `D' …dropdown and select the document you want to attach …the system automatically selects the respective document type, document part, document version and document description
2) Attaching document to an item: …go to the `General Item Overview' screen …select the particular item by F2 …the item all data screen appears …go to tab page `document assignment' …dropdown and select the `document type' you want to attach …dropdown and select the document you want to attach …the system automatically selects the respective document part, document version and document description
3) Attach document to the header material: …go to header overview screen …go to tab page `document assignment' …dropdown and select the `document type' you want to attach …the system automatically selects the respective, document part, document version and document description
Wednesday, July 30, 2008
Total Plan Activities in Minutes
afru -> Order completion confirmations afru-smeng -> Operations qty
afvv -> DB structure of the quantities/dates/values in the operation afvv-bmsch -> Base quantity afvv-vgw01 -> Standard value for Direct Labour afvv-vgw02 -> Standard value for Setup afvv-vgw03 -> Standard value for Machine Time afvv-vgw04 -> Standard value for Adjustment of Tool
Formula Direct Labour = ( afru-smeng / afvv-bmsch ) * afvv-vgw01 * 60. Setup = afvv-vgw02 * 60. Machine Time = ( afru-smeng / afvv-bmsch ) * afvv-vgw03 * 60. Adjustment of Tool = afvv-vgw04 * 60.
Formula CR03 - Display Work Center At CR03, click Assignments. Then double click on the Cost Center. Place your cursor at the Activity type, click Extra -> Formula -> Display.
afvv -> DB structure of the quantities/dates/values in the operation afvv-bmsch -> Base quantity afvv-vgw01 -> Standard value for Direct Labour afvv-vgw02 -> Standard value for Setup afvv-vgw03 -> Standard value for Machine Time afvv-vgw04 -> Standard value for Adjustment of Tool
Formula Direct Labour = ( afru-smeng / afvv-bmsch ) * afvv-vgw01 * 60. Setup = afvv-vgw02 * 60. Machine Time = ( afru-smeng / afvv-bmsch ) * afvv-vgw03 * 60. Adjustment of Tool = afvv-vgw04 * 60.
Formula CR03 - Display Work Center At CR03, click Assignments. Then double click on the Cost Center. Place your cursor at the Activity type, click Extra -> Formula -> Display.
Configuring an Additional Activity Type
Additional Activities Type for Work Center
The following are the steps to configure an additional activities type:-
OP51 - Check Settings for formulas
OP54 - Check formulas for Costing
Ensure that usage of the parameters are indicated. Some parameters are appropriate for capacity calculation but not for schedule calculation. If you like to find out the parameter id, you could use the Search Fld. for Param. pull down button to do so.
KLH2 - Maintain hierarchy of Activity type group.
OP19 - Define standard value key
The purpose of standard value keys is to group together a set of parameters for the purpose of ensuring that the standard values for the parameters are supplied in the operations of the routing. This is so that the formula (for calculating cost, schedule, and capacity) could have the necessary figures to work with. Once the parameters are associated with the standard value keys, work centers quoting this standard values will be able to dictate whether or not the parameter values are optional or mandatory entry in the operations of the routing. The pre-requisite for using this transaction is that the parameters must have been pre-created.
KA01 - Create Primary Cost Element for the new activities type.
KL01 - Create Activity Type tied to the primary cost element. (the Cost element field)
KP26 - Change Activity Type/Activity Price Planning - maintain the Variable price If the user include the additional activities in their work center, the routing that used the work center will required more time to finished the jobs.
The operations Start and Finish date will be extended due to the extra time spent on the work center. The cost of production increases in line with the extra activity which will be reflected in the Factory Output when you do a cost analysis in the production order. The new activity will have a price attached to it and the moving average price will increase.
The following are the steps to configure an additional activities type:-
OP51 - Check Settings for formulas
OP54 - Check formulas for Costing
Ensure that usage of the parameters are indicated. Some parameters are appropriate for capacity calculation but not for schedule calculation. If you like to find out the parameter id, you could use the Search Fld. for Param. pull down button to do so.
KLH2 - Maintain hierarchy of Activity type group.
OP19 - Define standard value key
The purpose of standard value keys is to group together a set of parameters for the purpose of ensuring that the standard values for the parameters are supplied in the operations of the routing. This is so that the formula (for calculating cost, schedule, and capacity) could have the necessary figures to work with. Once the parameters are associated with the standard value keys, work centers quoting this standard values will be able to dictate whether or not the parameter values are optional or mandatory entry in the operations of the routing. The pre-requisite for using this transaction is that the parameters must have been pre-created.
KA01 - Create Primary Cost Element for the new activities type.
KL01 - Create Activity Type tied to the primary cost element. (the Cost element field)
KP26 - Change Activity Type/Activity Price Planning - maintain the Variable price If the user include the additional activities in their work center, the routing that used the work center will required more time to finished the jobs.
The operations Start and Finish date will be extended due to the extra time spent on the work center. The cost of production increases in line with the extra activity which will be reflected in the Factory Output when you do a cost analysis in the production order. The new activity will have a price attached to it and the moving average price will increase.
Work Center Creation and Change
Work Center (CR01 - Create, CR02 - Change, CR03 - Display)
Using the data maintained for a work center, you can
determine which machines or people are to be used in the operations
calculate costs, capacities and dates for the operations OP42 - Configure the default value for Work Center during the initial creation
Using the data maintained for a work center, you can
determine which machines or people are to be used in the operations
calculate costs, capacities and dates for the operations OP42 - Configure the default value for Work Center during the initial creation
The Concept (use) of Phantom Assembly
classic example of phantom assembly is packing material, they cannot be included in the BOM of the FG but still it is an assembly that goes with the FG.
Phantom assembly is something that you produce/used but you cannot count/measure for it, you only can measure for its component. For example, you are the producer of clip (paper clip) you cannot measure how much paper clip you already produce, all you know is how much wire I used to produce clip and how much box of clip, I have produce if you want to maintain material master for the Clip before it goes to the box, you can assume that the clip is phantom
A phantom assembly is used when you want to be able to structure a BOM so it is easy to understand, but don't want to create too many production orders. Assume an auto Engine. There are hundreds of components. You might structure them as: Engine block and parts, camshaft and parts, and 6 piston assemblies. But you don't want to create 3 production orders, too much hassle. So you want to issue the components for the piston assembly in the same production order as the Engine block. So you create a new material number for the Piston assembly, but you mark it as a phantom assembly. That means that when you create the bom for the Engine assembly, you only have two assemblies, the Engine block and the Camshaft. You add the phantom assembly for the Piston Assembly to the Engine block BOM, saying it requires 8 of the phantom assembly. When the production order is created for the Engine block, the picklist will also include all of the components of the 8 piston assemblies.
1) When to use, or not use a phantom assembly? If you need to do cost accounting on how many hours it takes to assemble a piston assembly, it cannot be a phantom assembly, because as a part of the Engine block assembly, the labor costs are included in the Engine block production order, and therefore in the standard cost.
2) Can the assembly people pick out the parts for the phantom assembly from the all of the components in the Kit? If the guy assembling the Engine Block gets confused because of all of the components for the Piston assemblies are there, then it cannot be a phantom assembly. But if they can seperate them easily, go for it. A printed circuit board assembly should never be a phantom assembly, because all of those little parts for each type of PC board must be kept separate.
3) Do you usually build 100 piston assemblies, put them into stock, then issue 8 at a time to build an Engine Assembly? If so, it is not a phantom assembly. If the Piston assembly is a phantom, you only build the 8 you need while you are building the Engine Block assembly. You normally do NOT store a piston assembly (phantom assembly) in stock.
4) However, sometimes a customer calls and wants you to send them all of the components for One Piston Assembly. By having it set as a phantom assembly, even though you don't usually create seperate production orders, in this case you CAN create a production order for one, pull the components, close the PO, and send the parts off to your customer.
5) You complete a Engine Assembly. As you are walking it back to the stockroom, you drop it on the floor, and it breaks! Damn, but you can still save the piston assemblies. Since they do have a SAP material number, you CAN put those back into stock. Most MRP systems WILL recognize that you happen to have 8 piston assemblies in stock, and will issue those whole assemblies to the next order for a Engine Block.
In summary: 1. When to use phantom assembly: a. You want costing to be done but will not treat that stage as confirmation point. b. You find that operation is not so important i.e you do not want analyse the work center output details, etc. c. You want the operation to be in the BOM as well as routing, so that product go through that operation.
2. When not to use phantom assembly. a. If you find that operation is critical - you cannot treat that as phantom. b. If you are sending the product to outside for subcontracting operation.
Phantom assembly is something that you produce/used but you cannot count/measure for it, you only can measure for its component. For example, you are the producer of clip (paper clip) you cannot measure how much paper clip you already produce, all you know is how much wire I used to produce clip and how much box of clip, I have produce if you want to maintain material master for the Clip before it goes to the box, you can assume that the clip is phantom
A phantom assembly is used when you want to be able to structure a BOM so it is easy to understand, but don't want to create too many production orders. Assume an auto Engine. There are hundreds of components. You might structure them as: Engine block and parts, camshaft and parts, and 6 piston assemblies. But you don't want to create 3 production orders, too much hassle. So you want to issue the components for the piston assembly in the same production order as the Engine block. So you create a new material number for the Piston assembly, but you mark it as a phantom assembly. That means that when you create the bom for the Engine assembly, you only have two assemblies, the Engine block and the Camshaft. You add the phantom assembly for the Piston Assembly to the Engine block BOM, saying it requires 8 of the phantom assembly. When the production order is created for the Engine block, the picklist will also include all of the components of the 8 piston assemblies.
1) When to use, or not use a phantom assembly? If you need to do cost accounting on how many hours it takes to assemble a piston assembly, it cannot be a phantom assembly, because as a part of the Engine block assembly, the labor costs are included in the Engine block production order, and therefore in the standard cost.
2) Can the assembly people pick out the parts for the phantom assembly from the all of the components in the Kit? If the guy assembling the Engine Block gets confused because of all of the components for the Piston assemblies are there, then it cannot be a phantom assembly. But if they can seperate them easily, go for it. A printed circuit board assembly should never be a phantom assembly, because all of those little parts for each type of PC board must be kept separate.
3) Do you usually build 100 piston assemblies, put them into stock, then issue 8 at a time to build an Engine Assembly? If so, it is not a phantom assembly. If the Piston assembly is a phantom, you only build the 8 you need while you are building the Engine Block assembly. You normally do NOT store a piston assembly (phantom assembly) in stock.
4) However, sometimes a customer calls and wants you to send them all of the components for One Piston Assembly. By having it set as a phantom assembly, even though you don't usually create seperate production orders, in this case you CAN create a production order for one, pull the components, close the PO, and send the parts off to your customer.
5) You complete a Engine Assembly. As you are walking it back to the stockroom, you drop it on the floor, and it breaks! Damn, but you can still save the piston assemblies. Since they do have a SAP material number, you CAN put those back into stock. Most MRP systems WILL recognize that you happen to have 8 piston assemblies in stock, and will issue those whole assemblies to the next order for a Engine Block.
In summary: 1. When to use phantom assembly: a. You want costing to be done but will not treat that stage as confirmation point. b. You find that operation is not so important i.e you do not want analyse the work center output details, etc. c. You want the operation to be in the BOM as well as routing, so that product go through that operation.
2. When not to use phantom assembly. a. If you find that operation is critical - you cannot treat that as phantom. b. If you are sending the product to outside for subcontracting operation.
Configure Phantom assembly
This indicator determines the special procurement type of a material which is either procured externally or produced in-house.
The system determines the special procurement key from the Procurement type and Special procurement fields in the material master record (Detail Screen: MRP 1) and displays the value if the BOM is only allocated to one plant. Only the values which are relevant to the explosion type are displayed for a BOM item.
This type of assembly is only required for engineering purposes, but it does not occur physically in the course of production. In the planning run, dependent requirements are not created for the header material of the assembly but are transferred immediately to the component materials. In the standard SAP System, the special procurement key phantom assembly has the value 50.
BOM Design Production 0 Z Z
1 B C B C
2 B1 B2 B1 B2
B - In production, to produce Z, you need B1, B2 and C. You need not produced
The system determines the special procurement key from the Procurement type and Special procurement fields in the material master record (Detail Screen: MRP 1) and displays the value if the BOM is only allocated to one plant. Only the values which are relevant to the explosion type are displayed for a BOM item.
This type of assembly is only required for engineering purposes, but it does not occur physically in the course of production. In the planning run, dependent requirements are not created for the header material of the assembly but are transferred immediately to the component materials. In the standard SAP System, the special procurement key phantom assembly has the value 50.
BOM Design Production 0 Z Z
1 B C B C
2 B1 B2 B1 B2
B - In production, to produce Z, you need B1, B2 and C. You need not produced
BOM Display Changes
Transaction CS80 keep track of changes done to the BOM. To check all the changes, at the second screen, you must specify the earliest possible Selection date. If don't know the earliest date, just key in XX.XX.1990. Click Goto for the various type of changes to be displayed.
CC04 - Product Structure Browser. This is a great transaction for viewing and modifying anything that were related to the Material. e.g BOM, Routing etc.
CS20 - Mass changes : Material Selection - You add or delete a component from all the BOM.
CC04 - Product Structure Browser. This is a great transaction for viewing and modifying anything that were related to the Material. e.g BOM, Routing etc.
CS20 - Mass changes : Material Selection - You add or delete a component from all the BOM.
BOM components never explode
After executing MD02, you found that the components did not explode accordingly:
Checklist for checking :-
Material Type must be FERT - Finished products or HALB - Semi-finished products
MM02 - MRP View 2 - Procurement type ( X - Both procurement type or E - In-house production)
CS02 - Validity periods of Parents parts and Components
Checklist for checking :-
Material Type must be FERT - Finished products or HALB - Semi-finished products
MM02 - MRP View 2 - Procurement type ( X - Both procurement type or E - In-house production)
CS02 - Validity periods of Parents parts and Components
MRP Run Exception Description
Exception Group - Exception Description Meaning Severity
1 2 New, and opening date in the past SAP has created a new requisition and scheduled it appropriately based on the demand, however, given the lead time of the material the Purchase Order should have already been issued to the supplier. High potential that this order will need to be expedited! Critical 1 5 Opening date in the past
2 3 New, and start date in the past The order or requisition is scheduled to start in the past. High potential that this order will need to be expedited or that the demand can not be supplied! Critical 2 6 Start date in the past
2 63 Production start before order start System configuration should not allow this situation. Review the order and ensure that the scheduled & basic dates are in line and notify the HelpDesk to report 'Inconsistent Scheduling Configuration". Critical
3 4 New, and finish date in the past The order or requisition is scheduled to finish in the past. High potential that this order will need to be expedited or that the demand can not be supplied! Critical
3 7 Finish date in the past
3 64 Production finish after order finish System configuration should not allow this situation. Review the order and ensure that the scheduled & basic dates are in line and notify the Helpdesk to report 'Inconsistent Scheduling Configuration". Error 4 1 Newly created order proposal New order created Informational
4 42 Order proposal has been changed Order rescheduled by SAP Informational
4 44 Order proposal re-exploded Order regenerated by SAP Informational
4 46 Order proposal has been manually changed Order rescheduled by planner Informational
4 61 scheduling: Customizing inconsistent System configuration should not allow this situation. Ensure that the order shows up properly in CM25 and notify the Helpdesk to report 'Inconsistent Scheduling Configuration". Error
4 62 Scheduling: Master data inconsistent Check master data ! Remove "In House Processing Time" from the Material Master MRP2 view. Ensure that the Production Version & Routing are correct. Run MPS/MRP manually once corrected. Error
4 82 Item is blocked The requisition has been manually blocked and therefore cannot be converted. Remove the block from the requisition or delete the requisition and run MD02 for the material to regenerate. Critical
5 50 No BOM exists SAP was unable to find a valid Bill Of Material for the item. Check the BOM, Production Version & Selection Method. Error
5 52 No BOM selected SAP was unable to find a valid Bill Of Material for the item. Check the BOM, Production Version & Selection Method. Error
5 53 No BOM explosion due to missing config. Plant Set-Up incorrect. Contact the Helpdesk to report this error! Error
5 54 No valid run schedule header Material set for repetitive manufacturing on the Material Master MRP views. Correct Material Master or contact the Helpdesk for assistance with this error. Error
5 55 Phantom assembly not exploded SAP was unable to find a valid Bill Of Material for the phantom material. Check the BOM or contact the Helpdesk for assistance with this error. Error
5 69 Recursive BOM components possible Bill of material inaccurate (material consuming itself). Review and correct BOM and run MPS manually. Error
6 25 Excess stock Excess stock planned based on the "Range of Coverage" profile. Coverage profiles should not be in use. Remove the "Range Of Coverage Profile" from the MRP view of the Material Master and run MRP manually. Error
6 26 Shortage in individual segment There is material in the "Provided To Vendor" bucket in SAP. Remove the material using transaction MB1B and run MRP manually. Critical
6 40 Coverage not provided by master plan Excess stock planned based on the "Range of Coverage" profile. Coverage profiles should not be in use. Remove the "Range Of Coverage Profile" from the MRP view of the Material Master and run MRP manually. Contact the HelpDesk for assistance if unable to resolve. Error
6 50 Shortage in the planning time fence SAP unable to automatically cover demand due to the time fence. Review and reschedule supply elements appropriately. Important
6 57 Disc. matl partly replaced by follow-up Order is planning to use remaining run-out material and the balance of the requirement using the replacement material. Adjust order quantities based on the run-out as appropriate. Important
6 58 Uncovered reqmt after effective-out date System unable to find replacement material. Review the run-out strategy and adjust master data appropriately. Run MRP manually once resolved. Critical
6 59 Receipt after effective-out date Receipt of discontinued material planned. Review the run-out strategy and adjust orders appropriately. Run MRP manually once resolved. Critical
6 70 Max. release qty - quota exceeded System unable to determine source of supply. Check the effective dates of the Quota Arrangements and adjust appropriately. If Quota Arrangements are not appropriate for the material remove the "Quota Arrangement" selection from the Material Master. Error
6 96 Stock fallen below safety stock level Supply plan insufficient to cover safety stock requirement. Review and adjust if appropriate. Important
7 10 Bring process forward Order or requisition is too late to cover requirements. Review and reschedule appropriately. Important
7 15 Postpone process Order or requisition is too early based on requirements. Review and reschedule appropriately. Important
7 20 Cancel process Supply is beyond total demand in the system. Stock Not Required! Review and re-plan appropriately. Critical
7 30 Plan process according to schedule Order or requisition early or late and within close proximity to the Time Fence, Hard Order, or Current Date. Review and reschedule appropriately. Important
8 98 Abnormal end of requirements planning System unable to process the material - Major Data or Configuration problem! Check Material Status and seek assistance if unable to resolve. Materials flagged for deletion should be set to the "DIS" MRP controller to remove them from the list. Error
1 2 New, and opening date in the past SAP has created a new requisition and scheduled it appropriately based on the demand, however, given the lead time of the material the Purchase Order should have already been issued to the supplier. High potential that this order will need to be expedited! Critical 1 5 Opening date in the past
2 3 New, and start date in the past The order or requisition is scheduled to start in the past. High potential that this order will need to be expedited or that the demand can not be supplied! Critical 2 6 Start date in the past
2 63 Production start before order start System configuration should not allow this situation. Review the order and ensure that the scheduled & basic dates are in line and notify the HelpDesk to report 'Inconsistent Scheduling Configuration". Critical
3 4 New, and finish date in the past The order or requisition is scheduled to finish in the past. High potential that this order will need to be expedited or that the demand can not be supplied! Critical
3 7 Finish date in the past
3 64 Production finish after order finish System configuration should not allow this situation. Review the order and ensure that the scheduled & basic dates are in line and notify the Helpdesk to report 'Inconsistent Scheduling Configuration". Error 4 1 Newly created order proposal New order created Informational
4 42 Order proposal has been changed Order rescheduled by SAP Informational
4 44 Order proposal re-exploded Order regenerated by SAP Informational
4 46 Order proposal has been manually changed Order rescheduled by planner Informational
4 61 scheduling: Customizing inconsistent System configuration should not allow this situation. Ensure that the order shows up properly in CM25 and notify the Helpdesk to report 'Inconsistent Scheduling Configuration". Error
4 62 Scheduling: Master data inconsistent Check master data ! Remove "In House Processing Time" from the Material Master MRP2 view. Ensure that the Production Version & Routing are correct. Run MPS/MRP manually once corrected. Error
4 82 Item is blocked The requisition has been manually blocked and therefore cannot be converted. Remove the block from the requisition or delete the requisition and run MD02 for the material to regenerate. Critical
5 50 No BOM exists SAP was unable to find a valid Bill Of Material for the item. Check the BOM, Production Version & Selection Method. Error
5 52 No BOM selected SAP was unable to find a valid Bill Of Material for the item. Check the BOM, Production Version & Selection Method. Error
5 53 No BOM explosion due to missing config. Plant Set-Up incorrect. Contact the Helpdesk to report this error! Error
5 54 No valid run schedule header Material set for repetitive manufacturing on the Material Master MRP views. Correct Material Master or contact the Helpdesk for assistance with this error. Error
5 55 Phantom assembly not exploded SAP was unable to find a valid Bill Of Material for the phantom material. Check the BOM or contact the Helpdesk for assistance with this error. Error
5 69 Recursive BOM components possible Bill of material inaccurate (material consuming itself). Review and correct BOM and run MPS manually. Error
6 25 Excess stock Excess stock planned based on the "Range of Coverage" profile. Coverage profiles should not be in use. Remove the "Range Of Coverage Profile" from the MRP view of the Material Master and run MRP manually. Error
6 26 Shortage in individual segment There is material in the "Provided To Vendor" bucket in SAP. Remove the material using transaction MB1B and run MRP manually. Critical
6 40 Coverage not provided by master plan Excess stock planned based on the "Range of Coverage" profile. Coverage profiles should not be in use. Remove the "Range Of Coverage Profile" from the MRP view of the Material Master and run MRP manually. Contact the HelpDesk for assistance if unable to resolve. Error
6 50 Shortage in the planning time fence SAP unable to automatically cover demand due to the time fence. Review and reschedule supply elements appropriately. Important
6 57 Disc. matl partly replaced by follow-up Order is planning to use remaining run-out material and the balance of the requirement using the replacement material. Adjust order quantities based on the run-out as appropriate. Important
6 58 Uncovered reqmt after effective-out date System unable to find replacement material. Review the run-out strategy and adjust master data appropriately. Run MRP manually once resolved. Critical
6 59 Receipt after effective-out date Receipt of discontinued material planned. Review the run-out strategy and adjust orders appropriately. Run MRP manually once resolved. Critical
6 70 Max. release qty - quota exceeded System unable to determine source of supply. Check the effective dates of the Quota Arrangements and adjust appropriately. If Quota Arrangements are not appropriate for the material remove the "Quota Arrangement" selection from the Material Master. Error
6 96 Stock fallen below safety stock level Supply plan insufficient to cover safety stock requirement. Review and adjust if appropriate. Important
7 10 Bring process forward Order or requisition is too late to cover requirements. Review and reschedule appropriately. Important
7 15 Postpone process Order or requisition is too early based on requirements. Review and reschedule appropriately. Important
7 20 Cancel process Supply is beyond total demand in the system. Stock Not Required! Review and re-plan appropriately. Critical
7 30 Plan process according to schedule Order or requisition early or late and within close proximity to the Time Fence, Hard Order, or Current Date. Review and reschedule appropriately. Important
8 98 Abnormal end of requirements planning System unable to process the material - Major Data or Configuration problem! Check Material Status and seek assistance if unable to resolve. Materials flagged for deletion should be set to the "DIS" MRP controller to remove them from the list. Error
Individual Collective Indicator in the MRP 4 View
MRP 4 view in material master is for material that are listed as BOM of product or material or for material defined as dependent requirement.
Dependent requirement is affected when there are change in the Planned Independent Requirement (PIR).
When you choose 1 parameter,material requirements to buy will be generated when a customer order was entered under SD module (VA01).
On the other hand, parameter 2 like parameter 1 it is used in the BOM explosion of a product but in sales forecast basis (MD61).
To simplify, if material is unique or not common, with high value, with shelf life or short lead time, order proposals will be generated only during a customer order was received and entered in the system.
Choose parameter 1, you have better control to manage the stocks and values, parameter 2 is the reverse, when a material that is commonly used in many products that your company is producing. and when you planned product via forecast or sales plan basis then parameter 2 is your option to choose, if works when sales forecast of a product where the dependent requirement or material were being used it propose a buying proposals for the material requirement even though no receive or confirm customer order yet.
Dependent requirement is affected when there are change in the Planned Independent Requirement (PIR).
When you choose 1 parameter,material requirements to buy will be generated when a customer order was entered under SD module (VA01).
On the other hand, parameter 2 like parameter 1 it is used in the BOM explosion of a product but in sales forecast basis (MD61).
To simplify, if material is unique or not common, with high value, with shelf life or short lead time, order proposals will be generated only during a customer order was received and entered in the system.
Choose parameter 1, you have better control to manage the stocks and values, parameter 2 is the reverse, when a material that is commonly used in many products that your company is producing. and when you planned product via forecast or sales plan basis then parameter 2 is your option to choose, if works when sales forecast of a product where the dependent requirement or material were being used it propose a buying proposals for the material requirement even though no receive or confirm customer order yet.
Processing Keys NETCH & NETPL in MRP
There's a Planning File in SAP and in that file, materials with planning entries are listed. According to those entries MRP decides whether or not to include a material in MRP run.
For a newly created material all entries are on. And after the first MRP run, material is planned and all entries are cleared for that material. Later in time, you execute transactions, which make changes to the material that changes the material's planning status (e.g. goods receipt for the material, creating planned orders for the material, and such..).
During these transactions, Planning File entries are updated accordingly. And next time you run MRP material is included in MRP, or not included if no changes have occurred which relates to the Planning File.
Difference between NETCH and NETPL are:
NETCH is any material that has undergone some changes since last MRP run. (e.g. you have created a new planned order for the material, so al other planning data has to be replanned according to this change)
NETPL is any material that has undergone some changes since last MRP run, and those changes are in the planning horizon. (e.g. you have created a planned order which is inside the planning horizon. If your planning horizon is 3 months, and you created planned order for a date 5 months from now, that material is not included in planning with NETPL)
For a newly created material all entries are on. And after the first MRP run, material is planned and all entries are cleared for that material. Later in time, you execute transactions, which make changes to the material that changes the material's planning status (e.g. goods receipt for the material, creating planned orders for the material, and such..).
During these transactions, Planning File entries are updated accordingly. And next time you run MRP material is included in MRP, or not included if no changes have occurred which relates to the Planning File.
Difference between NETCH and NETPL are:
NETCH is any material that has undergone some changes since last MRP run. (e.g. you have created a new planned order for the material, so al other planning data has to be replanned according to this change)
NETPL is any material that has undergone some changes since last MRP run, and those changes are in the planning horizon. (e.g. you have created a planned order which is inside the planning horizon. If your planning horizon is 3 months, and you created planned order for a date 5 months from now, that material is not included in planning with NETPL)
How System choose Production Version
You can change the Production Versions in MRP 4 screen in MM02. Click on the version then click details. Here you can set validity dates for the version or you can also set lot sizes. Based on the quantity of the order, a certain version will be picked. Or, the version will be picked if it falls in the date range.
The selection of Production versions can be 1) Automatic or 2) Manual
This depends on your customisations for order type.
However, the Production version number which gets selected depends on following factors: 1) Validity date of the Production version as maintained in MRP4 view Production version details (material master), and 2) Lot size maintained in MRP1 view i.e. FX (Fixed) or EX etc 3) Lot size maintained in MRP4 view Production version details(Material Master)
----------------------------------------------------------
Maybe you change the Production Versions in MRP 4 interface from MM02. - Choice and Click on Prodversion. - May be You have more than one Production version. - Then You click detail, - And then where are BOM do you want to choice
And the others may be you can use in MD02, If you have more than one of Production version. when did You choice? May be number one and etc
----------------------------------------------------------
But my problem is the follow: I've 5 different production version all with same valitity date and all with the same lot size. The numbers of different production version are 0001, 0002, 0003, 0004, 0005. When I release the order the choice of production version is automatic and the system always choses the production version 0001. How I can define that the sistem choses production version 0004?
----------------------------------------------------------
When there is five different versions available in the system, why do you want to select only version 0004. On what basis the system has to select this. If it has to select 0004 always then why do you want to keep the other versions validity. You can change the validity period of others. Otherwise you can go into Quota arrangement and give the version 0004.
----------------------------------------------------------
I've 5 different production version because I can realize the same product on 5 different work center (same product but different work center). But when I release the order I want the system choses automatically as default production version 0004 used for work center number 4. After, if I want, I can change production version, so I can change work center in wich realize the product. I don't know where I can define quota arrangement for production version.
----------------------------------------------------------
In customisation order type dependent parameters TZ OPL8, you have selection of production version. Change that to manual selection. While creating order, all versions will pop up for selection. All the best
----------------------------------------------------------
As mentioned, you can control this for manual selection. Or otherwise you can do the control thru Quota arrangement settings. This you can do from MEQ1 transaction. If you set the required version for 100 percent, then automatically this version will be selected.
The selection of Production versions can be 1) Automatic or 2) Manual
This depends on your customisations for order type.
However, the Production version number which gets selected depends on following factors: 1) Validity date of the Production version as maintained in MRP4 view Production version details (material master), and 2) Lot size maintained in MRP1 view i.e. FX (Fixed) or EX etc 3) Lot size maintained in MRP4 view Production version details(Material Master)
----------------------------------------------------------
Maybe you change the Production Versions in MRP 4 interface from MM02. - Choice and Click on Prodversion. - May be You have more than one Production version. - Then You click detail, - And then where are BOM do you want to choice
And the others may be you can use in MD02, If you have more than one of Production version. when did You choice? May be number one and etc
----------------------------------------------------------
But my problem is the follow: I've 5 different production version all with same valitity date and all with the same lot size. The numbers of different production version are 0001, 0002, 0003, 0004, 0005. When I release the order the choice of production version is automatic and the system always choses the production version 0001. How I can define that the sistem choses production version 0004?
----------------------------------------------------------
When there is five different versions available in the system, why do you want to select only version 0004. On what basis the system has to select this. If it has to select 0004 always then why do you want to keep the other versions validity. You can change the validity period of others. Otherwise you can go into Quota arrangement and give the version 0004.
----------------------------------------------------------
I've 5 different production version because I can realize the same product on 5 different work center (same product but different work center). But when I release the order I want the system choses automatically as default production version 0004 used for work center number 4. After, if I want, I can change production version, so I can change work center in wich realize the product. I don't know where I can define quota arrangement for production version.
----------------------------------------------------------
In customisation order type dependent parameters TZ OPL8, you have selection of production version. Change that to manual selection. While creating order, all versions will pop up for selection. All the best
----------------------------------------------------------
As mentioned, you can control this for manual selection. Or otherwise you can do the control thru Quota arrangement settings. This you can do from MEQ1 transaction. If you set the required version for 100 percent, then automatically this version will be selected.
Connecting the planning calendar to your lot size key
First, you will need to set up the planning calendar.
Menu path: Production -> MRP -> Master Data -> Planning Calendar (MD25)
You will then need to use this planning calendar (the one you created) in the material master when planning your raw materials (MRP2 View in 4.6C - Field name : Planning Calendar).
1. When you maintain the planning calendar you will need to enter a valid from date and valid to date.
2. Your periods will also need to be set up and they will be weekly, for example: From Date : 11/23/2001 To Date : 11/29/2001 (11/23 is a Friday, this is your from date). Do this for as may weeks as you wish (say weekly for 2 years).
3. When you have set up the planning calendar, you will then need to make some changes to the weekly lot size configuration (WB), or you may need to create a new lot size key if you do not want to change 'WB'. Essentially, you will need to use the following in the lot size configuration (OMI4) :
No. of Periods : 1 LotSizeProced.: P LotSize ind : K Scheduling : 1
By using the above, you are connecting the planning calendar to your lot size key.
Menu path: Production -> MRP -> Master Data -> Planning Calendar (MD25)
You will then need to use this planning calendar (the one you created) in the material master when planning your raw materials (MRP2 View in 4.6C - Field name : Planning Calendar).
1. When you maintain the planning calendar you will need to enter a valid from date and valid to date.
2. Your periods will also need to be set up and they will be weekly, for example: From Date : 11/23/2001 To Date : 11/29/2001 (11/23 is a Friday, this is your from date). Do this for as may weeks as you wish (say weekly for 2 years).
3. When you have set up the planning calendar, you will then need to make some changes to the weekly lot size configuration (WB), or you may need to create a new lot size key if you do not want to change 'WB'. Essentially, you will need to use the following in the lot size configuration (OMI4) :
No. of Periods : 1 LotSizeProced.: P LotSize ind : K Scheduling : 1
By using the above, you are connecting the planning calendar to your lot size key.
Number Range by Plants during MRP Run
Define different sets of number range by Plants for :-
Planned Orders
Reservations
Purchase Requisitions
MRP Lists
Sim. Dependent Requirements OMI8 - Maintain Plant Parameters
Environment -> Number Ranges
Planned Orders
Reservations
Purchase Requisitions
MRP Lists
Sim. Dependent Requirements OMI8 - Maintain Plant Parameters
Environment -> Number Ranges
MRP Planning Strategy for SAP
Strategy 10 - PIR Type - LSF
Net requirements planning. That is even the warehouse/storage location stock is also taken into account besides planned receipts / issues during planning for calculating the order quantity. Planned Independence Requirement quantity is reduced at the time of Goods Issue for delivery. Strategy 11 - PIR Type - BSF
Gross requirement planning. Warehouse / storage location stock is not considered, and only planned receipts / issues are considered. Also Planned Independent Required quantity is reduced during Goods Receips for production / planned order (Repetitive). It is generally recommended for mass production industries and process oriented industries where the production has to be carried on, regardless of the stock available. The constraint in such industries is that it is not economically viable / possible to stop production. Strategy 30 - PIR Type LSF - Production only with sales order (Demand Management entry are ignored during MRP run)
Maintain the following master data for the finished product:
Strategy group 30 on the MRP screen
Availability check field (on the MRP screen and the Sales: General/Plant screen) so that you can perform an availability check with replenishment lead times (01 in the standard system)
Item category group (for example, NORM) on the Sales Organization screen Strategy 40 - PIR Type VSF - Make to Order Production - Production triggered by sales order. (Widely use around the world.)
Planned Independent Requirements will be reduced by sales order delivery to reflect the current stock requirement. (depending on your configuration, sales order will consume the VSF (planned independent requirement) quantity on the same date or two to three days away from it)
You can set up the consumption parameters in the material master on the MRP screen.
Check whether the fields Consumption mode, Bwd consumption, Fwd consumption contain entries. If empty, default values are taken from the MRP group parameters in Customizing. If these fields are filled in the material master, they override the MRP group parameters.
In MD04, VSF will disappear once it is consume by the sales order 4.6c
Choose Logistics -> Production -> Master Planning -> Demand Management -> Evaluations -> Display total requirements. (The Total Requirements List shows only those sales orders that have reduced the independent requirements.) Strategy 52 - PIR Type - VSE
The lot size key EX must be set in the MRP screen because lot size optimization would be incompatible with the allocation logic, which could result in over-planning and incorrect result in the ATP check.
You also must ensure that no rounding profile or rounding values are taken into account.
Maintain consumption parameters (Consumption mode, Bwd consumption, Fwd consumption) so that the independent requirements can be found. For more information, see Consumption Strategies and Logic.
Maintain the item category group (for example, NORM) on the Sales Organization screen.
A BOM is required for the finished product. There are no major implications for the BOM components. However, it is important to note the following:
You need to set the MRP type to P* (or M*) on the MRP screen to plan the components in MRP.
You may want to consider setting the Individual/coll. Indicator to 2 on the MRP screen as a starting point for your master data setup. Strategy 63 - PIR Type - VSEV
Set Ind./Coll. Indicator to 2 in MRP4 View for all your lower level components. It allows you to build or purchase some components only after receipt of the sales order.
Net requirements planning. That is even the warehouse/storage location stock is also taken into account besides planned receipts / issues during planning for calculating the order quantity. Planned Independence Requirement quantity is reduced at the time of Goods Issue for delivery. Strategy 11 - PIR Type - BSF
Gross requirement planning. Warehouse / storage location stock is not considered, and only planned receipts / issues are considered. Also Planned Independent Required quantity is reduced during Goods Receips for production / planned order (Repetitive). It is generally recommended for mass production industries and process oriented industries where the production has to be carried on, regardless of the stock available. The constraint in such industries is that it is not economically viable / possible to stop production. Strategy 30 - PIR Type LSF - Production only with sales order (Demand Management entry are ignored during MRP run)
Maintain the following master data for the finished product:
Strategy group 30 on the MRP screen
Availability check field (on the MRP screen and the Sales: General/Plant screen) so that you can perform an availability check with replenishment lead times (01 in the standard system)
Item category group (for example, NORM) on the Sales Organization screen Strategy 40 - PIR Type VSF - Make to Order Production - Production triggered by sales order. (Widely use around the world.)
Planned Independent Requirements will be reduced by sales order delivery to reflect the current stock requirement. (depending on your configuration, sales order will consume the VSF (planned independent requirement) quantity on the same date or two to three days away from it)
You can set up the consumption parameters in the material master on the MRP screen.
Check whether the fields Consumption mode, Bwd consumption, Fwd consumption contain entries. If empty, default values are taken from the MRP group parameters in Customizing. If these fields are filled in the material master, they override the MRP group parameters.
In MD04, VSF will disappear once it is consume by the sales order 4.6c
Choose Logistics -> Production -> Master Planning -> Demand Management -> Evaluations -> Display total requirements. (The Total Requirements List shows only those sales orders that have reduced the independent requirements.) Strategy 52 - PIR Type - VSE
The lot size key EX must be set in the MRP screen because lot size optimization would be incompatible with the allocation logic, which could result in over-planning and incorrect result in the ATP check.
You also must ensure that no rounding profile or rounding values are taken into account.
Maintain consumption parameters (Consumption mode, Bwd consumption, Fwd consumption) so that the independent requirements can be found. For more information, see Consumption Strategies and Logic.
Maintain the item category group (for example, NORM) on the Sales Organization screen.
A BOM is required for the finished product. There are no major implications for the BOM components. However, it is important to note the following:
You need to set the MRP type to P* (or M*) on the MRP screen to plan the components in MRP.
You may want to consider setting the Individual/coll. Indicator to 2 on the MRP screen as a starting point for your master data setup. Strategy 63 - PIR Type - VSEV
Set Ind./Coll. Indicator to 2 in MRP4 View for all your lower level components. It allows you to build or purchase some components only after receipt of the sales order.
Quota Arrangement for Multi Plant Purhasing
If you have more than two Plant, you can used quota arrangement to distribute the percentage of internal purchasing accordingly.
Plant A purchase from Plant B Plant C MM02 - Procurement type F Special procurement Blank Quota arr.usage 3
Plant B and Plant C MM02 - Procurement type F Special procurement Blank Quota arr.usage Blank
OMD9 - Maintain Special Procurement
Plnt SP Type Special Procurement type description Plant A Plant B Procure from Plant B Plant A Plant C Procure from Plant C
MEQ1 - Quota Arrangement for Plant A
If you press Enter, the start date comes automatically. Multiple period can be maintained.
Click Item Overview for Overview of Quota items
P S PPl. Quota F U Plant B 30 F U Plant C 70
P - Procurement type S - Special Procurement
Plant A purchase from Plant B Plant C MM02 - Procurement type F Special procurement Blank Quota arr.usage 3
Plant B and Plant C MM02 - Procurement type F Special procurement Blank Quota arr.usage Blank
OMD9 - Maintain Special Procurement
Plnt SP Type Special Procurement type description Plant A Plant B Procure from Plant B Plant A Plant C Procure from Plant C
MEQ1 - Quota Arrangement for Plant A
If you press Enter, the start date comes automatically. Multiple period can be maintained.
Click Item Overview for Overview of Quota items
P S PPl. Quota F U Plant B 30 F U Plant C 70
P - Procurement type S - Special Procurement
Subcontracting upgrade 3.0/3.1 to 4.x
Element MatSub in the MRP Requirement (MD04) is calculated wrongly. Apply note 121238. Run the OSS note program ZZSUBC40 once and the problems is solved. In the new version, stocks are tied to the Vendor.
If you want the old logic (3.0x), you can apply note 170597 and the planning will not check for Vendor
If you want the old logic (3.0x), you can apply note 170597 and the planning will not check for Vendor
Shortage/Surplus of material stock level due to differences in Planned/Production Order Start and Finish date
Normally, the planned order determined the date from Material Master. The Planned Order created by the MRP reads the production capacity requirement from Material Master. (MM03 – Work Scheduling – Lot size dependent in-house production time). When you convert the planned order to a production order, SAP determined the date from Routing.
User Requirements:- Planned and Production Order should read the requirement from routing.
Solutions:- Run MRP Scheduling -> 2 – Lead time scheduling and capacity planning
Transaction OPA9 (Sel. Profile - SAPA010) - Change configuration for Capacity Planning to read Production Order. Untick the Planned orders under the Order categories.
User Requirements:- Planned and Production Order should read the requirement from routing.
Solutions:- Run MRP Scheduling -> 2 – Lead time scheduling and capacity planning
Transaction OPA9 (Sel. Profile - SAPA010) - Change configuration for Capacity Planning to read Production Order. Untick the Planned orders under the Order categories.
MD02 - Run MRP Single item Multi level
MRP reads the requirement from:
Material Master View
Purchasing
MRP 1 and 2
Work Scheduling
Sales Order
Planned Independent Requirement
BOM
Routing Points to note:- If you have just changed the BOM and want to have the latest update. Execute with Planning Mode 2 - BOM is re-exploded
When you found that the MRP did not automatically Create the Purchase Requisitions for in-house production. Execute with Planning Mode 3 - Delete planning dates.
MRP can easily re-create Purchase Requistions and Planned Orders based on the latest requirement changes. Therefore, it is allright to execute with Planning Mode 3.
BOM - Do not built a BOM with a Material Type ROH Level 1 and Level 2, as MRP will not consider the requirement for Level 2 since it is a Raw Material. (no additional process required).
Level 1 ROH
...Level 2 ROH
Material Master View
Purchasing
MRP 1 and 2
Work Scheduling
Sales Order
Planned Independent Requirement
BOM
Routing Points to note:- If you have just changed the BOM and want to have the latest update. Execute with Planning Mode 2 - BOM is re-exploded
When you found that the MRP did not automatically Create the Purchase Requisitions for in-house production. Execute with Planning Mode 3 - Delete planning dates.
MRP can easily re-create Purchase Requistions and Planned Orders based on the latest requirement changes. Therefore, it is allright to execute with Planning Mode 3.
BOM - Do not built a BOM with a Material Type ROH Level 1 and Level 2, as MRP will not consider the requirement for Level 2 since it is a Raw Material. (no additional process required).
Level 1 ROH
...Level 2 ROH
MD02 - Run MRP Single item Multi level
MRP reads the requirement from:
Material Master View
Purchasing
MRP 1 and 2
Work Scheduling
Sales Order
Planned Independent Requirement
BOM
Routing Points to note:- If you have just changed the BOM and want to have the latest update. Execute with Planning Mode 2 - BOM is re-exploded
When you found that the MRP did not automatically Create the Purchase Requisitions for in-house production. Execute with Planning Mode 3 - Delete planning dates.
MRP can easily re-create Purchase Requistions and Planned Orders based on the latest requirement changes. Therefore, it is allright to execute with Planning Mode 3.
BOM - Do not built a BOM with a Material Type ROH Level 1 and Level 2, as MRP will not consider the requirement for Level 2 since it is a Raw Material. (no additional process required).
Level 1 ROH
...Level 2 ROH
Material Master View
Purchasing
MRP 1 and 2
Work Scheduling
Sales Order
Planned Independent Requirement
BOM
Routing Points to note:- If you have just changed the BOM and want to have the latest update. Execute with Planning Mode 2 - BOM is re-exploded
When you found that the MRP did not automatically Create the Purchase Requisitions for in-house production. Execute with Planning Mode 3 - Delete planning dates.
MRP can easily re-create Purchase Requistions and Planned Orders based on the latest requirement changes. Therefore, it is allright to execute with Planning Mode 3.
BOM - Do not built a BOM with a Material Type ROH Level 1 and Level 2, as MRP will not consider the requirement for Level 2 since it is a Raw Material. (no additional process required).
Level 1 ROH
...Level 2 ROH
Excluding/Including Safety Stock on Stock Requirements List
You can do this in transaction OMIL.
In the safety stock field, you can define whether the system is to use the number of days until the warehouse stock falls below the safety stock or below the physical stock, for the days' supply or the receipt days' supply.
In the standard settings, the system uses the number of days until the warehouse stock falls below the safety stock.
If you enter indicator 1, the system uses the number of days until the stock falls below 0.
In the safety stock field, you can define whether the system is to use the number of days until the warehouse stock falls below the safety stock or below the physical stock, for the days' supply or the receipt days' supply.
In the standard settings, the system uses the number of days until the warehouse stock falls below the safety stock.
If you enter indicator 1, the system uses the number of days until the stock falls below 0.
Planned Independant Requirement included/excluded in MRP run
MD62 - Look for the indicator version
Tick to include in MRP run Untick to exclude in MRP run
OMPG - Define consumption mode and period of adjustment. MM02 - The field in Material Master (MRP Group) determine whether the configuration is check during MRP run.
For example, if you configure consume forward as 2 days. During MRP run, forcast (VSF) must be at least 2 days ahead of the last firm Sales Order or it would be consume into the Sales Order.
Tick to include in MRP run Untick to exclude in MRP run
OMPG - Define consumption mode and period of adjustment. MM02 - The field in Material Master (MRP Group) determine whether the configuration is check during MRP run.
For example, if you configure consume forward as 2 days. During MRP run, forcast (VSF) must be at least 2 days ahead of the last firm Sales Order or it would be consume into the Sales Order.
Storage Location included/excluded from MRP
To control whether a particular storage location will be included or excluded from the MRP run. (MD02/MD41).
To exclude it from MRP run :-
OMIR - Define storage location MRP per plant
Put the MRP ind. as. 1 - storage location stock excluded for MRP To include it from MRP run:-
OMIR - Define storage location MRP per plant
Put the MRP ind. as. space - storage location stock also planned at plant level and save it
Next go to transaction MM01 - tick only view MRP 2
Key in Plant and Storage Location
Look at the Storage Location MRP section
change the SLoc MRP indicator to space and save it MMD1 - Create MRP Profile - MRP profile is a useful entry aid and makes it easier to manage MRP data. You define which fields are filled with values when MRP data is entered in the material master record, which of these values can be overwritten and which not. You use the information stored in a profile is standard information that is needed again and again in similar constellations when material master records are maintained.
To exclude it from MRP run :-
OMIR - Define storage location MRP per plant
Put the MRP ind. as. 1 - storage location stock excluded for MRP To include it from MRP run:-
OMIR - Define storage location MRP per plant
Put the MRP ind. as. space - storage location stock also planned at plant level and save it
Next go to transaction MM01 - tick only view MRP 2
Key in Plant and Storage Location
Look at the Storage Location MRP section
change the SLoc MRP indicator to space and save it MMD1 - Create MRP Profile - MRP profile is a useful entry aid and makes it easier to manage MRP data. You define which fields are filled with values when MRP data is entered in the material master record, which of these values can be overwritten and which not. You use the information stored in a profile is standard information that is needed again and again in similar constellations when material master records are maintained.
Main difference between the MRP type PD and MPS type M0
When running MRP using transaction MD02 and MD41, what the difference should be?
There is no difference in the processing logic as such. The only difference is that MPS only acts on materials with an MRP type relevant to MPS (e.g. M0, M1, etc...), and MRP acts on materials with an MRP type relevant to MRP (e.g. PD). How the materials are processed is exactly the same.
This functionality allows you to run MRP for 2 sets of materials separately (and with a different frequency).
For example, some businesses may do planning for their finished goods once per week, but would want to run MRP for their components daily (although this is generally not necessary with SAP). So, for this example, you would define all finished goods with an MRP type relevant for MPS, and all components with an MRP relevant.
Basically, MPS is a form of MRP that concentrates planning on parts or products that greatly influence the company profits or those that require critical resources. Items marked as master schedule items can be finished goods, assemblies or raw materials. These items are selected for separate MPS run that takes place before the MRP planning run. MPS run is executed without any BOM explosion. This is to allow the MRP controller to ensure that the master schedule items are correctly planned before any detailed MRP run take place.
There is no difference in the processing logic as such. The only difference is that MPS only acts on materials with an MRP type relevant to MPS (e.g. M0, M1, etc...), and MRP acts on materials with an MRP type relevant to MRP (e.g. PD). How the materials are processed is exactly the same.
This functionality allows you to run MRP for 2 sets of materials separately (and with a different frequency).
For example, some businesses may do planning for their finished goods once per week, but would want to run MRP for their components daily (although this is generally not necessary with SAP). So, for this example, you would define all finished goods with an MRP type relevant for MPS, and all components with an MRP relevant.
Basically, MPS is a form of MRP that concentrates planning on parts or products that greatly influence the company profits or those that require critical resources. Items marked as master schedule items can be finished goods, assemblies or raw materials. These items are selected for separate MPS run that takes place before the MRP planning run. MPS run is executed without any BOM explosion. This is to allow the MRP controller to ensure that the master schedule items are correctly planned before any detailed MRP run take place.
Difference between MRP type manual reorder point and automatic reorder
In manual reorder point, you must define the reorder point (and eventually the safety stock) according to your criteria.
For automatic, these values are estimated by SAP as a function of the forecast (coming from historical data), so the base-quantities for the calculation of the reorder are not fixed but dynamic.
For automatic, these values are estimated by SAP as a function of the forecast (coming from historical data), so the base-quantities for the calculation of the reorder are not fixed but dynamic.
How To Delete Old Production Orders
Note that CO78 is the start of the Archive process. We are not using Archiving yet but the initial process fits the bill for what we need to do as mentioned in the original note.
Decide the range of orders you want to delete. This range will be used in the program variant. Note that we will be running CO78 many times because of the number of orders involved.
Running CO78 calls program PPARCHP1 and this involves the use of a Variant where the parameters for selection etc. are set.
First of all, create the variant via SE38 for PPARCHP1.
Enter details for number range, order type, plant and set deletion flag. Flag Detailed log and set this to go to Spool when running. Save the variant. You can also force the job to run in background at this point (which I would recommend) via menu line Variant --> Attributes. Also here you can flag order number, order type and plant to be required fields.
Decide the range of orders you want to delete. This range will be used in the program variant. Note that we will be running CO78 many times because of the number of orders involved.
Running CO78 calls program PPARCHP1 and this involves the use of a Variant where the parameters for selection etc. are set.
First of all, create the variant via SE38 for PPARCHP1.
Enter details for number range, order type, plant and set deletion flag. Flag Detailed log and set this to go to Spool when running. Save the variant. You can also force the job to run in background at this point (which I would recommend) via menu line Variant --> Attributes. Also here you can flag order number, order type and plant to be required fields.
What and How To Create Routing
You have to proceeds following steps:
1) CA01 - Create routing First screen = Material on which you have to create a routing Plant Second screen = Usage 1 if you create routing for production purpose. Status 4 release general Enter 2) Now go on to application tool bar and select operation Here you have to enter work center, control key and description For eg. w/c 1 plant pp01 description w/c 2 plant pp01 description plant pp99 goods reciepts 3) Now select the component allocation Select the material here and click on to the new assignemnt for assign the operation seqence on to the material.
4) SAVE
Now routing is create with routing group number .
What is meant by routing?
Routing is nothing but your Process Plan.
A routing is a description of which operations (process steps) have to be carried out and in which order to produce a material (product). As well as information about the operations and the order in which they are carried out, a routing also contains details about the work centers at which they are carried out as well as about the required production resources and tools (includes jigs and fixtures). Standard values for the execution of individual operations are also saved in routings.
Routings (generic) consist of the following objects:
- Routing - Rate routing - Reference operation set - Reference rate routing
Routings enable you to plan the production of materials (products)
In a routing you plan
- The operations (work steps) to be carried out during production
- The activities to be performed in the operations as a basis for determining dates, capacity requirements, and costs
- The use of materials during production
- The use of work centers
- The quality checks to be carried out during production
1) CA01 - Create routing First screen = Material on which you have to create a routing Plant Second screen = Usage 1 if you create routing for production purpose. Status 4 release general Enter 2) Now go on to application tool bar and select operation Here you have to enter work center, control key and description For eg. w/c 1 plant pp01 description w/c 2 plant pp01 description plant pp99 goods reciepts 3) Now select the component allocation Select the material here and click on to the new assignemnt for assign the operation seqence on to the material.
4) SAVE
Now routing is create with routing group number .
What is meant by routing?
Routing is nothing but your Process Plan.
A routing is a description of which operations (process steps) have to be carried out and in which order to produce a material (product). As well as information about the operations and the order in which they are carried out, a routing also contains details about the work centers at which they are carried out as well as about the required production resources and tools (includes jigs and fixtures). Standard values for the execution of individual operations are also saved in routings.
Routings (generic) consist of the following objects:
- Routing - Rate routing - Reference operation set - Reference rate routing
Routings enable you to plan the production of materials (products)
In a routing you plan
- The operations (work steps) to be carried out during production
- The activities to be performed in the operations as a basis for determining dates, capacity requirements, and costs
- The use of materials during production
- The use of work centers
- The quality checks to be carried out during production
What is the difference between alternative and parallel sequence.How these are used?
Generally in routing 3 types of sequence are present which are standard, parellel and alternate sequence. Alternate sequences are linked to the standard sequence which is the main sequence. The place where alternate sequence starts from the standard sequence is called branch operation and again the place where it joins the standard sequence is called the return operation. Parellel sequences are set of operation which run parellel to the standard sequence, for example in a chemical industry for analytical processes that occur parellel to the main production process. Alternate sequence consists of set of operations other than the standard sequence so that either of the sequences can be run for a production process.Generally branch operations in the standard sequence are ingored in this process.
Split In Routing / Difference Between Alternative And Parallel Seq
The term "Splitting" in SAP means having more than one person or maching working on an operation in a production order.
SAP assumes that only one person/machine will be working on a job at a time. If it takes one hour to make one, and the order is for 10, the system will schedule the job at that work center to take 10 hours. However, if in the operation in the routing, you select "Required Splitting", then you put in "number of splits" as 2, then the system will assume you are having two people/machines work on the job at the same time, hence it will only schedule the job to take 5 hours, not 10. If you put in splitts as 4, then the system will assume 2.5 hours to get the job done.
Also, sometimes it might be ridiculous to split the job. For instance, if that previous example order was only for 2 piedes. Having two machines working on it would be dumb, because you would have to do two setups. So the system gives you a Minimum processing time, so if it's less than, say, 5 hours, do not split it.
SAP assumes that only one person/machine will be working on a job at a time. If it takes one hour to make one, and the order is for 10, the system will schedule the job at that work center to take 10 hours. However, if in the operation in the routing, you select "Required Splitting", then you put in "number of splits" as 2, then the system will assume you are having two people/machines work on the job at the same time, hence it will only schedule the job to take 5 hours, not 10. If you put in splitts as 4, then the system will assume 2.5 hours to get the job done.
Also, sometimes it might be ridiculous to split the job. For instance, if that previous example order was only for 2 piedes. Having two machines working on it would be dumb, because you would have to do two setups. So the system gives you a Minimum processing time, so if it's less than, say, 5 hours, do not split it.
A basic SAP Engineering Change Management Setup
This are the basic IMG settings in order to used the engineering change managementfeatures. x refers to a tick.First setup the control data in OS54.Revision sectionsFields :-Revision level active xExt. revision level xHigher revision level xObject Management Record sectionsFields :-Object maintenance xAssign alternative date xOveride value/assignment date sectionsFields :-Only with leading change mst. xSetting the Revision level active is to activate the engineering change management formaterial master. If you do not want the engineering change management for materials,remove the tick.With a tick in "Higher revision level", the new revision level has to be always higherthan the old revision.Secondly, setup the external number range in OS53.If you use the internal number range, then remove the external number range.Third, define the status for the change master records in transaction SM30 - V_T419S.Change No. Chg Date Chg Dist. Lock DescriptionStatus Poss 1 x x ' ' Active 2 ' ' ' ' ' ' Inactive 3 ' ' ' ' x LockedFourth, define modification parameters for the BOM in OS27.Fields :-BOM Validty Maint. xEC Management Active xHistory Requirement ' 'Unit Piece PCThe rest of the fields are blank.If the History Requirement is tick, every time during creation of the BOM, SAP willprompt your for an ECN number as is compulsory.Lastly, define fields selection for routing in OP5A.PP task lists: initial screen -> Change number -> Transaction code -> Tick Req.Setting the Transaction code fields Required indicate that you have make the ECN number compulsory when changing the routing. Finally, do a test by making changes to the Material Master, BOM and Routing.
Planned Order Conversion to Process Orders
First ensure that setting in the material master for BOM explosion is "Selection thru prod version".
Then Pls check the validity periods of the new production version.
e.g Prod Ver Val frm val to No lot size variation 0001 01.01.2007 31.12.9999 0002 01.01.2007 31.01.2007 or 0001 01.01.2007 31.12.9999 0002 01.01.2007 31.12.2007
Then in both the cases system will always pick prod ver 0001 default (Longer validity period). If not the case then Check for lot size variation (if lot size dependent.)
Further if you are not able to select the req prod Ver then you can lock the earlier prod version(if it is not in use).
To avoid this prob in future.... always use "Valid to date" either in limits (31.12.2007) or without limit (31.12.9999) for all prod version of a material.
Then Pls check the validity periods of the new production version.
e.g Prod Ver Val frm val to No lot size variation 0001 01.01.2007 31.12.9999 0002 01.01.2007 31.01.2007 or 0001 01.01.2007 31.12.9999 0002 01.01.2007 31.12.2007
Then in both the cases system will always pick prod ver 0001 default (Longer validity period). If not the case then Check for lot size variation (if lot size dependent.)
Further if you are not able to select the req prod Ver then you can lock the earlier prod version(if it is not in use).
To avoid this prob in future.... always use "Valid to date" either in limits (31.12.2007) or without limit (31.12.9999) for all prod version of a material.
Assign Multiple Planned Order to a Purchase Requisition
In order to assign multiple planned order to a single purchase requisition number, you need to make used of the external purchase requisition number range.Define your external purchase requisition number range in OMDN.Assign the external purchase requisition group number range to used in OMI3.Once the IMG settings are completed, you can used MD15 to assign the multiple planned order into a single purchase requisition number.In MD15, select the planned order you want to convert to a purchase requisition.Next, click the Convert Online button.SAP will display the planned order in change mode.Now, look for the Purchase Requisition fields and supply the Purchase requisition number.For example, assuming that you assign the external number range 2000001.In the planned order, you type the first number range 2000001 and item number 10 subsequently, copy and paste the number range but input the item number manually. It would be like 2000001 10 and save 2000001 20 and save.....The disadvantages is that the user have to track and enter the external number range manually. Therefore, there is a trade off, between 1. having a single planned order for a single purchase requisition number or 2. having multiple planned order to a single purchase requisition number.
How to “permanently” delete new planned orders?
Your company insists on fixing planned orders, to try to keep a stable, six-month plan. But you still get new planned orders generated in-between the fixed ones. You thought that you would get exception messages to pull in all the fix planned orders before new ones are generated. You need to “permanently” delete the new planned orders and leave only the fixed ones.
Two ideas which you can they apply to the scenario:
1) In OPPQ, exclude firm planned orders from rescheduling. This will add a rescheduling exception to the planned orders, and you could filter/report that way.
For example, if you discovered that the rescheduling horizon was only 100 days, you can made it 999. Now the fixed planned orders are all being rescheduled and no new planned orders are created “in between” the fixed ones.
2) Convert planned orders into production orders. Then you can look at production orders as your fixed plan, and ignore planned orders.
Deleting planned orders will be a short joy, as soon as you run MRP (assuming you do...) they will be recreated.
Two ideas which you can they apply to the scenario:
1) In OPPQ, exclude firm planned orders from rescheduling. This will add a rescheduling exception to the planned orders, and you could filter/report that way.
For example, if you discovered that the rescheduling horizon was only 100 days, you can made it 999. Now the fixed planned orders are all being rescheduled and no new planned orders are created “in between” the fixed ones.
2) Convert planned orders into production orders. Then you can look at production orders as your fixed plan, and ignore planned orders.
Deleting planned orders will be a short joy, as soon as you run MRP (assuming you do...) they will be recreated.
Set Parameter and Work Center Formula
How to set parameter and formula for e.g. Power, Fuel, Repair and Maintenance?
Some inputs for setting parameters and formula::
Go-to : OP7B "Parameters Overview"
Define your requirements Eg. For Power – say ZELECT like that
(Short Key work/Keyword – Electricity, Dimension " Energy", Std. Value Unit – KWH)
Then Go-to : OP19 " Standard Value Key Formula : Overview "
Select SAP1 – Normal Production and Copy as (F6) and Create new Activity Type Say eg. ZELE
Then Assign this new Parameter ZELECT and save (handle the transport request)
For Formula Definition :
Go-to : OP54 "Formula Definition"
Select SAP002 – Prod.: Machine Time and Copy as (F6) and Create ur new Formula Say Eg. ZELECT
And replace SAP_02 with your Parameter – ZELECT
Then it’ll look some thing like "ZELECT * SAP_09 / SAP_08 / SAP_11"
Assign The Standard Value Key " ZELE" to your Work Center-Basic Data Screen
Now Go-to Costing Tab Page assign your formula to your Predefined Activity Type for Power.
(Otherwise – First Create Secondary Cost Element (T.Code KA06), Assign this Sec. Cost Element to your new Activity Type, then KP26 " Change Activity / Price Planning"
Assign Activity Type in Work Center Costing Tab & Assign Your Formula)
You can assign max. 6 Standard Values to your WC, I.e If you want to capture Power & Fuel Consumption for an Operation you can have both parameters set as per above procedure.
For costing part, please refer to your CO-person for help.
Some inputs for setting parameters and formula::
Go-to : OP7B "Parameters Overview"
Define your requirements Eg. For Power – say ZELECT like that
(Short Key work/Keyword – Electricity, Dimension " Energy", Std. Value Unit – KWH)
Then Go-to : OP19 " Standard Value Key Formula : Overview "
Select SAP1 – Normal Production and Copy as (F6) and Create new Activity Type Say eg. ZELE
Then Assign this new Parameter ZELECT and save (handle the transport request)
For Formula Definition :
Go-to : OP54 "Formula Definition"
Select SAP002 – Prod.: Machine Time and Copy as (F6) and Create ur new Formula Say Eg. ZELECT
And replace SAP_02 with your Parameter – ZELECT
Then it’ll look some thing like "ZELECT * SAP_09 / SAP_08 / SAP_11"
Assign The Standard Value Key " ZELE" to your Work Center-Basic Data Screen
Now Go-to Costing Tab Page assign your formula to your Predefined Activity Type for Power.
(Otherwise – First Create Secondary Cost Element (T.Code KA06), Assign this Sec. Cost Element to your new Activity Type, then KP26 " Change Activity / Price Planning"
Assign Activity Type in Work Center Costing Tab & Assign Your Formula)
You can assign max. 6 Standard Values to your WC, I.e If you want to capture Power & Fuel Consumption for an Operation you can have both parameters set as per above procedure.
For costing part, please refer to your CO-person for help.
Guide To Mass Replace Work Center
On the work center I have defined an activity type for preparation, machine work, personal work. When I modify an activity type on a work center, the routings where these work center are employed are not automatically updated.
Use Tcode CA85 with same workcenter in New work center field. Change the new activity type in default values screen. But if your activtity types don't change in the routings where ever the workcenter is used, then check the reference indicator in the workcenter itself. So whenever you change the activity type in the workcenter, routing data will also get changed automatically.
The step by step guide below gave you a blow by blow account of the steps for CA85. Just ensure you only select a few materials initially, and change the mode of transfer so that it works like a BDC and you are sure that the data is correctly changed.
Use Tcode CA85 with same workcenter in New work center field. Change the new activity type in default values screen. But if your activtity types don't change in the routings where ever the workcenter is used, then check the reference indicator in the workcenter itself. So whenever you change the activity type in the workcenter, routing data will also get changed automatically.
The step by step guide below gave you a blow by blow account of the steps for CA85. Just ensure you only select a few materials initially, and change the mode of transfer so that it works like a BDC and you are sure that the data is correctly changed.
SAP PP-CRP-LVL - Capacity Leveling Profile Setup
Capacity leveling is used in various areas of a company and at different planning levels with the following objectives:
- High capacity load - Adherence to dates - Short lead times - Low stocks
The objectives of capacity leveling include:
- Leveling overloads and under loads at work centers - Achieving optimum commitment of machines and production lines - Selection of appropriate resources
Show here is an example on how to customize the Capacity Leveling Profile.
Define time profile in OPD2.
Assuming you want to create a time profile for 2 months.
Entry Type Start Date End Date Database Read Period J -3 3
The database read period specifies the period in which capacity requirements are read from the database. All requirements are accessed which are partially or completely within the database read period.
Evaluation Period G -1 60
The evaluation period specifies the period over which data is formatted and displayed. The evaluation period must lie within the database read period.
Planning Period G -1 60
The planning period defines the period in which the SAP system can carry out planning. The planning period is smaller than or equal to the evaluation period. You cannot move operations outside the planning period. Equally, when automatic finite scheduling is carried out for an operation the system only searches for a new date within the planning period.
Dispatch of backlog G Backlog dispatch Date = 0
The date for dispatching the backlog is of importance in period-related planning. You use the date for dispatching the backlog to determine the date backlogs are to be allocated.
The following types of entry are available:
Actual date specifications
These date specifications (for example, calendar day, calendar year) are only useful in the profiles in exceptional cases.
Relative date specifications
These date specifications (for example, number of calendar days, number of calendar years) are always calculated from the current day.
For every period, you can specify in what form you want to enter the date by using the respective field "Type of entry".
Define the strategy profile in OPDB.
In this menu option you define strategy profiles to control capacity leveling with the planning tables.
You can copy the standard strategy profile like SAPSFCVER1 or SAP_T001.
Assuming you copy the strategy profile to ZAPSFCVER1 ticking the followings:-
1. Dispatch at earliest point in time. 2. Change production version on error. 3. Cancel dispatching due to error. 4. Use operations floats. 5. Use float before production. 6. Use float after production.
and copy the strategy to ZAP_T001 ticking the Change Planning direction.
Define the Overall profiles in OPD0.
The overall profiles are used as follows to control capacity planning:
If you select the menu options: Capacity planning -> Leveling -> Work center view -> Planning table, then the profile SAPSFCG001 is processed in the standard version.
You can change the profile, but the SAP sub-profiles should remain unchanged as far as possible.
You can define your own profiles and allocate them to particular users by means of user parameters. (See user parameters CYA -> CYX)
For example, when you access the planning table enter using the application menu "Capacity planning" -> Leveling -> Work center view -> Planning table the user parameter "CYA" is operative.
You can select any overall profile you like by entering via the application menu "Capacity planning" -> Leveling -> Variable.
Your details of the profile can be as follows:-
Profile ZONLINE ZBACKGRD Selection profile SAPSFCS005 SAPSFCS001 Control profile SAP__C001 SAP__C002 Time profile ZTIME SAP__Z002 Evaluation profile SAP__A001 SAP__A001 Strategy profile SAP__T001 ZSTRATEGY Period profile SAP__P002 Planning table profile SAPSFCL010 Prof. Plan tab (tab) SAPSFCR011 List profile SAPSFCI001 SAPSFCI001
- High capacity load - Adherence to dates - Short lead times - Low stocks
The objectives of capacity leveling include:
- Leveling overloads and under loads at work centers - Achieving optimum commitment of machines and production lines - Selection of appropriate resources
Show here is an example on how to customize the Capacity Leveling Profile.
Define time profile in OPD2.
Assuming you want to create a time profile for 2 months.
Entry Type Start Date End Date Database Read Period J -3 3
The database read period specifies the period in which capacity requirements are read from the database. All requirements are accessed which are partially or completely within the database read period.
Evaluation Period G -1 60
The evaluation period specifies the period over which data is formatted and displayed. The evaluation period must lie within the database read period.
Planning Period G -1 60
The planning period defines the period in which the SAP system can carry out planning. The planning period is smaller than or equal to the evaluation period. You cannot move operations outside the planning period. Equally, when automatic finite scheduling is carried out for an operation the system only searches for a new date within the planning period.
Dispatch of backlog G Backlog dispatch Date = 0
The date for dispatching the backlog is of importance in period-related planning. You use the date for dispatching the backlog to determine the date backlogs are to be allocated.
The following types of entry are available:
Actual date specifications
These date specifications (for example, calendar day, calendar year) are only useful in the profiles in exceptional cases.
Relative date specifications
These date specifications (for example, number of calendar days, number of calendar years) are always calculated from the current day.
For every period, you can specify in what form you want to enter the date by using the respective field "Type of entry".
Define the strategy profile in OPDB.
In this menu option you define strategy profiles to control capacity leveling with the planning tables.
You can copy the standard strategy profile like SAPSFCVER1 or SAP_T001.
Assuming you copy the strategy profile to ZAPSFCVER1 ticking the followings:-
1. Dispatch at earliest point in time. 2. Change production version on error. 3. Cancel dispatching due to error. 4. Use operations floats. 5. Use float before production. 6. Use float after production.
and copy the strategy to ZAP_T001 ticking the Change Planning direction.
Define the Overall profiles in OPD0.
The overall profiles are used as follows to control capacity planning:
If you select the menu options: Capacity planning -> Leveling -> Work center view -> Planning table, then the profile SAPSFCG001 is processed in the standard version.
You can change the profile, but the SAP sub-profiles should remain unchanged as far as possible.
You can define your own profiles and allocate them to particular users by means of user parameters. (See user parameters CYA -> CYX)
For example, when you access the planning table enter using the application menu "Capacity planning" -> Leveling -> Work center view -> Planning table the user parameter "CYA" is operative.
You can select any overall profile you like by entering via the application menu "Capacity planning" -> Leveling -> Variable.
Your details of the profile can be as follows:-
Profile ZONLINE ZBACKGRD Selection profile SAPSFCS005 SAPSFCS001 Control profile SAP__C001 SAP__C002 Time profile ZTIME SAP__Z002 Evaluation profile SAP__A001 SAP__A001 Strategy profile SAP__T001 ZSTRATEGY Period profile SAP__P002 Planning table profile SAPSFCL010 Prof. Plan tab (tab) SAPSFCR011 List profile SAPSFCI001 SAPSFCI001
Discrete Manufacturing - The Step By Step Tcodes
Step 1: Material Master Logistics > Production > Master Data > Material Master > Material > Create General > Immediately MM01
Step 2: BOM creation Logistics > Production > Master Data > Bills of Material > Bills of Material > Material BOM > Create CS01
Step 3: Work Center creation Logistics > Production > Master Data > Work Center > ( New Screen ) Work Center > Create CR01
Step 4: Route creation Logistics > Production > Master Data > Routings > Routings > Routing > Create CA01
Step 5: PIR Generation Logistics> Production>production planning>demand management>PIR>Create MD61
Step 6: MRP Run Logistics>Materials Management>Material planning>MRP>MRP>Total Planning>Online MD01
or
Logistics > Production > MRP > MRP > Sng-Item, Multi-Level MD02
Step 7: Evaluation through MRP list and Stock requirement list Logistics>Materials Management>Materials Planning>MRP>Evaluations>MRP List>Individual Display MD05
Logistics>Materials Management>Materials Planning>MRP>Evaluations>Stock Requirements List MD04
Step 8: Conversion of Planned order to Production order
Logistics > Production > Production control > Order > Create > With a planned order CO40
or
Logistics >Production > Production control >Order > Create >With material CO01(For creating production order Without planned order)
Step 9: Order management Logistics >Production > Production control >Order > Change >With material CO02
Step10: Confirmations Logistics >Production >Production control >Confirmation >Enter >For order CO15
or
Logistics >Production >Production control >Confirmation >Enter >For Operation >For time ticket CO11N
Step11: Goods issue 1. Logistics >Production >Production Control >Environment >Goods Movement >Goods Issue 2. Logistics >Materials Management >Inventory Management >Goods Movement >Goods Issue MB1A--261Movement type
Step12: Goods receipt Logistics > Production > Production Order > Environment > Material Movement > Post Mat to Stock
or
Logistics > Materials Management > Inventory Management > Goods Movement > Good Receipt > For Order MB31
Step13: Techo Or Close Order.
Step 2: BOM creation Logistics > Production > Master Data > Bills of Material > Bills of Material > Material BOM > Create CS01
Step 3: Work Center creation Logistics > Production > Master Data > Work Center > ( New Screen ) Work Center > Create CR01
Step 4: Route creation Logistics > Production > Master Data > Routings > Routings > Routing > Create CA01
Step 5: PIR Generation Logistics> Production>production planning>demand management>PIR>Create MD61
Step 6: MRP Run Logistics>Materials Management>Material planning>MRP>MRP>Total Planning>Online MD01
or
Logistics > Production > MRP > MRP > Sng-Item, Multi-Level MD02
Step 7: Evaluation through MRP list and Stock requirement list Logistics>Materials Management>Materials Planning>MRP>Evaluations>MRP List>Individual Display MD05
Logistics>Materials Management>Materials Planning>MRP>Evaluations>Stock Requirements List MD04
Step 8: Conversion of Planned order to Production order
Logistics > Production > Production control > Order > Create > With a planned order CO40
or
Logistics >Production > Production control >Order > Create >With material CO01(For creating production order Without planned order)
Step 9: Order management Logistics >Production > Production control >Order > Change >With material CO02
Step10: Confirmations Logistics >Production >Production control >Confirmation >Enter >For order CO15
or
Logistics >Production >Production control >Confirmation >Enter >For Operation >For time ticket CO11N
Step11: Goods issue 1. Logistics >Production >Production Control >Environment >Goods Movement >Goods Issue 2. Logistics >Materials Management >Inventory Management >Goods Movement >Goods Issue MB1A--261Movement type
Step12: Goods receipt Logistics > Production > Production Order > Environment > Material Movement > Post Mat to Stock
or
Logistics > Materials Management > Inventory Management > Goods Movement > Good Receipt > For Order MB31
Step13: Techo Or Close Order.
Discrete Manufacturing - The Made To Stock Cycle
The Made To Stock Cycle
The Made to stock scenario will start from Demand Management here we can create Planed independent requirements manually or by using data from SOP. After MRP run system will create planned orders which we can convert to Production order As the Stocks produced there off are not customer stock or the stock is not attached to any specific customer. Further confirmations are done and issues of material are carried out to the production order. Finally the production is put in to stock (GR).
Here at any point of time a sales order might come in and delivery to the customer is done from the existing stock.
Production Master Data
The Production Master Data consists of Material Master, Bill of Material, Work Center, Route, and Production Line Design.
The Material Master is created first for all components involved in making the Final product. Then these components are put in a product relationship i.e. a list of materials required to make the final product are put in a hierarchy, this is called a Bill of Material.
The next task is to identify the work centers required to produce the product; if the work centers are already created then they can be readily put in a sequence, which would be a sequence of work centers required to produce the product. This sequence of work centers one after the other (in the sequence of work to be done) is called a Route.
The Cycle of Made to stock: Steps: MTS Scenario
1. Material Creation (Made To Stock Material with major changes of: Item Category: NORM ) 2. Creation of BOM 3. Route Creation 4. Demand requirements 5. MRP Run 6. Creation/conversion of Production order (Made To stock), Scheduling, Costing, Release and Save 7. Production order Quantity confirmations for operations, Parallel task of material Issue to order or to reservations (261) 8. Fully Produced Production Quantities will be put into stock (GR) 9. Sales order Creation 10. Delivery against sales order
The Made to stock scenario will start from Demand Management here we can create Planed independent requirements manually or by using data from SOP. After MRP run system will create planned orders which we can convert to Production order As the Stocks produced there off are not customer stock or the stock is not attached to any specific customer. Further confirmations are done and issues of material are carried out to the production order. Finally the production is put in to stock (GR).
Here at any point of time a sales order might come in and delivery to the customer is done from the existing stock.
Production Master Data
The Production Master Data consists of Material Master, Bill of Material, Work Center, Route, and Production Line Design.
The Material Master is created first for all components involved in making the Final product. Then these components are put in a product relationship i.e. a list of materials required to make the final product are put in a hierarchy, this is called a Bill of Material.
The next task is to identify the work centers required to produce the product; if the work centers are already created then they can be readily put in a sequence, which would be a sequence of work centers required to produce the product. This sequence of work centers one after the other (in the sequence of work to be done) is called a Route.
The Cycle of Made to stock: Steps: MTS Scenario
1. Material Creation (Made To Stock Material with major changes of: Item Category: NORM ) 2. Creation of BOM 3. Route Creation 4. Demand requirements 5. MRP Run 6. Creation/conversion of Production order (Made To stock), Scheduling, Costing, Release and Save 7. Production order Quantity confirmations for operations, Parallel task of material Issue to order or to reservations (261) 8. Fully Produced Production Quantities will be put into stock (GR) 9. Sales order Creation 10. Delivery against sales order
Discrete Manufacturing - The Made To Order Cycle
In sap there is specific transaction flow for a particular Mfg. Process.it all depends upon the req. of client and process.
Here is the basic flow of transactions which is req. for creating master data, planning and order processing...
The Made TO Order Cycle:
The sale department passes on the Made to order-Sales Order to the Material department so that material requirement is analyzed. This is done in SAP by carrying on an MRP Run for all the levels of the product BOM. This MRP Run would create Planned Orders for the shortages. Here the planned orders for fert sub assemblies, Components etc, are created. This planned orders for materials produced in house are converted in to Production order and planned orders for materials procured from outside are converted in to Purchase order. The creation of Production order through the planned orders will convert all the dependant requirements in to dependant reservations.
The dates of production or purchase are decided through the total replenishment time mentioned in the material master, If it is, in-house production, then the Route times precede over the total replenishment time entered in the material master. And the availability of all the components is ruled by the availability checking rules and by availability checking scopes. Thus whenever the system declares a product to be ready or available by a date it implies that the system has checked the availability of the material with respect to the Ware house stock, in coming stock (Receipts) and all other planned orders already existing for the product or material.
In the Made to order production, sales order produced for Fert and Sub assemblies are converted in to production order during MRP run. The production orders created have a specific quantity, specific Basic start date and a specific Basic Finish Date, a set of operations and a set of component attached from the BOM. In course of production the quantities produced in the operation for an order should be confirmed so that the current status of work is available in real time situation. The components required for production are issued to the production order through goods issue by a movement type 261 and the issue is always made to the reservations or to the order, thereby clearing the reservations. Issues of unplanned components are made as new items issue and not as order issue. The quantities, for an order which are produced completely are the put in to stock i.e. a Goods Receipt is done.
Thus the made to order cycle starts with the sales orders and converting them to Production Orders through MRP Run and there off confirming produced quantities for an order and finally putting the order in to stock.
The Cycle of Made to order: Steps: MTO Scenario
1. Material Creation (Made To order Material with major changes of: Item Category: 0004-make to order/assem.,or 0001-make to order) 2. Route Creation 3. Creation of BOM 4. Sales order 5. Production order Scheduling, Costing, Release and Save 6. Production order Quantity confirmations for operations, Parallel task of material issue to order or to reservations (261) 7. Fully Produced Production Quantities will be put into stock (GR) 8. Delivery against sales order
Here is the basic flow of transactions which is req. for creating master data, planning and order processing...
The Made TO Order Cycle:
The sale department passes on the Made to order-Sales Order to the Material department so that material requirement is analyzed. This is done in SAP by carrying on an MRP Run for all the levels of the product BOM. This MRP Run would create Planned Orders for the shortages. Here the planned orders for fert sub assemblies, Components etc, are created. This planned orders for materials produced in house are converted in to Production order and planned orders for materials procured from outside are converted in to Purchase order. The creation of Production order through the planned orders will convert all the dependant requirements in to dependant reservations.
The dates of production or purchase are decided through the total replenishment time mentioned in the material master, If it is, in-house production, then the Route times precede over the total replenishment time entered in the material master. And the availability of all the components is ruled by the availability checking rules and by availability checking scopes. Thus whenever the system declares a product to be ready or available by a date it implies that the system has checked the availability of the material with respect to the Ware house stock, in coming stock (Receipts) and all other planned orders already existing for the product or material.
In the Made to order production, sales order produced for Fert and Sub assemblies are converted in to production order during MRP run. The production orders created have a specific quantity, specific Basic start date and a specific Basic Finish Date, a set of operations and a set of component attached from the BOM. In course of production the quantities produced in the operation for an order should be confirmed so that the current status of work is available in real time situation. The components required for production are issued to the production order through goods issue by a movement type 261 and the issue is always made to the reservations or to the order, thereby clearing the reservations. Issues of unplanned components are made as new items issue and not as order issue. The quantities, for an order which are produced completely are the put in to stock i.e. a Goods Receipt is done.
Thus the made to order cycle starts with the sales orders and converting them to Production Orders through MRP Run and there off confirming produced quantities for an order and finally putting the order in to stock.
The Cycle of Made to order: Steps: MTO Scenario
1. Material Creation (Made To order Material with major changes of: Item Category: 0004-make to order/assem.,or 0001-make to order) 2. Route Creation 3. Creation of BOM 4. Sales order 5. Production order Scheduling, Costing, Release and Save 6. Production order Quantity confirmations for operations, Parallel task of material issue to order or to reservations (261) 7. Fully Produced Production Quantities will be put into stock (GR) 8. Delivery against sales order
What is Discrete Manufacturing, REM and Demand Management?
Here are difference between Discrete and REM and small explanation about discrete and repetative manf.:
- A typical characteristic of discrete manufacturing is the frequent switching from one manufactured product to another. The products are typically manufactured in individually defined lots, the sequence of work centers through production varying for each one of these. Costs are calculated on the basis of orders and individual lots.
- In Repetitive Manufacturing, products remain unchanged over a longer period and are not manufactured in individually defined lots. Instead, a total quantity is produced over a certain period at a certain rate.
- Discrete manufacturing typically involves varying the sequence of work centers through which the products can pass during production. The order of work centers is determined in routings, which can often be very complex. There can be waiting times between the individual work centers. Also, semi-finished products are frequently placed in interim storage prior to further processing.
- Repetitive Manufacturing, on the other hand, normally involves a relatively constant flow on production lines. Semi-finished products are usually processed further immediately without being put in interim storage. Routings tend to be relatively simple.
- In discrete manufacturing, component materials are staged with specific reference to the individual production lots. Completion confirmations for the various steps and processes document the work progress and enable fine-tune controlling.
- In Repetitive Manufacturing, components are often staged at the production line without reference to a particular order. Completion confirmations are less detailed, and the recording of actual data is simplified.
- The function of Demand Management is to determine requirement quantities and delivery dates for finished products assemblies. Customer requirements are created in sales order management. To create a demand program, Demand Management uses planned independent requirements and customer requirements.
To create the demand program, you must define the planning strategy for a product. Planning strategies represent the methods of production for planning and manufacturing or procuring a product.
Using these strategies, you can decide if production is triggered by sales orders (make-to-order production), or if it is not triggered by sales orders (make-to-stock production).You can have sales orders and stock orders in the demand program. If the production time is long in relation to the standard market delivery time, you can produce the product or certain assemblies before there are sales orders. In this case, sales quantities are planned, for example, with the aid of a sales forecast.
Tips by : Panda.
- A typical characteristic of discrete manufacturing is the frequent switching from one manufactured product to another. The products are typically manufactured in individually defined lots, the sequence of work centers through production varying for each one of these. Costs are calculated on the basis of orders and individual lots.
- In Repetitive Manufacturing, products remain unchanged over a longer period and are not manufactured in individually defined lots. Instead, a total quantity is produced over a certain period at a certain rate.
- Discrete manufacturing typically involves varying the sequence of work centers through which the products can pass during production. The order of work centers is determined in routings, which can often be very complex. There can be waiting times between the individual work centers. Also, semi-finished products are frequently placed in interim storage prior to further processing.
- Repetitive Manufacturing, on the other hand, normally involves a relatively constant flow on production lines. Semi-finished products are usually processed further immediately without being put in interim storage. Routings tend to be relatively simple.
- In discrete manufacturing, component materials are staged with specific reference to the individual production lots. Completion confirmations for the various steps and processes document the work progress and enable fine-tune controlling.
- In Repetitive Manufacturing, components are often staged at the production line without reference to a particular order. Completion confirmations are less detailed, and the recording of actual data is simplified.
- The function of Demand Management is to determine requirement quantities and delivery dates for finished products assemblies. Customer requirements are created in sales order management. To create a demand program, Demand Management uses planned independent requirements and customer requirements.
To create the demand program, you must define the planning strategy for a product. Planning strategies represent the methods of production for planning and manufacturing or procuring a product.
Using these strategies, you can decide if production is triggered by sales orders (make-to-order production), or if it is not triggered by sales orders (make-to-stock production).You can have sales orders and stock orders in the demand program. If the production time is long in relation to the standard market delivery time, you can produce the product or certain assemblies before there are sales orders. In this case, sales quantities are planned, for example, with the aid of a sales forecast.
Tips by : Panda.
What is User Status in PP?
A user status is activated by the user and can be created as an addition to the existing system status. You can define and activate any number of user statuses. To define a user status, you need to have created a status profile, which is created per order type in Customizing.
The Main user statuses which are in use at Netafim: - Rel. = Released. This user status is given to the production order with its creation. - Prod. = Production. Once a first production confirmation has been made, the Rel. status is changed to Prod. - Clo. = Closed. User status given to a production order which was fully confirmed (system status CNF). - Check = The controller marks a production order as "Check" after performing a thorough examination with the aid of "Work Order for Check" report (the report list all the production orders with CNF system statuses but with no TECO system status). Upon marking the production order as "Check", the system will automatically mark the production order as TECO. The status indicates that controlling can process the production order.
The Main user statuses which are in use at Netafim: - Rel. = Released. This user status is given to the production order with its creation. - Prod. = Production. Once a first production confirmation has been made, the Rel. status is changed to Prod. - Clo. = Closed. User status given to a production order which was fully confirmed (system status CNF). - Check = The controller marks a production order as "Check" after performing a thorough examination with the aid of "Work Order for Check" report (the report list all the production orders with CNF system statuses but with no TECO system status). Upon marking the production order as "Check", the system will automatically mark the production order as TECO. The status indicates that controlling can process the production order.
Explain System and User Status In Production Order
What is System Status in PP? A system status is a status set by the system. It informs the user that a particular function was carried out on an object. You cannot influence a system status in any way, that is, it cannot be directly deleted or changed. Example: When you release a production order, the system automatically sets the system status "released". You cannot influence this status unless you carry out a business transaction that leads to a change of the system status.
You can activate any number of statuses in a production order. It is possible for a production order to be simultaneously "released", "pre-costed", "printed" and "confirmed".
The Main system statuses which are in use at Netafim: - CRTD = Created. This is the status given to each production order upon creation. As long as a production order has not been released, it cannot be printed or confirmed. - REL = Released. Once a production order is created, it can be released for production either automatically or manually. - PCNF = Partially Confirmed. This status is given to an order once the first confirmation had been received from the shopfloor. This status will change automatically to CNF when a final confirmation will be done. - CNF = Confirmed. Confirmations of production progress and produced goods are reported to SAP from the shop flor. A final confirmation is given to an order when its production is complete. - PDLV = Partially delivered. This status is given to production order that is partially delivered. - DLV = Delivered. This status is given to production order that is fully delivered. - TECO = Technically Complete. This status is given to production orders which had been given both CNF status (final production confirmation) as well as User Status of CHECK (see "User Status" section). TECO is set automatically by a daily job running in the background. - DLFL = Deletion Flag. This status indicates that the order had been marked for deletion, but was not erased from the information system.
You can activate any number of statuses in a production order. It is possible for a production order to be simultaneously "released", "pre-costed", "printed" and "confirmed".
The Main system statuses which are in use at Netafim: - CRTD = Created. This is the status given to each production order upon creation. As long as a production order has not been released, it cannot be printed or confirmed. - REL = Released. Once a production order is created, it can be released for production either automatically or manually. - PCNF = Partially Confirmed. This status is given to an order once the first confirmation had been received from the shopfloor. This status will change automatically to CNF when a final confirmation will be done. - CNF = Confirmed. Confirmations of production progress and produced goods are reported to SAP from the shop flor. A final confirmation is given to an order when its production is complete. - PDLV = Partially delivered. This status is given to production order that is partially delivered. - DLV = Delivered. This status is given to production order that is fully delivered. - TECO = Technically Complete. This status is given to production orders which had been given both CNF status (final production confirmation) as well as User Status of CHECK (see "User Status" section). TECO is set automatically by a daily job running in the background. - DLFL = Deletion Flag. This status indicates that the order had been marked for deletion, but was not erased from the information system.
Tuesday, July 29, 2008
Production Order System Status
Tell the difference between TECHO and CLOSED.
TECO means Technically completed order, means with out full completion of order. That production order stopped because of some reasons. CLOSED means after completion of confirmation and settlement the order is fully closed for further processing.
How to delete released production orders?
In the prodcution order, select Functions --> Deletion flag -->Active to delete production order. This method can be used for production orders having CRTD (ie created) and REL (released) status. However, it is not possible to delete a production order with REL and GMPS (ie. after the withdrawl of materials for the order) status.
You can TECO the production orders with REL and GMPS status.
CO13 is used to cancel the confirmation of a production order.
Once Final Goods Receipt is post & Order is completed n it is Technically Completed it should not allow any goods movement against that order but this is not happening & one can issue goods even if the order is TECO.
When order status is Teco, system allow us to do the posting against the order. Once order status is closed, then only order treated as closed for execution.
In TECO status you can post the remaining activity/goods movement. Like if you have one order that contains the 5 operation and out of 5, 3 you are confirming in the current period and suppose, rest you are doing in the next period. So at the time of settlement for current period, order status should be Teco cause you will do some operation is the next period and cost for next period should be settle on next period. after that you have to close the order.
So TECO allows the postings.
If the requirement is not allowing any goods movement while system status TECO is active, pls try this approach in the config: 1. go to tcode BS22 (Maintain: System Status) 2. look for the system status TECO. 3. Double click the field "TECO". 4. in the transaction control tab look for the business transaction "RMWA" or goods movement (you can type it in the lower left corner buttom box). 5. select the radio button from "Allowed" to Disallowed".
TECO means Technically completed order, means with out full completion of order. That production order stopped because of some reasons. CLOSED means after completion of confirmation and settlement the order is fully closed for further processing.
How to delete released production orders?
In the prodcution order, select Functions --> Deletion flag -->Active to delete production order. This method can be used for production orders having CRTD (ie created) and REL (released) status. However, it is not possible to delete a production order with REL and GMPS (ie. after the withdrawl of materials for the order) status.
You can TECO the production orders with REL and GMPS status.
CO13 is used to cancel the confirmation of a production order.
Once Final Goods Receipt is post & Order is completed n it is Technically Completed it should not allow any goods movement against that order but this is not happening & one can issue goods even if the order is TECO.
When order status is Teco, system allow us to do the posting against the order. Once order status is closed, then only order treated as closed for execution.
In TECO status you can post the remaining activity/goods movement. Like if you have one order that contains the 5 operation and out of 5, 3 you are confirming in the current period and suppose, rest you are doing in the next period. So at the time of settlement for current period, order status should be Teco cause you will do some operation is the next period and cost for next period should be settle on next period. after that you have to close the order.
So TECO allows the postings.
If the requirement is not allowing any goods movement while system status TECO is active, pls try this approach in the config: 1. go to tcode BS22 (Maintain: System Status) 2. look for the system status TECO. 3. Double click the field "TECO". 4. in the transaction control tab look for the business transaction "RMWA" or goods movement (you can type it in the lower left corner buttom box). 5. select the radio button from "Allowed" to Disallowed".
Production Planning - Production Control System Messages
You can manage the production control system messages with transaction OPJB. In this step you can specify whether the SAP System will :-- suppress this information - displays it as a warning - displays it as an error message In the case of the error message you can only process it further if you correct the entry.You can also group the messages according to user classes by saving the messages in different
versions.
Process the list of messages by assigning every message a message category.
If you have saved message categories under different versions you can assign a version to
specific users. This has the effect that the same message appears as an error for one user
and a warning for another.
To do this you must assign the parameter ID "MSV" and the version number to the
corresponding user master records in transaction SU01.
versions.
Process the list of messages by assigning every message a message category.
If you have saved message categories under different versions you can assign a version to
specific users. This has the effect that the same message appears as an error for one user
and a warning for another.
To do this you must assign the parameter ID "MSV" and the version number to the
corresponding user master records in transaction SU01.
Changing warning msgs to error msg n vice-versa
In the customizing, for some of the modules, there are some transactions which allow us to change the type of the system messages, to warning, error, or no message at all. But they work only for some of the specific messages, not all of them! You should check the corresponding customizing menu and check if suits your needs..
Some examples: OPJB for production messages OBA5 for CO messages OMT4 for material master messages
Otherwise, you have to find other work-arounds to meet the requirement to change the message type.
FYI:
Why is the need to restrict to only some of the messages? System divides the messages into 2 categories from business side. Some messages are issued by the processing ABAP program and they cannot be changed. Because the program cannot continue to run without correcting those errors. But some messages do not result in any contradictions for the processing program, but might affect the succeeding operations in that business process.
Here's the example:
For the first case, When creating the production order, we have to enter the order quantity. There's no way thet system can continue if we do not enter the quantity. So there's no doubt that we shouldn't be able to change the error type for this.
For the second case, When i create a production order, i can create the batch number for the product in the order before saving the order. And the system checks whether i entered the batch number in the order or not. For the production order creation, it's not a must to enter product batch number beforehand. System can save the order. We can create the product batch separately, or even we can create it during goods receipt for order. Therefore, system could allow us to change the message type to error or warning. If our production process is desingned, so that the person making the goods receipt shouldn't enter other batch number than that entered in production order, we should make the message type error, so that the planner should have to create the batch number during creation. If however, we only create the batch number during goods receipt, we should allow the planner not to enter batch number beforehand... (This was just a fiction example, do not question it, and don't look for this setting in the customizing)
Some examples: OPJB for production messages OBA5 for CO messages OMT4 for material master messages
Otherwise, you have to find other work-arounds to meet the requirement to change the message type.
FYI:
Why is the need to restrict to only some of the messages? System divides the messages into 2 categories from business side. Some messages are issued by the processing ABAP program and they cannot be changed. Because the program cannot continue to run without correcting those errors. But some messages do not result in any contradictions for the processing program, but might affect the succeeding operations in that business process.
Here's the example:
For the first case, When creating the production order, we have to enter the order quantity. There's no way thet system can continue if we do not enter the quantity. So there's no doubt that we shouldn't be able to change the error type for this.
For the second case, When i create a production order, i can create the batch number for the product in the order before saving the order. And the system checks whether i entered the batch number in the order or not. For the production order creation, it's not a must to enter product batch number beforehand. System can save the order. We can create the product batch separately, or even we can create it during goods receipt for order. Therefore, system could allow us to change the message type to error or warning. If our production process is desingned, so that the person making the goods receipt shouldn't enter other batch number than that entered in production order, we should make the message type error, so that the planner should have to create the batch number during creation. If however, we only create the batch number during goods receipt, we should allow the planner not to enter batch number beforehand... (This was just a fiction example, do not question it, and don't look for this setting in the customizing)
Monday, July 28, 2008
Attachment Of Drawings in BOMs
Now one can attach a document to a BOM in one of the following three ways… 1) Attach document as an item in the item overview, 2) Attach document to an item and 3) Attach document to the header material.
1) Attaching document as an item in the item overview: …go to the `General Item Overview' screen …select the tab page `Document' …enter item category `D' …dropdown and select the document you want to attach …the system automatically selects the respective document type, document part, document version and document description …the system also enters component quantity `1' and component unit of measure as `PC' by default.
2) Attaching document to an item: …go to the `General Item Overview' screen …select the particular item by F2 …the item all data screen appears …go to tab page `document assignment' …dropdown and select the `document type' you want to attach …dropdown and select the document you want to attach …the system automatically selects the respective document part, document version and document description
3) Attach document to the header material: …go to header overview screen …go to tab page `document assignment' …dropdown and select the `document type' you want to attach …the system automatically selects the respective, document part, document version and document description
Pre-requisites… …create document by transaction CV01N …Customizing settings…in document management customizing determines which objects can be assigned to documents per object type. …go to IMG -> cross-application components -> document management -> control data -> define documents type …select the document type for example `DRW' …select the sub dialog `define object links' …select new entries and enter following objects… …'STPO_DOC' and screen `257'(linking document to BOM header) …'STKO_DOC' and screen `258'(linking document to BOM item) …now documents can be linked to BOM header as well as BOM item.
1) Attaching document as an item in the item overview: …go to the `General Item Overview' screen …select the tab page `Document' …enter item category `D' …dropdown and select the document you want to attach …the system automatically selects the respective document type, document part, document version and document description …the system also enters component quantity `1' and component unit of measure as `PC' by default.
2) Attaching document to an item: …go to the `General Item Overview' screen …select the particular item by F2 …the item all data screen appears …go to tab page `document assignment' …dropdown and select the `document type' you want to attach …dropdown and select the document you want to attach …the system automatically selects the respective document part, document version and document description
3) Attach document to the header material: …go to header overview screen …go to tab page `document assignment' …dropdown and select the `document type' you want to attach …the system automatically selects the respective, document part, document version and document description
Pre-requisites… …create document by transaction CV01N …Customizing settings…in document management customizing determines which objects can be assigned to documents per object type. …go to IMG -> cross-application components -> document management -> control data -> define documents type …select the document type for example `DRW' …select the sub dialog `define object links' …select new entries and enter following objects… …'STPO_DOC' and screen `257'(linking document to BOM header) …'STKO_DOC' and screen `258'(linking document to BOM item) …now documents can be linked to BOM header as well as BOM item.
What exactly is a Phantom item or Assembly means?
A phantom assembly is used when you want to be able to structure a BOM so it is easy to understand, but don't want to create too many production orders.
Assume an auto Engine. There are hundreds of components. You might structure them as: Engine block and parts, camshaft and parts, and 6 piston assemblies. But you don't want to create 3 production orders, too much hassle. So you want to issue the components for the piston assembly in the same production order as the Engine block. So you create a new material number for the Piston assembly, but you mark it as a phantom assembly. That means that when you create the bom for the Engine assembly, you only have two assemblies, the Engine block and the Camshaft. You add the phantom assembly for the Piston Assembly to the Engine block BOM, saying it requires 8 of the phantom assembly. When the production order is created for the Engine block, the picklist will also include all of the components of the 8 piston assemblies.
Assume an auto Engine. There are hundreds of components. You might structure them as: Engine block and parts, camshaft and parts, and 6 piston assemblies. But you don't want to create 3 production orders, too much hassle. So you want to issue the components for the piston assembly in the same production order as the Engine block. So you create a new material number for the Piston assembly, but you mark it as a phantom assembly. That means that when you create the bom for the Engine assembly, you only have two assemblies, the Engine block and the Camshaft. You add the phantom assembly for the Piston Assembly to the Engine block BOM, saying it requires 8 of the phantom assembly. When the production order is created for the Engine block, the picklist will also include all of the components of the 8 piston assemblies.
Mass Change Bill of Materials
Use Transaction CS20 to mass change your BOM.
In this transaction code, you can :-
1. mass change item data 2. mass delete items 3. mass add materials etc.
In this transaction code, you can :-
1. mass change item data 2. mass delete items 3. mass add materials etc.
Allocating BOM to Other Plant
Use Transaction CS07 to link this BOM to the other plants.
This shall make the BOM available in the other plants
This shall make the BOM available in the other plants
PP - Controlling data for your Bill of Materials
You define the default values for BOM in OS28.- Based quantity- BOM Status- Size Unit- Var-size item unitYou control the Material type allowed for the BOM header in transaction OS24.In transaction OS27, you define the central settings for your BOM management system. This are one-time settings for BOM management, which should not be change after production.Low dateWhen you create or process BOMs, the default date is the date defined in your system as the earliest processing date (01/01/1900 in the standard system).BOM validity maintenanceTick if want the user to specify a valid-from date when maintaining BOMs. If not tick the BOMcreated as of the current date or the system low date (1/1/1990).EC management activeTick if you want to make historical changes to BOMs with reference to a change number. (This means that the status of the BOM both before and after the change is stored in the system.) In this step, you only specify whether engineering change management can be used for maintaining bills of material. In transaction OS25, Configure history requirement for BOMs, you define whether you want to make the use of engineering change management a requirement in certain cases.Hist. reqmt variantUse this indicator to control when history requirement applies to new variants or alternatives in a BOM group. Sub-item documentnYou use the Sub-item documentation indicator to define whether changes to sub-items are documented. HeaderCreate BOM header with parameter validityTECHINCAL TYPE
Mult. BOM inactive
Tick if no multiple BOMs can be maintained in this R/3 system.
Variant BOM inactive
Tick if no variant BOMs can be maintained in this R/3 system
BILL OF MATERIAL ITEM
BOM item explosion type
If you create a BOM item with reference to a change number and change the valid-from date
(in the change header or alternative date), then this can change the sequence of validity
periods of a BOM item. The indicator BOM item explosion type specifies whether and according to what rules,
the system determines a unique change status, when you display, evaluate or change a BOM to
a date in the overlap period.
Description variable-sized item
This indicator controls which text is displayed in BOM processing for a variable-sized item.
Repeated effectivity via external item ID
This indicator ensures that an item that already exists under an external item ID can be used.
General settings
Unit 'piece'
In the standard system, this field contains a unit of measure for "piece". You can change
this unit. This unit is the base unit of measure (BOM header) or the component unit of
measure.
Base unit of measure for:
Equipment BOM
Functional location BOM
Document structure
Standard BOM
Component unit of measure for:
Text item
Document item
Non-stock item without material master record
CAD active
If you want to maintain BOMs from a CAD system, set this indicator. This activates an
additional field in the BOM header and BOM item, which tells you whether the BOM header or
BOM item was maintained from a CAD system.
If you deactivate engineering change management, changes to bills of material are not
recorded.
The modification parameters defined here apply to all BOM categories.
The following settings are made in the standard R/3 System:
1. Validity date maintenance and engineering change management are active.
2. The current system date is the default valid-from date.
3. CAD is active.
4. Explosion type for BOM item: blank.
Mult. BOM inactive
Tick if no multiple BOMs can be maintained in this R/3 system.
Variant BOM inactive
Tick if no variant BOMs can be maintained in this R/3 system
BILL OF MATERIAL ITEM
BOM item explosion type
If you create a BOM item with reference to a change number and change the valid-from date
(in the change header or alternative date), then this can change the sequence of validity
periods of a BOM item. The indicator BOM item explosion type specifies whether and according to what rules,
the system determines a unique change status, when you display, evaluate or change a BOM to
a date in the overlap period.
Description variable-sized item
This indicator controls which text is displayed in BOM processing for a variable-sized item.
Repeated effectivity via external item ID
This indicator ensures that an item that already exists under an external item ID can be used.
General settings
Unit 'piece'
In the standard system, this field contains a unit of measure for "piece". You can change
this unit. This unit is the base unit of measure (BOM header) or the component unit of
measure.
Base unit of measure for:
Equipment BOM
Functional location BOM
Document structure
Standard BOM
Component unit of measure for:
Text item
Document item
Non-stock item without material master record
CAD active
If you want to maintain BOMs from a CAD system, set this indicator. This activates an
additional field in the BOM header and BOM item, which tells you whether the BOM header or
BOM item was maintained from a CAD system.
If you deactivate engineering change management, changes to bills of material are not
recorded.
The modification parameters defined here apply to all BOM categories.
The following settings are made in the standard R/3 System:
1. Validity date maintenance and engineering change management are active.
2. The current system date is the default valid-from date.
3. CAD is active.
4. Explosion type for BOM item: blank.
Where used list for BOM
Transaction code : CS15
First screen :
Material : your material code
Type of where used list : Tick Direct
Valid from date : default system date (change if you want other dates)
Next screen :
Required qty : required qty of material
Resulting qty : resulting qty of the header material
Plant : restrict selection to a single plant
First screen :
Material : your material code
Type of where used list : Tick Direct
Valid from date : default system date (change if you want other dates)
Next screen :
Required qty : required qty of material
Resulting qty : resulting qty of the header material
Plant : restrict selection to a single plant
Explode BOM
Transaction code :
CS11 to explode BOM level by level
CS12 to explode BOM Multi level
Material : Your Material code
Plant : Your Plant
Alternative BOM : if you have multiple BOMs
BOM application : PP01 if you follows SAP default for Production General
Valid from : date of BOM you want to change
Required qty : enter required quantity (optional)
CS11 to explode BOM level by level
CS12 to explode BOM Multi level
Material : Your Material code
Plant : Your Plant
Alternative BOM : if you have multiple BOMs
BOM application : PP01 if you follows SAP default for Production General
Valid from : date of BOM you want to change
Required qty : enter required quantity (optional)
Simple BOM & Group BOM
How to Create a Simple BOM?
Transaction code : CS01
Material : Your Material code
Plant : Your Plant
BOM Usage : 1
Item Category Componment Quantity
0010 L Your Material code Your required quantity
Save your entries
You can used CS02 to changed the BOM and CS03 to display the BOM.
What are the use of Group bom? - By Vikram
A bom WITHOUT A PLANT IS CALLED GROUP BOM.
Group BOM: If you create a material BOM without reference to a plant, the BOM is valid throughout your company. To do this, you leave the Plant field blank. The system checks whether material masters exist. There are no system checks for plant data.
However, you can also create a group BOM, without reference to a plant. For example, a designer maintains a group BOM during the design phase of a product, then the BOM is allocated to one or more plants for production purposes.
For single BOM (one production line) do I need to do Production Version? Whats the purpose of using Prod. Version for single BOM?
It depends on your company needs as a production version determines the various production techniques that can be used to produce a material. It defines the following information: - Alternative BOM for a BOM explosion - Task list type, task list group, and group counter for assignment to task lists - Lot-size restrictions and period of validity A material can have one or more production versions.
During the process order creation system picks up the required version to produce the material.
Transaction code : CS01
Material : Your Material code
Plant : Your Plant
BOM Usage : 1
Item Category Componment Quantity
0010 L Your Material code Your required quantity
Save your entries
You can used CS02 to changed the BOM and CS03 to display the BOM.
What are the use of Group bom? - By Vikram
A bom WITHOUT A PLANT IS CALLED GROUP BOM.
Group BOM: If you create a material BOM without reference to a plant, the BOM is valid throughout your company. To do this, you leave the Plant field blank. The system checks whether material masters exist. There are no system checks for plant data.
However, you can also create a group BOM, without reference to a plant. For example, a designer maintains a group BOM during the design phase of a product, then the BOM is allocated to one or more plants for production purposes.
For single BOM (one production line) do I need to do Production Version? Whats the purpose of using Prod. Version for single BOM?
It depends on your company needs as a production version determines the various production techniques that can be used to produce a material. It defines the following information: - Alternative BOM for a BOM explosion - Task list type, task list group, and group counter for assignment to task lists - Lot-size restrictions and period of validity A material can have one or more production versions.
During the process order creation system picks up the required version to produce the material.
A BOM is not exploded in the following situations:
- No BOM is effective: -- On the explosion date and in the given area of validity For the given effectivity parameters
- The BOM has a deletion indicator.
- The BOM is a multiple BOM, and has no alternative that matches the lot size for your required quantity.
- No BOM matches the selection criteria of the BOM application you selected.
- This is possible in the following situations, for example:
-- The application does not take all BOM usages into account. For example, the application only takes BOMs that are relevant to production into account, so a BOM that is relevant to sales and distribution is not exploded.
-- The application selects a specific alternative on the explosion date you require. The material master record supports alternative determination by Explosion date. If the specified alternative is not valid on the explosion date, the BOM is not exploded.
-- The application takes production versions in the material master record into account, but no production version has a BOM that is valid on the explosion date you require. The material master record supports alternative determination by Production version. The system only explodes the BOM defined for the production version that matches the alternative and/or usage entered on the explosion date required.
-- The application only takes BOMs with certain status indicators into account. For example, the application for MRP only explodes BOMs that have at least the status Explosion for MRP.
Further checks: - Do the proper Scheduling in Routing (Backward/forward). In md61 give the requirement in next month.check your in-house production, planned delivery time in md02 give MRP Control parameter Rexplode BOM and Routing.
- Check BOM explosion data in MRP4 view of material master view ( Individual/Coll data).
- No BOM is effective: -- On the explosion date and in the given area of validity For the given effectivity parameters
- The BOM has a deletion indicator.
- The BOM is a multiple BOM, and has no alternative that matches the lot size for your required quantity.
- No BOM matches the selection criteria of the BOM application you selected.
- This is possible in the following situations, for example:
-- The application does not take all BOM usages into account. For example, the application only takes BOMs that are relevant to production into account, so a BOM that is relevant to sales and distribution is not exploded.
-- The application selects a specific alternative on the explosion date you require. The material master record supports alternative determination by Explosion date. If the specified alternative is not valid on the explosion date, the BOM is not exploded.
-- The application takes production versions in the material master record into account, but no production version has a BOM that is valid on the explosion date you require. The material master record supports alternative determination by Production version. The system only explodes the BOM defined for the production version that matches the alternative and/or usage entered on the explosion date required.
-- The application only takes BOMs with certain status indicators into account. For example, the application for MRP only explodes BOMs that have at least the status Explosion for MRP.
Further checks: - Do the proper Scheduling in Routing (Backward/forward). In md61 give the requirement in next month.check your in-house production, planned delivery time in md02 give MRP Control parameter Rexplode BOM and Routing.
- Check BOM explosion data in MRP4 view of material master view ( Individual/Coll data).
How to link BOM component to storage location
If you have to issue a component for production order of main item always from a specific storage location (component is stored in multiple storage locations but for production of a top item reservations should be created only on a specific storage loc), where can you provide the link between BOM component and storage Loc??
Is it possible to provide that link in BOM? or while allocating BOM components to routing operations or else where?
You can use the issue storage location field on the MRP 2 screen in the material master
or
You have 3 ways of doing it - not including the material master since the components are stored in multiple locations.
1. BOM item - very flexible but very time consuming to maintain if you have lots of BOM's. In CS02 you can set st. loc. on each component, and SAP will take this st. loc. first.
2. from level above - you can set it up so that whatever st. loc. is the default prod. st. loc on the material master for the level above will be the issue st. loc for the components you choose, if the component exists in that st. loc. - kind of a champagne waterfall effect. If the st. loc. is not maintained on the component, it will take the material master default of the component.
3. using supply area and work center. create supply areas and link them to st. loc's. - then link the supply area to the work center on CR02. Then allocate components to operations going through those work centers.
Note: Supply Areas are meant to be used in conjunction with Kanban. However you can just use them to link the work center to a storage location. You will never see an inventory balance in MMBE in a supply area. With Kanban you can set up automatic triggers to replenish stock to the supply areas from a main stock location.
Is it possible to provide that link in BOM? or while allocating BOM components to routing operations or else where?
You can use the issue storage location field on the MRP 2 screen in the material master
or
You have 3 ways of doing it - not including the material master since the components are stored in multiple locations.
1. BOM item - very flexible but very time consuming to maintain if you have lots of BOM's. In CS02 you can set st. loc. on each component, and SAP will take this st. loc. first.
2. from level above - you can set it up so that whatever st. loc. is the default prod. st. loc on the material master for the level above will be the issue st. loc for the components you choose, if the component exists in that st. loc. - kind of a champagne waterfall effect. If the st. loc. is not maintained on the component, it will take the material master default of the component.
3. using supply area and work center. create supply areas and link them to st. loc's. - then link the supply area to the work center on CR02. Then allocate components to operations going through those work centers.
Note: Supply Areas are meant to be used in conjunction with Kanban. However you can just use them to link the work center to a storage location. You will never see an inventory balance in MMBE in a supply area. With Kanban you can set up automatic triggers to replenish stock to the supply areas from a main stock location.
How To Do Master Record Mass Maintenance
Mass maintainance in MM-
1. Mass Maintainance means to change a master data or transactional data in mass
2. SAP has provided Mass Maintainance for many objects
Examples:Material masters, BOMs, Routings, Workcenters in PP
In MM --> Inforecords, PO,s Preqs etc
To do master record mass maintenance
You can use tcode MASS and then select your Object type or there is few specific mass maint. Tcode is available like for PO = MEMASSPO etc. but you can use MASS also for that you need to select the object type for PO
Tips for mass modification:
Use object type BUS1001 and generate. Then you have to know the tables where the field you want to modify is. Pick the fields in their folder and generate again. Then in selection pick the materials or use other selection criteria. Generate again.
In the upper side of the screen insert the data and click the button 'carry out a mass change'.
Save and leave.
Master records mass maintenance can be done:
Material master, info record, vendor, PO, PR, etc.
What do you mean by mass maintenance?
MASS maintenance means - suppose you want to change prticaulr field of material for all the mateirl of certian plant or all the plant you can do using mass like wise for certian PO value if you want to cahnge you can use mass.
There a lot of transactions for specific mass changes. MASS is also one of the transactions among them.
- Mass Change in material master. MM17 - Mass change in BOM. CS20 - Mass change in work center. CA85 - Mass change in Reference opn set. CA95 - Mass change in PRT. CA75
- SU10 Mass changes to User Master. - SU12 Mass Changes to User Master Records.
- CO44 Mass processing of orders. - F.80 Mass reversal of documents. - FOFO Mass release. - FOVX Mass processing of offers. - IMAM Mass maintenance of approp.requests. - KE55 Mass Maintenance PrCtr Master Data. - XD99 Customer master mass maintenance. - XK99 Mass maintenance, vendor master.
1. Mass Maintainance means to change a master data or transactional data in mass
2. SAP has provided Mass Maintainance for many objects
Examples:Material masters, BOMs, Routings, Workcenters in PP
In MM --> Inforecords, PO,s Preqs etc
To do master record mass maintenance
You can use tcode MASS and then select your Object type or there is few specific mass maint. Tcode is available like for PO = MEMASSPO etc. but you can use MASS also for that you need to select the object type for PO
Tips for mass modification:
Use object type BUS1001 and generate. Then you have to know the tables where the field you want to modify is. Pick the fields in their folder and generate again. Then in selection pick the materials or use other selection criteria. Generate again.
In the upper side of the screen insert the data and click the button 'carry out a mass change'.
Save and leave.
Master records mass maintenance can be done:
Material master, info record, vendor, PO, PR, etc.
What do you mean by mass maintenance?
MASS maintenance means - suppose you want to change prticaulr field of material for all the mateirl of certian plant or all the plant you can do using mass like wise for certian PO value if you want to cahnge you can use mass.
There a lot of transactions for specific mass changes. MASS is also one of the transactions among them.
- Mass Change in material master. MM17 - Mass change in BOM. CS20 - Mass change in work center. CA85 - Mass change in Reference opn set. CA95 - Mass change in PRT. CA75
- SU10 Mass changes to User Master. - SU12 Mass Changes to User Master Records.
- CO44 Mass processing of orders. - F.80 Mass reversal of documents. - FOFO Mass release. - FOVX Mass processing of offers. - IMAM Mass maintenance of approp.requests. - KE55 Mass Maintenance PrCtr Master Data. - XD99 Customer master mass maintenance. - XK99 Mass maintenance, vendor master.
Planning & Production Alternate Plant
The planning plant and production plant are used in case of the cross plant planning. Through demand management we can plan across the plants.For each material there is a planning plant and production plant or ordering plant. The planning plant procures and stores the materials independently of orders. There are also one or more ordering plants in which the materials are used for sales orders, production orders, or for other requirements.It can be controlled through the special procurement key in MRP 2 view of the material master. - Planning plant is the plant in which you don't produce that particular plant (A) but you need them so you plan them and get produced in another plant(B). And this plant also belongs to the same orgainisation.
Now you create a special procuremnt for the Plant A and you maintain in the mateirl master.so whenever demand comes in the Plant (A) it will be planned here and the same requreiemnt will be transfered to plant b and there it will prodcued and transfered to the plant-a. - Suppose there are two plants A & B in an organisational structure. Suppose you need a material in plant A but you cannot produce it in plant A because of unavailability of resources. And these resources are available in plant B.
So you can produce the material in plant B and the requirement is thru plant A (e.g thru MRP). Here plant A becomes planning plant & plant B becomes production plant.
To carry out the actual planning and production, follow the following steps- 1) In SPRO, in the special proc key parameter's setting for plant A, mention plant B as the alternative plant.
2) Prepare the material master of the required material in plant A, in MRP 2 view maintain spl proc key as 40 (proc from alt plant) or 80 (production in alternative plant)
3) Maintain the material master in the alternative plant too. In MRP 2 maintain proc type = E. Maintain routing.
4) Carry out MRP run in plant A. If there is any demand, a STPR (spl proc key 40) or planned order (spl proc key 80) will be created in plant A. The stock requirement list will show plant B as the production plant.
5) In case of 40, a planned order will be created in plant B. In case of 80, with proper settings, the planned order in plant A after converting becomes a production order in B.
6) Carry out the production. In case of 40 the material can be sent to plant A from B thru STPO. In 80 the stock in plant A is directly updated when you hit a
Now you create a special procuremnt for the Plant A and you maintain in the mateirl master.so whenever demand comes in the Plant (A) it will be planned here and the same requreiemnt will be transfered to plant b and there it will prodcued and transfered to the plant-a. - Suppose there are two plants A & B in an organisational structure. Suppose you need a material in plant A but you cannot produce it in plant A because of unavailability of resources. And these resources are available in plant B.
So you can produce the material in plant B and the requirement is thru plant A (e.g thru MRP). Here plant A becomes planning plant & plant B becomes production plant.
To carry out the actual planning and production, follow the following steps- 1) In SPRO, in the special proc key parameter's setting for plant A, mention plant B as the alternative plant.
2) Prepare the material master of the required material in plant A, in MRP 2 view maintain spl proc key as 40 (proc from alt plant) or 80 (production in alternative plant)
3) Maintain the material master in the alternative plant too. In MRP 2 maintain proc type = E. Maintain routing.
4) Carry out MRP run in plant A. If there is any demand, a STPR (spl proc key 40) or planned order (spl proc key 80) will be created in plant A. The stock requirement list will show plant B as the production plant.
5) In case of 40, a planned order will be created in plant B. In case of 80, with proper settings, the planned order in plant A after converting becomes a production order in B.
6) Carry out the production. In case of 40 the material can be sent to plant A from B thru STPO. In 80 the stock in plant A is directly updated when you hit a
The Overall Flow For SAP PP
What are the stages in PP?
The PP flow consists of planning and execution as described.
Here is the flow of PP in simple language:
First of all demand is generated for the product to be produced through demand management. It calculated the quantities to produce and the time for the final assembly.
The data from demand management is transferred to MRP. The data from demand mgt can come from Customer Sales Order (firm) or Planned Order (forecast).
The MRP checks for the availability of material at various stages of BOM. In case material is not available MRP generated planned order and Purchase requisition for production of components in house and procurement from vendor respectively.
The planned orders are converted into production order by the planner and the purchase requisition are converted into purchase order by the purchaser.
Production in charge converts the planned order to production order and carries out the production activities once the order is released for production. Production is carried out as per the operation steps provided in the routing. Work centers are also mentioned with each operation in the routings where these operations are to be carried out.
Once the production is completed production confirmation is done and goods movement (delivery created) takes place.
Capacity planning is yet another part of PP which planes the capacities for various work centers. MPS is another tool which is used to plan out the master products. If MPS is to be run the inputs are provided from demand management to MPS. And the out put from MPS is then feed into MRP
The PP flow consists of planning and execution as described.
Here is the flow of PP in simple language:
First of all demand is generated for the product to be produced through demand management. It calculated the quantities to produce and the time for the final assembly.
The data from demand management is transferred to MRP. The data from demand mgt can come from Customer Sales Order (firm) or Planned Order (forecast).
The MRP checks for the availability of material at various stages of BOM. In case material is not available MRP generated planned order and Purchase requisition for production of components in house and procurement from vendor respectively.
The planned orders are converted into production order by the planner and the purchase requisition are converted into purchase order by the purchaser.
Production in charge converts the planned order to production order and carries out the production activities once the order is released for production. Production is carried out as per the operation steps provided in the routing. Work centers are also mentioned with each operation in the routings where these operations are to be carried out.
Once the production is completed production confirmation is done and goods movement (delivery created) takes place.
Capacity planning is yet another part of PP which planes the capacities for various work centers. MPS is another tool which is used to plan out the master products. If MPS is to be run the inputs are provided from demand management to MPS. And the out put from MPS is then feed into MRP
List of PP Transport Request and their IMG Path
1) Define Distribution Keys IMG > Production Planning for Process Industries > Master Data > Material List > Item Data > Item Data from related areas > Define Distribution Keys
2) Determine Person responsible for Resource – IMG > Production Planning for Process Industries > Master Data > Resource > General Data > Determine Person responsible
3Define Planner Group- IMG > Production Planning for Process Industries > Master Data > Master Recipe > Define Capacity Planner
4) Define Capacity Planner – IMG > Production Planning for Process Industries > Master Data > Resource > Capacity Requirement Planning > Determine Capacity Planner
5) Determine Standard Value Parameter – IMG > Production Planning for Process Industries > Master Data > Resource > General Data > Standard Value > Define Parameter
6) Define Setup Groups and Setup Group Categories Define set up groups and set up categories – IMG > Production Planning for Process Industries > Master Data > Master Recipe > Data for operations and phases > Define set up groups and set up group categories
7) Define copy setting between plants-Process IMG > Production Planning for Process Industries > Process Management > Tools > Define copy setting between plants
8) Define Set Up Control Recipe destination – IMG > Production Planning for Process Industries > Process Management > Control Recipe/PI sheet > Set up control recipe destination
9Define MRP controller – IMG > Material Management > Consumption based Planning > Master Data > Define MRP controller 10) Special Procurement – IMG > Material Management > Consumption based Planning > Master Data > Define Special procurement types
11) Define Floats (Scheduled Margin Key)- IMG > Material Management > Consumption based Planning > Planning > Define Floats (Scheduled Margin Key)
12Define Splitting of Forecast requirements for MRP- IMG > Material Management > Consumption based Planning > Evaluation > Forecast > Define Splittng of forecast requirements of MRP
13) Maintain Correction Factors for Forecast IMG > Material Management > Consumption based Planning > Planning > Procurement > Maintain Correction factors for forecast
14 Carry Out Overall Maintenance of Plant Parameters Maintaining plant parameters in MRP – IMG > Material Management > Consumption based Planning > Plant Parameters > Carry out overall maintenance of plant parameters
15) Define Planning Horizon Define Planning Horizon – IMG > Material Management > Consumption based Planning > Planning > MRP calculation > Define Planning Horizon
16) Activate Requirement Planning – IMG > Material Management > Consumption based Planning > Planning > Activate Requirement Planning
17) Define Range of Coverage Profiles (Dynamic Safety Stock) Range of coverage profile – IMG > Material Management > Consumption based Planning > Planning > MRP calculation > Define range of coverage profile (Dynamic Safety Stock)
18) Define Stock in Transfer and Blocked Stock Availability IMG > Material Management > Consumption based Planning > Planning > MRP calculation > Stocks > Define Stock in transfer and blocked stock
19) Define MRP Areas IMG > Material Management > Consumption based Planning > Master Data > MRP areas > Define MRP areas
20) Carry out maintenance of MRP groups IMG > Material Management > Consumption based Planning > MRP groups> Carry out maintenance of MRP groups
21) Define Scope of total Planning - MRP IMG > Material Management > Consumption based Planning > Planning > Define Scope of total Planning
22 Define Order Types Define Order Type- IMG > Production Planning for Process Industries > Process Order > Master Data > Order > Define Order Type
23Define Order Type Dependent parameters – IMG > Production Planning for Process Industries > Process Order > Master Data > Order > Define Order Type Dependent parameters
24) Define Production Scheduler – IMG > Production Planning for Process Industries > Process Order > Master Data > Bill of Material > Define Production Scheduler
25 Define Checking Control - Process Order Define Availability Check – Define Checking Control – IMG > Production Planning for Process Industries > Process Order > Operations > Availabilty Check > Define Checking Control
26) Define Checking Rule for backorder processing – IMG > Production Planning for Process Industries > Process Order > Operations > Availabilty Check > Define Checking rule for back order processing
27Define Stock and batch determination for good movement – IMG > Production Planning for Process Industries > Process Order > Operations > Define Stock and batch determination for good movement
28) Specify Scheduling Parameters Specify Scheduling Parameters – IMG > Production Planning for Process Industries > Process Order > Operations > Scheduling > Specify Scheduling Parameters
29) Define Reduction Strategies Define Reduction Strategy – IMG > Production Planning for Process Industries > Process Order > Operations > Scheduling > Resource data > Define Reduction Strategy
30) Define Confirmation Parameters Define Order Confirmation – IMG > Production Planning for Process Industries > Process Order > Operations > Confirmation > Define Confirmation Parameters
31) Define Valuation of Goods Received Define valuation of goods receive – IMG > Production Planning for Process Industries > Process Order > Integration > Define Valuation of goods received
32) MRP creation indicator – IMG > Material Management > Consumption based Planning > Planning > Define creation indicator
33) Define safety stock – IMG > Material Management > Consumption based Planning > Planning > MRP calculation > Stocks > Define Safety Stocks
34) Define alternative determination of Production – IMG > Production Planning for Process Industries > Process Order > Operations > BOM selection > Define alternate determination of production
35) Define no. ranges – IMG > Production Planning for Process Industries > Process Order > Master data > Order > Number Ranges > Define number ranges for orders
2) Determine Person responsible for Resource – IMG > Production Planning for Process Industries > Master Data > Resource > General Data > Determine Person responsible
3Define Planner Group- IMG > Production Planning for Process Industries > Master Data > Master Recipe > Define Capacity Planner
4) Define Capacity Planner – IMG > Production Planning for Process Industries > Master Data > Resource > Capacity Requirement Planning > Determine Capacity Planner
5) Determine Standard Value Parameter – IMG > Production Planning for Process Industries > Master Data > Resource > General Data > Standard Value > Define Parameter
6) Define Setup Groups and Setup Group Categories Define set up groups and set up categories – IMG > Production Planning for Process Industries > Master Data > Master Recipe > Data for operations and phases > Define set up groups and set up group categories
7) Define copy setting between plants-Process IMG > Production Planning for Process Industries > Process Management > Tools > Define copy setting between plants
8) Define Set Up Control Recipe destination – IMG > Production Planning for Process Industries > Process Management > Control Recipe/PI sheet > Set up control recipe destination
9Define MRP controller – IMG > Material Management > Consumption based Planning > Master Data > Define MRP controller 10) Special Procurement – IMG > Material Management > Consumption based Planning > Master Data > Define Special procurement types
11) Define Floats (Scheduled Margin Key)- IMG > Material Management > Consumption based Planning > Planning > Define Floats (Scheduled Margin Key)
12Define Splitting of Forecast requirements for MRP- IMG > Material Management > Consumption based Planning > Evaluation > Forecast > Define Splittng of forecast requirements of MRP
13) Maintain Correction Factors for Forecast IMG > Material Management > Consumption based Planning > Planning > Procurement > Maintain Correction factors for forecast
14 Carry Out Overall Maintenance of Plant Parameters Maintaining plant parameters in MRP – IMG > Material Management > Consumption based Planning > Plant Parameters > Carry out overall maintenance of plant parameters
15) Define Planning Horizon Define Planning Horizon – IMG > Material Management > Consumption based Planning > Planning > MRP calculation > Define Planning Horizon
16) Activate Requirement Planning – IMG > Material Management > Consumption based Planning > Planning > Activate Requirement Planning
17) Define Range of Coverage Profiles (Dynamic Safety Stock) Range of coverage profile – IMG > Material Management > Consumption based Planning > Planning > MRP calculation > Define range of coverage profile (Dynamic Safety Stock)
18) Define Stock in Transfer and Blocked Stock Availability IMG > Material Management > Consumption based Planning > Planning > MRP calculation > Stocks > Define Stock in transfer and blocked stock
19) Define MRP Areas IMG > Material Management > Consumption based Planning > Master Data > MRP areas > Define MRP areas
20) Carry out maintenance of MRP groups IMG > Material Management > Consumption based Planning > MRP groups> Carry out maintenance of MRP groups
21) Define Scope of total Planning - MRP IMG > Material Management > Consumption based Planning > Planning > Define Scope of total Planning
22 Define Order Types Define Order Type- IMG > Production Planning for Process Industries > Process Order > Master Data > Order > Define Order Type
23Define Order Type Dependent parameters – IMG > Production Planning for Process Industries > Process Order > Master Data > Order > Define Order Type Dependent parameters
24) Define Production Scheduler – IMG > Production Planning for Process Industries > Process Order > Master Data > Bill of Material > Define Production Scheduler
25 Define Checking Control - Process Order Define Availability Check – Define Checking Control – IMG > Production Planning for Process Industries > Process Order > Operations > Availabilty Check > Define Checking Control
26) Define Checking Rule for backorder processing – IMG > Production Planning for Process Industries > Process Order > Operations > Availabilty Check > Define Checking rule for back order processing
27Define Stock and batch determination for good movement – IMG > Production Planning for Process Industries > Process Order > Operations > Define Stock and batch determination for good movement
28) Specify Scheduling Parameters Specify Scheduling Parameters – IMG > Production Planning for Process Industries > Process Order > Operations > Scheduling > Specify Scheduling Parameters
29) Define Reduction Strategies Define Reduction Strategy – IMG > Production Planning for Process Industries > Process Order > Operations > Scheduling > Resource data > Define Reduction Strategy
30) Define Confirmation Parameters Define Order Confirmation – IMG > Production Planning for Process Industries > Process Order > Operations > Confirmation > Define Confirmation Parameters
31) Define Valuation of Goods Received Define valuation of goods receive – IMG > Production Planning for Process Industries > Process Order > Integration > Define Valuation of goods received
32) MRP creation indicator – IMG > Material Management > Consumption based Planning > Planning > Define creation indicator
33) Define safety stock – IMG > Material Management > Consumption based Planning > Planning > MRP calculation > Stocks > Define Safety Stocks
34) Define alternative determination of Production – IMG > Production Planning for Process Industries > Process Order > Operations > BOM selection > Define alternate determination of production
35) Define no. ranges – IMG > Production Planning for Process Industries > Process Order > Master data > Order > Number Ranges > Define number ranges for orders
PP Year End To Do List
These are the activities we have defined for ALL areas including PP and they are in addition to your normal month end closing:
1. Create new material document number ranges for the new year.
2. Generate period rules for Asset Accounting.
3. Do Asset Accounting year end close and Fiscal year change.
4. Roll all A/R and A/P balances.
5. Close out all nominal / P&L accounts in accounting.
6. Enter all cost center budgets for the new year.
7. Enter new standard costs for your materials for January 1 of the new year.
8. Maintain the planning for your activity type used in your work centers for the new year (otherwise you will not be able to do confirmations in the new year.)
9. Create calendar for new year.
1. Create new material document number ranges for the new year.
2. Generate period rules for Asset Accounting.
3. Do Asset Accounting year end close and Fiscal year change.
4. Roll all A/R and A/P balances.
5. Close out all nominal / P&L accounts in accounting.
6. Enter all cost center budgets for the new year.
7. Enter new standard costs for your materials for January 1 of the new year.
8. Maintain the planning for your activity type used in your work centers for the new year (otherwise you will not be able to do confirmations in the new year.)
9. Create calendar for new year.
Compare Production Confirmation against Planned by Work Centre
Compare Production Confirmation against Planned by Work Centre*REPORT ZASSEMBLY_EFFICIENCY LINE-SIZE 255 NO STANDARD PAGE HEADING LINE-COUNT 065(001).TABLES: AFKO, "Order header data PP orders AFPO, "Order item AFRU, "Order completion confirmations AUFM, "Goods movements for order AFVV, "DB structure of the quantities/dates/values in the oper MARA. "General Material DataDATA: BEGIN OF INT_EFF OCCURS 100, MATNR TYPE AFKO-STLBEZ, MTART TYPE MARA-MTART, AUFNR TYPE AFKO-AUFNR, GSTRI TYPE AFKO-GSTRI, GLTRI TYPE AFKO-GLTRI, GAMNG(9) TYPE C, MENGE(9) TYPE C, PLN01(9) TYPE C, ISM01(7) TYPE P DECIMALS 2, DAUAT TYPE AFPO-DAUAT, END OF INT_EFF.DATA: FDATE LIKE SY-DATUM, LDATE LIKE SY-DATUM.DATA: YGAMNG(7) TYPE P DECIMALS 2, YMENGE(7) TYPE P DECIMALS 2, YPLN01(7) TYPE P DECIMALS 2, XMENGE(7) TYPE P DECIMALS 0, XSTDRATE(7) TYPE P DECIMALS 2, XACTRATE(7) TYPE P DECIMALS 2, XLINEEFF(7) TYPE P DECIMALS 2, XUTILISA(7) TYPE P DECIMALS 2.SELECT-OPTIONS XWERKS FOR AFRU-WERKS DEFAULT 'SAP'.SELECT-OPTIONS XBUDAT FOR AFRU-BUDAT.SELECT-OPTIONS XAUFNR FOR AFRU-AUFNR.START-OF-SELECTION.SELECT * FROM AFRU WHERE BUDAT IN XBUDAT AND WERKS IN XWERKS AND AUFNR IN XAUFNR. CLEAR AFPO. SELECT SINGLE * FROM AFPO WHERE AUFNR = AFRU-AUFNR. CLEAR AFKO. SELECT SINGLE * FROM AFKO WHERE AUFNR = AFRU-AUFNR. CLEAR MARA. SELECT SINGLE * FROM MARA WHERE LVORM = '' AND MATNR = AFKO-STLBEZ. CLEAR AFVV. SELECT SINGLE * FROM AFVV WHERE AUFPL = AFRU-AUFPL AND APLZL = AFRU-APLZL. IF AFVV-VGE01 = 'MIN'. AFVV-VGW01 = AFVV-VGW01 / 60. ENDIF. PERFORM GET_DATA_AUFM. PERFORM GET_DATA.ENDSELECT.PERFORM LOOP_INT_EFF.END-OF-SELECTION.FORM GET_DATA.* Reverse Confirmation IF AFRU-STOKZ = 'X'. MULTIPLY AFRU-LMNGA BY -1. MULTIPLY AFRU-ISM01 BY -1. MULTIPLY AFRU-ISM02 BY -1. MULTIPLY AFRU-ISM03 BY -1. MULTIPLY AFRU-ISM04 BY -1. MULTIPLY AFKO-GAMNG BY -1. MULTIPLY AFVV-BMSCH BY -1. MULTIPLY AFVV-VGW01 BY -1. MULTIPLY AFVV-VGW02 BY -1. MULTIPLY AFVV-VGW03 BY -1. ENDIF.* Plan Activities IF AFVV-BMSCH <> 0. INT_EFF-PLN01 = ( AFKO-GAMNG / AFVV-BMSCH ) * AFVV-VGW01 * 60. ENDIF.* Actual Activities INT_EFF-ISM01 = AFRU-ISM01.* Material No. IF AFKO-PLNBEZ = SPACE. INT_EFF-MATNR = AFKO-STLBEZ. ELSE. INT_EFF-MATNR = AFKO-PLNBEZ. ENDIF. INT_EFF-MTART = MARA-MTART. INT_EFF-AUFNR = AFKO-AUFNR. INT_EFF-GSTRI = AFKO-GSTRI. INT_EFF-GLTRI = AFKO-GLTRI. INT_EFF-GAMNG = AFKO-GAMNG. INT_EFF-MENGE = XMENGE. INT_EFF-DAUAT = AFPO-DAUAT. COLLECT INT_EFF. CLEAR INT_EFF.ENDFORM.FORM GET_DATA_AUFM. CLEAR XMENGE. SELECT * FROM AUFM WHERE AUFNR = AFKO-AUFNR AND BWART IN ('101', '102'). IF AUFM-SHKZG = 'H'. MULTIPLY AUFM-MENGE BY -1. ENDIF. ADD AUFM-MENGE TO XMENGE. ENDSELECT.ENDFORM.FORM LOOP_INT_EFF. LOOP AT INT_EFF. CLEAR: XSTDRATE, XACTRATE, XLINEEFF, XUTILISA. IF INT_EFF-PLN01 <> 0. XSTDRATE = INT_EFF-MENGE / INT_EFF-PLN01. ENDIF. IF INT_EFF-ISM01 <> 0. XACTRATE = INT_EFF-MENGE / INT_EFF-ISM01. XUTILISA = INT_EFF-PLN01 - INT_EFF-ISM01. ENDIF. IF XSTDRATE <> 0. XLINEEFF = XACTRATE / XSTDRATE. ENDIF. YGAMNG = INT_EFF-GAMNG. YMENGE = INT_EFF-MENGE. YPLN01 = INT_EFF-PLN01. WRITE:/ INT_EFF-MATNR UNDER ' Material', INT_EFF-MTART UNDER ' Matl', INT_EFF-AUFNR UNDER 'Production', INT_EFF-GSTRI UNDER 'Start', INT_EFF-GLTRI UNDER ' Finish', YGAMNG UNDER 'Production Ord', YMENGE UNDER ' Receipt Qty', YPLN01 UNDER ' Plan Hr', INT_EFF-ISM01 UNDER ' Actual Hr', XSTDRATE UNDER ' Std Rate', XACTRATE UNDER ' Actual Rate', XLINEEFF UNDER 'Efficiency (%)', XUTILISA UNDER 'Utilisation Typ', INT_EFF-DAUAT UNDER 'PP Type'. ENDLOOP.ENDFORM.TOP-OF-PAGE.FORMAT COLOR COL_TOTAL. WRITE: / SY-DATUM, SY-UZEIT, SY-REPID, 110 'Assembly Line Efficiency Report - Closed (Period)', 200 SY-UNAME, SY-PAGNO. SKIP. WRITE: /1 ' Material', 20 ' Matl', 25 'Production', 36 'Start', 47 ' Finish', 58 'Production Ord', 73 ' Receipt Qty', 88 ' Plan Hr', 103 ' Actual Hr', 118 ' Std Rate', 133 ' Actual Rate', 148 'Efficiency (%)', 163 'Utilisation Typ', 179 'PP Type'.INITIALIZATION. LDATE = SY-DATUM. LDATE+6(2) = '01'. LDATE = LDATE - 1. FDATE = LDATE. FDATE+6(2) = '01'. MOVE: FDATE TO XBUDAT-LOW, LDATE TO XBUDAT-HIGH. APPEND XBUDAT.
Subscribe to:
Posts (Atom)