LO215 Production Orders LO215
Release 640 04/06/2006
LO215 Production Orders
LO215 Production Orders © SAP AG 1999 © SAP AG
System R/3 Release 4.6C October 2000 5004 2355
Copyright
Copyright 2004 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice.
© SAP AG 2004
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Production Planning Level 3
Level 2 LO980 3 days Engineering Change Management LO235
LO210 5 days Production Planning LO215 5 days Production Orders
2 days
KANBAN LO050 5 days Manufacturing Planning & Execution for Discrete & Repetitive
LO205 3 days Basic Data for Discrete Manufacturing LO985
3 days
Classification LO955 3 days Batch Management
© SAP AG 1999
LO206 3 days Basic Data Part 2
LO230
5 days
Capacity Planning
LO225 3 days Repetitive Manufacturing
2 days LO720 CAP Calculation of Standard Values
LO930 2 days Logistics Information System (LIS) Reporting
2 days LO275 Special Features of LIS in Production
5 days LO990 LO991 3 days Variant Variant Configuration Part 1 Configuration Part 2
2 days LO935 Logistics Info Planning
Requirements
Necessary:
Knowledge of Production Planning and Control LO205 Basic Data for Discrete Manufacturing LO206 Basic Data Part 2
Recommended:
© SAP AG 1999
LO050 Manufacturing Planning and Execution for Discrete and Repetitive
Target Group
Members of the project team who are responsible for the implementation of production orders (consultants and administrators) Managers and employees in production areas (production schedulers, controllers, supervisors and operators) Duration: 5 days
© SAP AG 1999
Information for participants The training materials are not designed to be a self-teach program. They are only complete when used in conjunction with the explanations of the instructor. You are given space on each page of the training materials to write down this additional information.
Course Overview: Contents
Course Goals Course Objectives Course Content Course Overview Diagram Main Business Scenario
© SAP AG 1999
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Course Goal
At the conclusion of this course, you will be able to: Use production orders. Create, release and fully implement production orders. You will be able to make system settings and also understand production orders in context.
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Course Objective(s)
At the conclusion of this course, you will be able to: Classify production orders in the production planning and execution environment (demand management, requirements and materials planning, sales order processing and so on) Implement or apply production orders and their most important functions Understand and use the basic order management functions in detail Use the information systems for production orders Take into consideration the integration relationships within the production order Teach yourself additional special functions
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Course Content
Preface
Unit 1
Introduction
Unit 8
Order Control
Unit 2
Overview
Unit 9
Confirmations
Unit 3
Order Structure / Processing
Unit 10
Goods Receipt
Unit 11 Unit 4
Order Creation / Order Change
Settlement, Archiving and Deletion
Unit 12
Information Systems
Unit 5
Order Release Unit 13
Unit 6
Printing Order Documents
Mass Processing and Automation
Unit 7
Material Staging
Unit 14
Collective Orders
Appendix
© SAP AG 1999
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Course Overview Diagram (1)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
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Course Overview: Main Business Scenario
Your company manufactures order-related products. You belong to the team in your organization that implements the part of production planning and control dealing with R/3 production orders. This means implementing the whole process chain for in-house production, which will allow your company to organize, steer and execute plant production using the R/3 System. Important stages of order-related manufacturing are creation, release, machine usage, printing of papers, material withdrawal, execution, confirmation, goods receipt and settlement. In practice, these functions are integrated into other areas in your company (controlling, material management and so on). It is therefore necessary to consider the extensive integration relationships during implementation. © SAP AG 1999
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Overview: Contents
Overview of the process chain for order-related production The process chain in other production planning and control scenarios Characteristics of order-related production Order-related production in the organization structures of the R/3 System Master data prerequisites for production orders
© SAP AG 1999
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Overview: Topic Objectives
At the conclusion of this unit you will be able to: Recognize the different steps in the process chain for order-related production Recognize the most important characteristics of orderrelated production Define how production orders are classified in the R/3 application component PP and in the organization structures
© SAP AG 1999
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Overview Diagram (2)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
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Production Orders in Practice
"Special" "Special" engineerengineerto-order to-order production production
P R O D U C T
Make-to-order Make-to-order production production
Assembly production/ Assemb.-to-order prod.
Production Production by by lot lot size size
Period-oriented production/ flow manufacturing with takts
C O M P L E X I T Y
Process manufacturing
Mass production
PRODUCT ST ABILIT Y © SAP AG 1999
You can apply the R/3 Production Planning System in a variety of production types. The production types used in practice are essentially dependent on product stability, product complexity and production processes.
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Subsystems of the PP Application
PP REM Rep. Mfg
PP KAN KANBAN PP CRP Capacity Planning
PP PI Process Mfg PP SFC Shop Floor Control
PP PC Prod. Costing
PP
PP MRP Mat. Rqmts Planning PP SOP Sales & Oper. Planning
PP MPS Demand Mgmt
PP IS Prod. Info System
PP BD Basic Data
© SAP AG 1999
The Production Planning (PP) application incorporates a number of integrated working subsystems. Each time you use the R/3 system, you should determine precisely which components are appropriate to your needs. PP-Shop Floor Control is the subsystem for order-related production.
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Order-Related Production: Characteristics (1)
Order-related production Based on production orders with order category '10' Production by order lot sizes (see Lot-Sizing Procedure) Integrated logistical and controlling functionality Production by production versions (for example, production lines) Detailed status management Full integration into capacity planning PDC - Interface (PP-PDC) for download and upload Material staging controlled by material reservations
© SAP AG 1999
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Order-Related Production: Characteristics (2)
Availability checks for material, capacity, production resources and tools Various options for entering actual data (quantity, time) Order, operation, time event and progress confirmations
Extensive order-related or product-related controlling Full integration in the Logistics Information System (LIS) and Business Information Warehouse (BW) Archiving and retrieval function Numerous special functions multi-level collective orders, trigger points, serial numbers, order split, external processing, rework, WIP, variance calculation, cross-plant production, batch creation and batch determination, co-products and so on © SAP AG 1999
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Cross-Application Functions Material forecast Planning
Sales & Distribution Demand program
Sales reqmts
B A C D E
Requirements planning Planned order
Production order
Purchase requisition
Order processing
Purchase order
Goods receipt
Goods receipt
Order settlement
Invoice receipt
Costing
Capacity planning
Inventory
Goods issue © SAP AG 1999
Production order management is a central component of a complex process chain that starts with independent requirements (planned or customer requirements) and ends in the issue of a finished product. Production order management in the SAP System only controls the whole process of in-house production. Production order management uses the following system components: ALE, Workflow, Customizing, word processing, factory calendar, classification, communication and graphics.
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Production Planning and Control Data Master data Factory calendar Mat. master Work centers Bills of material Routings Prod. resources/tools CAPP formulas Documents Transaction data Production orders Confirmations CO object (cost collector) Material movements (goods receipt / issue) © SAP AG 1999
Data that does not change frequently is defined as master data of the Production Planning System. Transaction data are documents that have a restricted time application. In the Production Planning System these are production orders. Documents for confirmations, costs (CO objects) and material movements are assigned to the production orders.
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Corporate Order Management
Company Internal
Sales-Related Goods sold
Goods in stock
Cannot be activated
Order
Can be activated
Order
Order
Assignment to a sales order
Assignment to a material
Overhead cost orders
Capital investment orders
Customer
Warehouse
Cost center
Asset portfolio
Logistic functions (quantities and values)
Order
Cost accounting functions (values)
Goods for the market
Internal company goods and services
© SAP AG 1999
Corporate order management is divided into two basic forms: Sales-related orders and company internal orders. Within company internal orders, a distinction has to be made between: Orders purely for object control within cost accounting (for example, for promotional purposes or for use in trade fairs). Productive and value-added orders that can be activated (for example, for inhouse production on a production line). In the R/3 System, both basic order forms are assigned to SAP applications via order category. Examples: Production order (PPS) -> PP Production Planning Plant maintenance order -> PM Plant Maintenance Network -> PS Project System Overhead cost order -> CO Controlling Capital investment order -> CO Controlling
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Document Type, Order Category, Order Type Document type Orders Material accounting documents Financial accounting documents Order category PP production order PP process order PS network CO internal order CO production order CO model order PM plant maintenance order Order type Production order (internal number range) Production order (external number range) Production order (special types) © SAP AG 2003
The document type is used to differentiate between business transactions in the R/3 System. Orders are one category of business transaction. Orders are divided up according to order category, as it is possible to have different orders within the different applications. The system predefines fixed order categories for each application. You have the option of individually defining order categories for each order type within an application. An order type is used to control different processes: Number assignment Setting default values User-specified status management User-specific field control (not for production orders in Release 4.7) Control of special functions (activating BDE, QM, LIS,....) You define the settings for this in Customizing.
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Definitions in the Production Order What is being produced? produced?
Products Activity
When is it being produced? produced?
Planned order dates Basic order dates Calculated dates Confirmed dates Release Start Final
How much has to be produced? produced?
Planned order quantity Production order quantity Confirmed quantity
For whom are we producing? producing? (cost object)
Material Cost center Order Asset
Which resources and methods are being used in the production? production?
Material usage Prod. resources/tools Checks
Which costs are incurred by the production? production?
Planned Actual
© SAP AG 1999
The production order is determined by a series of definitions for manufacturing a product.
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Production Orders and Organizational Structures
Organizational units Company Demand management
Controlling areas Purchasing organizations
Sales organizations
Requirements planning
Company codes
Shop floor control
Valuation areas
Production order
Inventory management
Plants
Storage locations/batches/special stocks © SAP AG 1999
Production orders generally relate to the organizational unit plant. The organizational units above a plant can be structured in various ways.
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Master Data for the Production Order Procurement type E or X MRP, work schedule, acct. and costing data Material status (MARA and MARC)
Material
BOM
BOM
Material usage (Mat. no., item cat., quantity) Storage location (proposal for withdrawal)
Work center
Operation default values Available capacity and formula requirements Activity type and formula costs
Routing
Routing
Prod. Prod. resources/ resources/tools
Operations Standard values
Required Required quantity quantity and and usage usage value value Control data Control data
© SAP AG 1999
The material to be produced must have already been designated procurement type in house production (X,E). The material status must be released for production on both a cross-plant level (MARA) and a plant level (MARC). At least one plant specific view (MRP and/or work scheduling) as well as financial accounting and costing views must be maintained for the material. You prepare BOMs as single level BOMs. A special selection procedure chooses the correct BOM. After you have prepared a routing, a special selection procedure chooses the correct one.
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Order-Related Production - Roles
Sales Sales planning planning
Production planner Plant manager MRP controller Production scheduler
Production operator Production scheduler
Detailed Planning
Production Production
Plant reqmts
Industrial engineer
Production Production preparation preparation
Production operator Production scheduler (supervisor)
Docu. Docu. && analysis analysis
Plant manager Quality inspector
Design engineer © SAP AG 1999
Within the development of the SAP product "mySAP.com", computer-supported work centers have been created along the entire process chain for order-related production. Production order management touches on at least those roles shown on the slide. Individual roles are assigned different activities (tasks), authorizations and responsibilities that correspond to the actual daily work carried out in practice.
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Production Order - Symbol Overview Change
Order header
Display Sequence overview Save
Operation overview
Deletion
Component overview
Schedule (order, collective order)
Document overview
Cost Check availability (material, capacity, PRT)
Trigger point overview Release (order, operation)
Status overview
Print
Collective order overview Detail screen (operation, component, PRT, ...)
Enter long text (text editor) Generate object (for example, order)
Log
Execute program (function) Key Update © SAP AG 2003
The slide shows the most frequently used pushbuttons (symbols) in the production order. The symbols have been arranged on the individual production order screens in such a way that you can always find the relevant symbol in the same place on the screen. Order functions are arranged on the left and navigation functions on the right. In the overviews of the operations, components and production resources/tools, the relevant pushbuttons for the individual object have been arranged underneath the overview. Where it was considered appropriate, pushbuttons were placed directly next to a data field.
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LO215 - Commonly Used Abbreviations
• PP-SFC
Production Planning - Shop Floor Control SAP + LO + PP + Shop Floor Control
• Order type
Table T003O SPRO + SFC + Master Data + Order Types
• Order type parameters
Table T399X SPRO + SFC + Master Data + Order-Type Dependent Parameters
• Scheduling parameters of the order type
Table TCX00_FA SPRO + SFC + Operations + Scheduling + Scheduling Parameters
• Task menu (SAP)
Transaction session_manager
• Customizing
Transaction SPRO SAP + Tools + Accelerated SAP + Customizing + Edit Project
© SAP AG 1999
During the LO215 course, the instructor may repeatedly use certain terms, tables and shortcuts. The slide contains the most important terms and their menu paths. The instructor will not always repeat these menu paths.
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Overview: Summary
You have gained an overview of the process chain for order-related production and the role it plays in the R/3 System. You have learned about the prerequisites for master data. You have been informed about the role of order management in the organization structures of the R/3 System. The orders are assigned to an application using the order category. This determines the scope of the functions. The order types serve as a control for special functions per order category.
© SAP AG 1999
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Order Structure and Processing: Contents
Order data structure Production order screens Overview of order processing
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Order Structure and Processing: Course Objectives
At the conclusion of this unit you will be able to: Describe production order data structure Describe the most important production order screens Summarize the main functions of order processing
© SAP AG 1999
(C) SAP AG
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Overview Diagram (3)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
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Elements of an Order Order header Order number Plant Production scheduler Operation sequences Standard sequence Other sequences Operations Work center Control key Standard values
Settlement rule
Document links
Settlement profile Settlement receiver
Doc. number Doc. category
Costs Planned Actual
Material components Material number Quantity Reqmts date Prod. Prod. resources/ resources/tools PRT number PRT category Number Trigger Points
Capacity splits
Functions
Individual machine Individual person
Confirmations Quantities Times
© SAP AG 1999
The order structure can be enhanced by adding certain elements. At least one operation is required. The system automatically creates this operation when missing. You have the choice of whether or not to assign material components, production resources / tools and trigger points to the operation. You can create several (parallel) operation sequences. You can make a selection from several alternative sequences. Suboperations are permitted within an operation. Costs are determined at operation level and submitted at order header level only in the case of orderrelated cost object controlling.
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Production Order - Header Definition
Origin
Product (activity) to be manufactured with the order
Order
Functions
Edit
Goto
Manual Planned order
Header Environment
Assignment Goods receipt
To Routing To BOM To Costing Entered by / Changed by Plants Assignments MRP controller
1000767
General
Order type Order number Plant Material or activity Quantities dates
Control
Dates/quantities Master data
Control of goods receipt Movement type Settlement rule Settlement receiver Percentages Deadline monitoring Quantity monitoring
© SAP AG 1999
The segment of the order header describes the product that is to be manufactured with the production order (finished product, assembly, individual part). There are a series of detail screens for the order header. The header text of a production order can either be the short text of the material master or the header text of the routing that has been copied into the production order (with reference to this, see the switch in table T399X).
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Production Order - Operation Operation overview Definition
Origin
Types
General Data
Single step in Order
Manual Routing
Operation Suboperation
Standard values Ext. processing Interoperation times
Order
Functions
Edit
Goto
Operation
Environment
Standard values calc. Splitting Overlapping
1000767 General Data
Operation dates Stand. values
Ext. processing
Interoperation times Standard value calc.
User fields Quantities/activities
Operation 0010
Confirmed dates
© SAP AG 1999
This segment of the operation describes the individual work steps of the production order. There are a series of detail screens for an operation. These screens, in turn, incorporate further detail screens. For example, you can branch from the component overview to screens for each material component. You have the option of inserting suboperations hierarchically with reference to an operation. This enhances calculation and capacity planning. The operation control key of the sub-operation plays an important role in this. Scheduling always occurs at operation level. The standard values of the suboperations can be cumulated on the corresponding operation when the dimension and units of measurement are the same. It is not possible to assign material components or production resources / tools to sub-operations.
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Production Order - Material Components Definition
Origin Manual
Materials required for an operation or for manufacturing a product
Order
Functions
Edit
Goto
BOM Planned order
Component
Material number Material description Requirements qty Reqmts date
Environment
1000767 General data
Purch.data
VarSzeltmDta
Co-product
Compon. 0010
Text item
Reservation Item category Bulk mat. indicator Available quantity Issued quantity Missing parts quantity Text editor
© SAP AG 1999
In a production order, you can assign any number of material components to an operation. The segment for the material component describes the material required to carry out the individual operations. There are a series of single screens for a material component.
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Production Order - Production Resources/Tools Origin
Definition Production resources/tools required to execute an operation
Order
Functions
Edit
Goto
PRTs
Manual Routing
Environment
Quantities
Material Equipment (as of 3.0) Document Other PRT number PRT control key Plant
1000767
General
Types
Requirements qty
Dates
Usage value Formulas Item
0010
Usage dates Document (graphics) PRT text
© SAP AG 1999
In a production order, you can assign any number of production resources/tools to an operation. The segment for production resources/tools describes the required devices, tools, test equipment and so on required for executing an individual operation. The production resources/tools category is essentially derived from the demands on a production resource/tool and its relationship to a certain object (material, equipment and so on).
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Production Order - Documents Origin
Definition Production resources/tools required execute an order
Order
Functions
Document
Doc. Data
Processing Go to
P-100
Manual Material Master Bill of Material Prod.Version
Document Environment
000
Additional Data Descriptions
Assignmt to operation Origin Format
00
Object Links
Document no. Subdocument Document version
Object link Original
Original appl. file(s) Storage data
Originals
© SAP AG 2003
You can assign any number of documents to a production order. These are maintained in the Document Management System (DMS). The documents themselves are only linked to the production order and not saved in it. You can create links from documents to a production order manually or automatically. Documents can be drawings, texts, videos and so on. Application example: Product descriptions Assembly instructions and diagrams Inspection instructions and certificates Work instructions Storage and transportation regulations Spare parts lists Maintenance regulations
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Production Order - Costs Definition
Origin
Costs arising during the execution of a production order
Order
Functions
Edit
Goto
Automatic Costing
Header Environment
Material costs Stock material Price determination according to valuation variant Non-stock material Price from purch. info record
Production costs 1000767 Itemization
Cost categories
Cost comp. structure
In-house production Activity price according to valuation variant Ext. processing Price acc. to valuation variant
Process costs Assigned acc. to template
Overhead costs Calculated in overhead structure © SAP AG 1999
If order-related cost object controlling is used, each individual production order has a cost object (CO). Order costs can be calculated manually or automatically. You define this by setting up the order-type dependent parameters accordingly in Customizing (table T399X). The CO object enables you to display different lists of costs for a production order. By choosing Goto + Costs in an order, you can find lists for the terms Itemization (detailed overview of the individual costing items) Analysis (overview structured according to cost category) Cost component structure (overview structured according to arithmetical cost components)
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Production Order - Settlement Rules
Definition Order header
Receiver of order costs Account assignment categories
Operations
Material Cost center CO order
Material components
Asset WBS element Prod. resources/tools
Costs
Planned Target Actual
100
Sales order 20 50
and so on
Origin Manual Automatic
© SAP AG 1999
You control order settlement by way of settlement rules. The order can be settled proportionally to one or more receivers. Settlement rules are created manually or automatically (during order creation). At the latest, they must be maintained before the goods receipts posting is carried out for the material to be produced. You define the settings for order settlement in Customizing. If you use product-related cost object controlling, the settlement rules are contained in the product cost collector and not in the production order.
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Processing a Production Order
Order request
Archiving / deleting
14
1 Order creation
Order settlement
2
13 Order header
Calculate variances
12
Availability checks
3
Operations
Material components
11
4
Goods receipt Prod. resources/tools
Determine WIP
10
Costs
5
Planned 20 100 Target 50 Actual
6 Confirmations
9
7 8
Machine reservation Order release
Print order Material staging
Order processing © SAP AG 1999
The production order runs through a wide range of individual activities. WIP calculation, variance calculation and settlement are generally periodic operations for cost object controlling that are processed in the background. You must define a series of settings for each individual stage if an order is to be processed successfully. CO Configuration includes a special feature that sets the prerequisites for WIP determination, variance calculation and settlement.
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Order Structure and Processing: Summary
You have gained an overview of the data structure of a production order You know the most important production order screens The basic functions of production order management were shown in an example
© SAP AG 1999
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Exercise Data Note: There will not be sufficient time to work through all the exercises during the course. The exercises marked Optional should be seen as supplementary examples that can be used, as required and time permitting, during the course. Attendees can also use these exercises after the course, to consolidate what they have learned.
Explanation of the Symbols in the Exercises and Solutions Exercises Solutions
Course Objectives
Business scenario
Tips & Tricks
Warning or caution
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Data in the exercises Type of data
Data in training system (ID3, client 400)
Data in the IDES system (ID3, client 800)
Group no.
xx (01....20)
User master records
LO215-xx password FERT
Client
400 (401, 402) as per training room
Customizing project
200
200
Company code
1000
1000
Business area
1000
1000
Purchasing organization
1000
1000
Sales organization
1000
1000
Distribution channel
10
Final customer sale
10
Final customer sale
Division
00
Multiple division
00
Multiple division
Sector
M Mechanical engineering
M Mechanical engineering
Personnel area
1000
1000
Chart of accounts
INT
INT
Controlling area
1000
1000
Cost center hierarchy
H1
H1
Cost center nodes
4200
4200
Personnel subarea
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Cost centers
4210, 4220, 4230
4210, 4220, 4230
Activity types
1410 Machine time
1410 Machine time
1420 Setup time
1420 Setup time
1430 Personnel time
1430 Personnel time
Factory calendar
01
01
Plants
1000 (Normal)
1000 (Normal)
1100 (special structures) 1100 (special structures) MRP controllers
100, 101
Demo
100, 101
Demo
100, 101
Demo
100, 101
Demo
001 to 002 Participants Capacity planner
099
Instructor
100, 101
Demo
001 to 002 Participants Production scheduler
099
Instructor
100, 101
Demo
001 to 002 Participants 099 Production scheduling profile
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Instructor
0000001 Normal
0000001 Normal
0000002
0000002
automatic
LO215
automatic
3-16
Work centers
T-Exx
T-Exx
T-Fxx
T-Fxx
T-Lxx
T-Lxx
T-Mxx
T-Mxx
T-Pxx
T-Pxx
T-Vxx
T-Vxx
T-WM
T-WM
1111
1111
1112
1112
1116
1116
1117
1117
1310
1310
1320
1320
1721
1721
1904
1904
1905
1905
1906
1906 Product
P-100
(see also following T-B1xx BOM structure for T-B2xx T-F1xx) T-B3xx
Assembly 1
100-100
Assembly 2
100-200
Assembly 3
100-300
T-B4xx
Assembly 4
100-400
T-T1xx
Indiv.comp 1
100-110
T-T2xx
Indiv.comp 2
100-120
T-T3xx
Indiv.comp 3
100-120
T-T4xx
Indiv.comp 4
100-310
T-T5xx
Indiv.comp 5
100-210
Material
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T-F1xx
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Normal flow
P-100
P-100
Collective order
P-400
P-400
Config.var. scn. 1
P-500
P-500
Config.var. scn. 2
P-501
P-501
Config.var. scn. 3
P-502
P-502
Change management
P-600
P-600
100-300
100-300
Normal flow
100-301
100-301
Rework
T-A
T-A
Automat. Procedure
T-V1, V2
T-V1, V2
Limited no. of Variants
T-MAN
T-MAN
T-SEL
T-SEL
W/o BOM and plan
T-OS
T-OS
T-COP
T-COP
Select. BOM/plan
T-MC
T-MC
Op. consequences
T-MS
T-MS
Co-products
T-MA
T-MA
Mat. components
T-MD
T-MD
Mat. staging
T-PDP
T-PDP
Availability
T-MV
T-MV
Discontinued parts T-BCH Cross-plant T-EX
T-BCH
Split valuation
T-SN
T-SN
Batch production
T-REP
T-REP
Ext. Proc. / proc.
T-STOCK
T-STOCK
T-EX
Serial numbers Repetitive /orderbased production Stock determination
(C) SAP AG
LO215
3-18
Bills of material
Routings
(C) SAP AG
T-F1xx P-100
P-100
P-400
P-400
P-500
P-500
P-501
P-501
P-502
P-502
P-600
P-600
T-A
T-A
T-V1, V2
T-V1, V2
T-SEL
T-SEL
T-OS
T-OS
T-COP
T-COP
T-MC
T-MC
T-MS
T-MS
T-MA
T-MA
T-MD
T-MD
T-PDP
T-PDP
T-MV
T-MV
T-BCH
T-BCH
T-EX
T-EX
T-SN
T-SN
T-REP
T-REP
T-F1xx P-100
P-100
P-400
P-400
P-500
P-500 LO215
3-19
P-501
P-501
P-502
P-502
P-600
P-600
T-A
T-A
T-V1, V2
T-V1, V2
T-SEL
T-SEL
T-OS
T-OS
T-COP
T-COP
T-MC
T-MC
T-MS
T-MS
T-MA
T-MA
T-MD
T-MD
T-PDP
T-PDP
T-MV
T-MV
T-BCH
T-BCH
T-EX
T-EX
T-SN
T-SN
T-REP
T-REP
50000003 standard task list
50000003 standard task list
WM storage bin
PROD-1310
PROD-1310
Standard trigger point
T-NACHARB
T-NACHARB
Order types
PP01 Demo and exercise
PP01 Demo
PP03 Demo and exercise
PP04 Demo
PP03 Demo PP06 Demo
PP04 Demo and (C) SAP AG
LO215
3-20
exercise
PP07 Demo
PP06 Demo and exercise
PP08 Demo
PP07 Demo and exercise PP08 Demo and exercise
(C) SAP AG
LO215
3-21
PP Exercise Material - BOM T-F1xx
T-F1xx (FERT, P-100) (1000, 0, _ )
Item 0010
1
0020
1
0030
1
0040
1
T-B1xx (HALB, 100-100)
T-B2xx (HALB, 100-200)
T-B3xx (HALB, 100-300)
T-B4xx (HALB, 100-400)
(1000, 10, 2 )
(1000, 10, 2 )(1100, 10, 2 )
(1000, 0, _ )
(1000, 10, 2 )
Pos. 0010
1
T-T1xx
0020
1
0030
T-T2xx
(ROH, 100-110) (1000, 1000, 2 )
(ROH, 100-120) (1000, 1000, 2 )
T-T3xx (ROH, 100-130) (1000, 1000, 2 )
8
0010
1
T-T0xx
0010
1
T-T4xx
(ROH, 100-210) (1000, 1000, 2 )
(ROH, 100-310) (1000, 1000, 2 )
0010
0050
1
Dokument T-F1xx DRW, 000, 00
1
T-T5xx (ROH, 100-410) (1000, 1000, 2 )
(1100, 1000, 2 )
Key:
(Material, IDES template) (Plant, stock qty, sec. reqmts ind.))
© SAP AG 1999
(C) SAP AG
LO215
3-22
PP Exercise Materials - Routings T-F1xx(FERT, P-100)
T-F2xx(FERT, P-100)
(1000, 0, _ )
(1000, 0, _ )
0010
10 T-Mxx TPLxx ( 1310 )
0020
Assig nment to sta t. w ork c enter a nd hiera rc hy no t a ssig ne d
T-Vxx ( 1320 )
0030
T-VH
hierarchy: T-V
T-Lxx ( 1906 )
0040
T-EH
T-Exx
hierarchy: T-E
( 1904 )
0050
T-Fxx ( 1721 )
0060
T-Pxx ( 1721 )
© SAP AG 1999
titel (author)
(C) SAP AG
2
LO215
3-23
Order Structure and Order Processing Exercises Unit: Order Structure and Order Processing Topic: Order Structure and Order Processing (LO215 Exercise 1)
•
Structure (data and contents) of a production order
In your capacity as production manager, production scheduler, supervisor or operator, you work with production orders all the time. In this exercise, you will become familiar with the structure of a production order.
1-1
Display the production order no. _______________ . Path:
1-2
S000 → LO → PP → SFC → ORDER → DISPLAY
Display the individual data segments, screens and their data fields in the following order: Note any questions you may have about the meaning of the data fields. If the meaning of any of the data fields is not clear, ask the instructor.
1-2-1 Order header screens Path:
(C) SAP AG
→ GOTO → HEADER
LO215
3-24
Select the corresponding tab index for the respective screen. General Assignment Goods Control Dates/quantities Master Long Settlement rule Path:
receipt
data text
→ HEADER → SETTLEMENT RULE
1-2-2 Overview of the operation sequences Path:
→ GOTO → OVERVIEWS → SEQUENCES
1-2-3 Operation sequence details Path:
→ SEQUENCE → DETAILS
1-2-4 Operation overview Path:
→ GOTO → OVERVIEWS → OPERATIONS
1-2-5 Operation screens (select operation "0010") Path:
(C) SAP AG
→ OPERATION → OPERATION DETAILS
LO215
3-25
Select the corresponding tab index for the respective screen. General Standard values External processing Interoperation times Standard value calculation Splitting Overlap Dates User fields Suboperation/dates Quantities/activities Confirmed dates Qualification Long text
1-2-6 Material components - Overview Path:
GOTO → OVERVIEWS → COMPONENTS
1-2-7 Material component screens (select component "0010" or "0070") Path:
COMPONENT → COMPONENT DETAILS
Select the corresponding tab index for the respective screen. Item ’0010’
General Data
Item ’0070’
VarSzeltmDta
1-2-8 Overview of production resources/tools for operation "0050" Path:
Go to the operation overview and select operation "0050". In the menu bar at the bottom of the screen, select the PRT pushbutton (Production resources/tools)
1-2-9 Screens for the production resources/tools (select production resource/tool "0020") (C) SAP AG
LO215
3-26
PRODUCTION RESOURCE/TOOL → PRODUCTION RESOURCE/TOOL DETAILSHILFSMITTEL
Path:
Select the corresponding tab index for the respective screen. Item ’0020’
General Quantities Dates
1-2-10 Document overview Path:
GOTO → OVERVIEWS → DOCUMENTS
1-2-11 Display of the document information record (select the first document) Path:
DOCUMENT → DISPLAY DOCUMENT INFORMATION RECORD
Select the corresponding tab index for the respective screen. Document data Additional data Descriptions Object links Original 1-2-12 Display of the original document (display both originals from the document overview for the order) Path:
DOCUMENT → DISPLAY ORIGINAL DOCUMENT
1-2-13 Costs Itemization Analysis (Cost categories) Cost comp. structure
(C) SAP AG
LO215
(Cost component
3-27
Path:
GOTO -> COSTS -> ITEMIZATION
→ ANALYSIS → COST COMP. STRUCTURE
(C) SAP AG
LO215
3-28
Order Structure and Order Processing Solutions Unit: Order Structure and Order Processing Topic: Order Structure and Order Processing (LO215 Exercise 1)
No answers are required for this exercise.
(C) SAP AG
LO215
3-29
Order Creation/Order Change: Contents
Function procedure "Creating an order" Automatic follow-on postings Creation variants Normal With production version No reference to material (any activity) Copy from order Related to sales order With variant configuration
Bill of material and task list selection Converting planned orders Reading master data Operation sequences in an order © SAP AG 1999
(C) SAP AG
LO215
4-1
Order Creation/Changing Orders: Course Objectives
At the conclusion of this unit you will be able to: Define the basic features and variants for creating production orders Describe subsequent functions in order creation Describe the process of routing and BOM selection when creating an order Define how master data is read into existing orders Describe how to create and convert planned orders
© SAP AG 1999
(C) SAP AG
LO215
4-2
Overview Diagram (4)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
(C) SAP AG
LO215
4-3
Creating Production Orders Friday July 27 1992
Manual
Tuesday December 18 1992
Automatic
Requirements planning Specify order type Define order item Copy routing Copy bill of material Lead time scheduling Availability check
Various functions (1) Add, change Optional (Customizing)
Save production order
© SAP AG 1999
The production order can be generated automatically (confirmation, sales order) or manually (directly) by converting it from a planned order. A start / finish date is entered for the order item (product) according to the scheduling type (forwards or backwards) . Lead time scheduling is executed automatically. It calculates the start / finish dates of the order and the detailed dates and capacity requirements of the operations. You also have the option of carrying out an availability check (specifiable in Customizing). You can determine the planned costs when saving the order (specifiable in Customizing). (1) Other functions that can be executed automatically are: Batch creation, determination, order classification, serial number assignment, document integration.
(C) SAP AG
LO215
4-4
Automatic Postings
Material reservations
Inventory management
Purchase requisitions
Purchasing
Costs (CO object)
Controlling
Capacity requirements
Capacity planning
Transport requirements
Warehouse management
Inspection lots
Quality management
PRT requirements
PRT management
© SAP AG 1999
When you create a production order, a series of additional posting procedures occur at the time of posting (the data is already formatted online). These automatically generate the required data for stored parts of the system. Material reservations are generated for all warehouse components. You can choose whether these reservations are to be immediately relevant to MRP or not until the time of release (indicator in the order-type dependent parameters T399X) Purchase requisitions are created for non-warehouse components and externally processed operations. Costs are determined when you save. Transport requirements are generated when the operation is released. PRT requirements are only generated internally. At the present time, however, there is no requirements planning for PRTs which works with these records. Transaction CF21 (using PRT in orders) is available for evaluating PRT requirements in production orders. Missing parts records are written for missing parts.
(C) SAP AG
LO215
4-5
Creation Variants 1 With reference to material Directly (manually)
Order header
From planned order Copy from order Operations
For sales order From SD (assembly order) From confirmation (rework)
Material components
As collective order With variant configuration
Prod. resources/tools
Costs
Without reference to material
Planned Target Actual
100
20 50
Activity
© SAP AG 1999
There are numerous possibilities for creating production orders.
(C) SAP AG
LO215
4-6
Creation Variants 2
Create without routing and bill of material Order
Create with routing and bill of material Planned
Create with routings Planned
Order
Material BOM Order
Create with planned order Planned order
Order
Planned © SAP AG 1999
Operations, material components and production resources / tools are normally copied from the routing and BOM. You can also input such information manually. The BOM is not reread when you convert a planned order. If you do not specify otherwise in a routing, the system automatically assigns the BOM components to the first operation.
(C) SAP AG
LO215
4-7
Scheduling in Production Planning Material requirements planning
Own scheduling for planned orders To the day Calculated basic dates Basic start date Basic finish date Creation date Base in-house production time or replenishment lead time Advantageous for performance No capacity requirements are determined
Lead time scheduling
Periods
Order Order head head er er
for orders and routings Used To the second Starts from basic dates Requirements planning Manual Determined production dates (scheduled dates) Start date Finish date Release date Base operations Determined capacity requirements
Oper ati o ns
Mater ial com po ne nts
Pr od. r es our ce s/t ool s
Cost s
Pla nn ed T arget Act ual
20
100 50
© SAP AG 1999
Production planning has two scheduling methods that are used differently and have different results: Scheduling of planned orders in material requirements planning (calculates the basic dates only) Lead time scheduling (starts from the basic dates and calculates the production dates) Only lead time scheduling calculates operation-related dates and capacity requirements. Lead time scheduling is the basis for Order scheduling Routing scheduling Scheduling in applications PS, PM, PI In addition, lead time scheduling can be activated in material requirements planning in order to determine capacity requirements for planned orders.
(C) SAP AG
LO215
4-8
Scheduling/Time Elements of an Order
Float Op. bef.prod. 0010 PS
Op. Op. 0020 0030
Op. 0040
........
Op. 0099
SS
Queue time ES
Float after production
SF
Setup time LS
GR Pick/pack Loading proc.time time time PF
AD
LT
Transit time GI
RDD
Proc. time Teardown Wait time Move time
EF
LF
Order dates
Operation dates
PS SS SF PF AD LT GI RDD
ES Earliest start date LS Latest start date EF Earliest finish date LF Latest finish date
Planned start date (basic start date) Production start date (scheduled start date) Production finish date (scheduled finish date) Planned finish date Planned availability date Loading time Goods issue date Requested delivery date
Time concepts Lead time of order or operation Float times for order/operation
Execution time of operation Interoperation times Processing times in sales
© SAP AG 1999
The slide shows all possible elements of the total lead time of a production order. There are two order float times, which serve different purposes. Float before production Postponement of dates, capacity planning Float after production Absorbs any delays The order float can be predefined using a scheduling margin key (order header screen). This key is entered in the material master and maintained in Customizing for Shop Floor Control by choosing "Scheduling". The duration of an operation is made up of a maximum of five time elements. Queue time Setup time Processing time Teardown Minimum wait time The duration of the move time is the time between two operations but it is assigned to the preceding operation. If a production order is being used to carry out production for a sales order (for example, assembly of a finished product), then other time segments that are relevant to sales have to be added to these.
(C) SAP AG
LO215
4-9
Number Assignment for a Production Order
Number range object for an order (general) general)
Range
from to
Number range Group 1
Number range Group 2
Number range Group 3
1000000 1999999
2000000 2999999
3000000 3999999
Assignment internal external(x)
Assignment of the order types (element)
....
X
PP01 IDES PP06 . . . .
PP02 PI02 . . . . .
PI01 . . . . . .
© SAP AG 1999
Order numbers are assigned according to order type. Numbers can be assigned either externally or internally. The order number can be composed of a maximum of 12 characters. Order numbers can be defined independent of company codes, plants and other organizational structures. A number range group must be specified for each predefined number range. You can create an unlimited amount of number range groups. The order categories can be assigned to any of the number range groups. The system does not allow multiple assignment. The current status of the internal number assignment can be changed manually provided that the sequences are taken into account. You maintain the number range in Customizing.
(C) SAP AG
LO215
4-10
Task List Selection Criteria Customizing Selection type (T399X)
Task list usage Task list type
"With / without routing" "Routing required / optional" "Manual / automatic selection" "With / without ref. operation set" "P" (Production) "N" (Normal) "S" (Standard)
Task list selection ID Usage "Production version" indicator (T399X) Material no. Plant
A
"Alternative selection" indicator (MRP screen 4)
Material
Production version
Group Group counter Status Validity Lot-size range Deletion flag
(in reference operation sets)
Routing
"Released" "Basic start/finish date" "Order quantity" = = "X"
© SAP AG 1999
You define the routing selection options in Customizing. The most important tables are: T399X order-type dependent parameters and TCA43 automatic selection You can determine whether a routing is necessary or not (selection type). All criteria are always checked and a routing is only selected if all criteria are fulfilled. Determining which validity the routing should be selected with is dependent on the setting in table T399D ( Customizing Requirements Planning).
(C) SAP AG
LO215
4-11
Task List Selection - Procedure
PP parameters for order type (T399X) "Task list selection" indicator Select a task list?
= No
Mat. master "Alternative selection" indicator
=3
Mandatory task list selection by PV
=2
Task list selection by production version
= Yes Automatic selection ?
= Yes
= No
PP parameters for order type (T399X) "ProdVersion" indicator
=1
Task list selection by selection ID (TCA43)
Automatic routing selection (TCA43)
Routing Routing Routing
= Blank Task list selection by selection ID (TCA43)
Manual selection
Create operation (default values from TCO41)
Additional criteria
Key: PV = Production version © SAP AG 1999
During automatic selection, the alternative selection indicator in the material master (MRP screen 4) determines how selection is carried out. Note the following special features: IND = Blank Using the selection ID from table T399X, the system searches the sequence of priorities contained in table TCA43 for the first available routing that fulfills the criteria: lot size and task list category, usage and status. IND = 1 Same as for "blank". IND = 2 The system searches the material master for production versions that fit the lot size. If only one exists, then its routing is checked against all criteria (also those contained in TCA43!). If there are more than one, table T399X decides (production version indicator) whether the user (dialog box) or the system (automatic) determines which production version is to be selected. If, despite this, no valid routing is found, the system does not stop. The system carries on searching using the procedure for when the indicator is "blank". IND = 3 Same as for value = 2. If no valid routing is found in this case, the system stops the search! No production order is created. Selection according to production version presupposes that valid production versions have been maintained in the material master. (C) SAP AG
LO215
4-12
If you create a routing for a sales order, then this is used independent of the other selection criteria.
(C) SAP AG
LO215
4-13
BOM
Stage Pump P-100
HEADER
0 Order header
...
Operations
ITEM
Pre-assembled casing
Pre-assembled shaft
100-100
100-300
1
Material components
Prod. resources/tools
Costs
Casing
Support base
Shaft
ITEM 100-110
100-700
...
Planned Targe t Actual
20
100 50
2
100-301
© SAP AG 1999
BOMs contain the material structure and required quantities of the individual components for a product. The required quantities are not dependent on the order. BOM data is copied to the production order. Subsequent changes you make to the BOM do not take effect on orders that already exist. When you create an order, a BOM is chosen on the basis of the corresponding selection criteria. The BOM is exploded on one level. An exception to this is multi-level BOM explosion for so-called phantom assemblies. Subitems are not copied to the order.
(C) SAP AG
LO215
4-14
Bill of Material Selection - Criteria Customizing BOM application (T399X) BOM selection ID BOM selection priority BOM alternative BOM usage
"Alternative no."
"Production version" indicator (T399X) "Automatic/manual"
Material no. A
Plant "Alternative selection" indicator (MRP screen 4)
Material
Production version
BOM header BOM status Validity Lot-size range
"Released" "Basic start/finish date" "Order quantity"
Deletion flag
= = "X"
Status Validity
'Production'
BOM
BOM item
© SAP AG 1999
You must define the BOM selection options in Customizing. The system always checks all criteria. Only BOM items relevant to production are copied to an order. (See the item category of the component). If there are several valid BOMs that could be selected, the system automatically chooses the first valid one. You can make the validity of a BOM item dependent on various parameters (for example, date, customer, serial and matieral number of the product to be manufactured). Refer to "Parameter Effectivity" in change management
(C) SAP AG
LO215
4-15
Bill of Material Selection - Procedure Mat. master Indicator "Alternative selection"
= Blank
BOM usage priorities (TCS41)
BOM usage(TC04)
BOM selection by lot size
Sel. ID = Yes
=1
BOM selection by date
=2
BOM selection by PV
=3
Mandatory BOM selection by PV
Key: PV = Production version
Selection by date permitted ? = No
Selection by PV permitted?
PP parameters for order type (T399X) "BOM usage"
BOM alternative alternative (T415A)
BOM BOM BOM
= No = Yes
PP parameters for order type (T399X) "ProdVersion" indicator
Additional criteria
© SAP AG 1999
During automatic selection, the alternative selection indicator in the material master (MRP screen 4) determines the selection procedure. Note the following special features: IND = Blank The system takes the BOM usage that is defined for each order type from table T399X, enters table TC04 with this and takes a selection ID from this table. The system uses this selection ID and searches the sequence of priorities contained in table TCS41 for the first available BOM that fulfills the lot size and BOM usage criteria. IND = 1 Selection according to date requires that an entry is maintained in Customizing for the material (T415A alternative selection multiple BOM). IND = 2 The system searches the material master for production versions that fit the lot size. If only one exists, then its BOM is checked against all criteria (also those contained in TCS41!). If there are more than one, table T399X decides (production version indicator) whether the user (dialog box) or the system (automatic) determines which production version is to be selected. If, despite this, no valid BOM is found, the system does not stop. The system carries on searching using the procedure for when the indicator is "blank". IND = 3 Same as for value = 2. If no valid BOM is found in this case, the system stops searching! The production order has no components. (C) SAP AG
LO215
4-16
Selection according to production version presupposes that valid production versions have been maintained in the material master.
(C) SAP AG
LO215
4-17
Item Categories in the Production Order
Order header Stock item Reservation
Operations
Variable-size item Material components
Non-stock item
Text item
Prod. resources/tools
Costs
Planned Target Actual
100
Purchase requisition
Class item
20 50
Find object for class
© SAP AG 1999
Item categories control the data scope and functions of a material component. Typical examples are: Stock item Non-stock item Variable-size item Text item Class item You cannot make alterations to item categories once they have been set. Follow-on documents are generated with the production order according to item category. Components with the item category "non-stock item" automatically generate a purchase requisition. This can be displayed for an item via a further screen. The class item stands for a wide variety of different materials. When you enter the command "find object function for class", the system can specify the class item in a particular stock item. The "document item" is transferred to the document list of the production order (document link)
(C) SAP AG
LO215
4-18
Reservation
Reservation Assignment Base date
Header
Check calendar
1
Item Item Item Item Item Item
Material
A Material
Plant / Storage location Reqmts date Movement allowed Committed qty
© SAP AG 1999
The system generates material reservations for all material components of a production order of the type "stock material". Reservations are taken into account when determining the conditions for material requirements planning. Reservations are also taken into account when creating goods movements for components of the production order. A reservation item applies to a plant or a plant's storage location. A requirements date is defined by the order for each item. You can control whether goods movements are allowed for the reservation item by means of an indicator. The reservations for material components of the production order are assigned to this production order. You can compile lists of reservations for the material or account assignment (production order).
(C) SAP AG
LO215
4-19
Material Assignment
A Material
B Material
Routing
BOM
Op. 10
Item 10
Op. 20
Item 20
Op. 30 © SAP AG 1999
You can assign material components to operations both when managing BOMs and routings. The assignment of material components to operations is copied to the production order. If no assignments are maintained, then the system automatically assigns the BOM material components to the leading operation. When you display the material components overview, you can assign material components to individual operations and display material components. The material components list can be sorted and filtered according to various criteria in order to enhance this overview. Other functions include: Assigning, reassigning and deleting material assignments. Navigating between operations You are able to reassign materials up to the point of order release.
(C) SAP AG
LO215
4-20
Assignment of Production Resources / Tools
Production order
Op. 10
PRT1
Op. 20
PRT2
Op. 30
© SAP AG 1999
You can assign production resources/tools to every operation in a production order. Production resource/tool assignments are copied from the routing to the production order.
(C) SAP AG
LO215
4-21
Document Integration in Production Orders Document Management System (DMS)
Master Data
DMS
Fri Document 1
B Material
Production order Order item
BOM
Overview of documents in PrO
Fri Document 2
Document link 1 Material item
10
Document link 2
Document 3 Fri
Document item 20
Document link 4
Document 4 Fri
Document item 30
Document 5
Document link 5
Routing Operation 10 Operation 20 Operation 10 Material item
Operation 20 Prod. res./tools
Document 6
10
Production res/tools
© SAP AG 2003
You can assign any number of documents to a production order. These are maintained in the Document Management System (DMS). Documents can be drawings, texts, videos and so on. The documents themselves are only linked to the production order and not saved in it. You can create links from documents to a production order manually or automatically. Automatic linking of documents takes place during order creation or release. The document items are copied from the BOM, the production version or from the document link to the material master of the product to be manufactured. (This must be activated in the production scheduling profile - Customizing for Shop Floor Control) Document links in the production order created in this way can be displayed, changed, deleted, printed (separate list), archived and displayed in the product structure browser. Original documents cannot be printed out. All document types that you use must be permitted for object PORDER (production order), work with status management and must be released. (See Customizing for the Document Management System). Examples, see above: Document 1 Link copied from material master Document 2 Link created manually Document 3 No link to production order Document 4 and 5 Link created from BOM item Document 6 does not appear in the document overview of the production order (C) SAP AG
LO215
4-22
Operation Sequences in a Production Order
Order header
Sequence types
Parallel sequence 0002
A Product
Standard sequence 0000
Alternative sequence 0001
Op. 10
Op. 10
Op. 20
Op. 15
Op. 30
Op. 20
Op. 40 Op. 50 Op. 60
Op. 70
Op. 70
Op. 80
Op. 80 Op. 90 . .
© SAP AG 1999
Alternative and parallel operation sequences are possible in production orders. The alternative sequence gives you the option of choosing alternative operations for a sequence of operations. The parallel sequence enables you to process operations parallel to and independent of other operations. You can copy both sequence types in an order from a routing (via Customizing).
(C) SAP AG
LO215
4-23
Alternative Sequences
Standard sequence 0000 Alternative sequence 0002
Operation 10
> 20
Operation 20
25
Operation 30
< 30
Operation 40 Operation 50
Alternative sequence 0001 > 10 15 20 25 < 30
© SAP AG 1999
Alternative sequences are linked to the standard sequence. An alternative sequence can be created automatically when you create a production order or read the master data. You can use the "exchange sequences" function to replace alternative sequences with a different sequence. This exchange is possible as long as certain functions have not yet been executed. For example, material withdrawals, confirmations, purchase orders. A switch is only possible if: The standard sequence has branch and return operations The operation numbers are within the standard sequence range There is no overlap with other alternative sequences. Application: Changed work procedures with different lot sizes and capacity bottlenecks (external processing).
(C) SAP AG
LO215
4-24
Parallel Sequences
Parallel sequence 1 20
Operation 10
25
Operation 20
30
IIIII
30
40
IIIIIIIII 50 45
60 55
Parallel sequence 3 IIIIIIIII 20
30
Parallel sequence 2
IIIIIIIII = Floats
© SAP AG 2003
Alternative and parallel operation sequences are possible in production orders. The parallel sequence enables you to process operations parallel to and independent of other operations. You can copy both sequence types in an order from a routing (via Customizing). Parallel sequences are linked to the standard sequence through predecessor / successor relationships. Parallel sequences are a special form of overlapping operations. Parallel sequences create network-like structures. Order scheduling inserts operation floats according to the alignment key specifications. Applications: In mechanical engineering for assemblies involving the production of individual components, inspection processes, and preparatory and closing operations. In the chemical industry for analysis processes that are carried out in parallel to the production process.
(C) SAP AG
LO215
4-25
Read Master Data Routing 1
Order header Routing 2 Operations
Material components
BOM 1
Prod. resources/tools
Costs
Planned Target Actual
100
BOM 2
20 50
© SAP AG 1999
You can use the function "Read PP master data" to switch the originally copied routing 1 and / or BOM 1 with a different routing and / or BOM alternative 2. This exchange is possible as long as certain functions have not yet been executed. For example, material withdrawals, confirmations, purchase orders. Assignments of components (BOMs) and production resources/tools are retained, provided that the corresponding operation still exists. This function can also be used for collective orders (refer to the "Collective Orders" unit)
(C) SAP AG
LO215
4-26
Order Change Management (OCM)
Aims of change management for production orders Provision of a system-supported tool for automated change of production orders which are already being used in the production process. The changes concerned can be triggered by changes in sales orders and/or master data
When are the OCM tools needed? 12 11 1 10 2 9 3 8 4 7 6 5
Production orders are already being used in the production process and have been worked on Customers change their order Engineering or technological changes are necessary Mass orders are affected by changes (for example, collective orders)
Who needs the OCM tools? Sales-order-related production, make-to-order production
© SAP AG 1999
If you wish to change orders already being used in production and the options provided by the "Read PP master data" function do not suffice, you can use Order Change Management for production orders (OCM) (as of Release 4.5). The R/3 change management function enables the user to make changes that are coordinated throughout the order process, in terms of content and dates, to one or more objects (product master data and documents from business transactions currently in process). Change management differentiates between: ECH = Engineering Change Management OCM = Order Change Management ECH concentrates on the preparation and execution of changes to product master data. OCM concentrates on the exection of changes to production orders that are already being used in the production process (and on finding planned orders or purchase orders that are affected by these changes). The changes in OCM are based on changes from the area of product master data (ECH), as well as certain changes from sales orders (SD). You cannot carry out automatic unchecked changes to production orders that are currently being used in the production process (for example, material consumption has been posted, order is partially confirmed,...). This is why the R/3 system provides functions for the controlled change of orders. Change management for production orders (OCM) is dealt with in detail in course LO980.
(C) SAP AG
LO215
4-27
Order Creation with Planned Orders Planned order Material number (Product) Requirements qty Reqmts date
Material number (component) Requirements qty
Order item
Material components
Production order Inspection lot Inspection data
Operations
Inspection characteristics Test values/ characteristics
Op number Work center Control key Standard values
PRT
PRT number Requirements qty Control key
Routing © SAP AG 1999
Planned orders are created via Material requirements planning (MRP). Creating production orders from planned orders is the most important function of the whole PP application. When you create a production order from a planned order, the system automatically supplies the production order data. When an inspection lot is generated, the inspection data is copied from the routing but not written to the production order.
(C) SAP AG
LO215
4-28
Material Requirements Planning (MRP)
Planning unit
MRP area: Plant
A Material
Planning run types
Processing key
Regenerative planning
NEUPL
Net change planning
NETCH
Net change planning in the short-term planning horizon
NETPL
© SAP AG 1999
Material requirements planning is executed at the level of the MRP area (plant, warehouse, ...). Regenerative planning means that you plan all materials from the planning file. Net change planning means that you can only plan materials which are already entered in the planning file and have therefore undergone a change relevant to MRP. Planning file entries can be generated either automatically or manually. Net change planning in the short-term planning horizon means that you can only plan materials that have already undergone a change relevant to MRP within a restricted planning horizon. You can only generate order proposals within the planning horizon. Planning can either be carried out online or in the background. Material requirements planning (MRP) is dealt with in detail in course LO210.
(C) SAP AG
LO215
4-29
Plnd order
Processing Goto
Extras
1000767
Header
Assignment Master Data
Components
Detailed sched.
Order type Quantity Dates Items
A Material
Required material - Quantity - Requirements date
Capacity req. records Capacity reqmts
t Periods Periods
- Operation - Work center - Reqmts date
© SAP AG 2003
R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3 R/3
Planned Order Structure
Planned receipt of the net requirements calculation for requirements coverage. Requirements transfer object for the dependent requirements. It can be used as a pegged requirement for capacity planning. It provides a data source for the production order.
(C) SAP AG
LO215
4-30
Multi-Level Materials Planning PlannedPlanned- Planned Salesindependent Salesrequirements E1
PLANNED ORDER
Dependent requirements
B1
B2
PLANNED ORDER
Dependent requirements
R1
R2
R3
PLANNED ORDER
© SAP AG 1999
Requirements planning covers a whole product structure. It runs in the following steps for each material. Checking the requirements coverage. Generating the planned order. Determining the dependent requirements. Entering the components into the planning file.
(C) SAP AG
LO215
4-31
MRP List
Contents MRP list
Purchase requisitions Planned orders
Header Material
Planning result
MRP parameters Net planning - Items Single item planning - Items Storage location planning - Items
© SAP AG 1999
An important result of material requirements planning is the MRP list. An MRP list is created for each MRP related material. Current stock and requirement situations are displayed as of the last planning run. The MRP list is subdivided according to different planning segments. Changes made between two planning runs are not displayed. Error messages are copied to a log.
(C) SAP AG
LO215
4-32
Current Stock/Requirements list
Stock/reqmts list Contents Header Material MRP parameters Net planning - Items Single item planning - Items
Material Material
Purchase requisitions Purchase orders Planned orders Sales orders Reservations Warehouse stock Production orders
Storage location planning - Items
© SAP AG 1999
A further result of material requirements planning is the current stock / requirements list. This list displays the current and therefore up-to-the-minute stock / requirements situation. You can generate the list dynamically by directly reading the MRP elements. From this list, individual planned orders can be converted to production orders.
(C) SAP AG
LO215
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Collective Conversion - Time-Oriented
Planned orders PD
Reqmts planning
t
PD
PS
x Days later
PO PS
Today
PO
Opening period
x Days earlier
Production orders Order Order header header
Purchase requisition
Operations
Materi al components
Prod. resour ces/tools
Costs
Planned Target Actual
100
20 50
© SAP AG 1999
You can convert planned orders online either individually, collectively, completely or partially. You can convert planned orders in the background using the program PPBICO40. Planned orders consist of a planned order start date (PS), a planned order finish date (PL) and a planned order opening date (PE). When the planned order opening date is reached, you should convert the planned order into a production order or a purchase requisition. When you convert a planned order into a production order, the planned order is deleted. The system reassigns the dependent requirements (material components) and any existing capacity requirements to the newly created production order. By changing an indicator, the dependent requirements can then be turned into a reservation. When a planned order is only partially converted, it remains intact and is fixed. You can perform a collective conversion that is dependent on the outcome of a material availability check (analogous to the order release).
(C) SAP AG
LO215
4-34
Converting Planned Orders - Time Frame
Opening period (from - to)
R1
B1 E1
R2 B2 R3
t Total lead time Current date © SAP AG 1999
The MRP controller uses the "collective conversion" function to convert the planned orders of a product structure falling within a set time period. In the framework of an entire product structure, the system will only convert those planned orders whose planned order opening dates are within a defined opening period. You can predefine the size of the opening period with reference to the current date in User Parameters (AEV, AEB). This procedure is particularly suited to deterministic make-to-stock production.
(C) SAP AG
LO215
4-35
Collective Conversion - Structure-Oriented
Prod. order 1
Prod. order 2 Prod. order 3
Preq
Prod. order 4
© SAP AG 1999
As an alternative to time-related collective conversion, the order progress report provides the "Convert planned orders" function for structure-related conversion. An order progress report is available in Release 4.5. It enables you to clearly chart the progress of all business transactions (in-house production and external procurement) that are required when carrying out a sales order or project, and to process them. Using this report, you can convert planned orders into production orders or purchase requisitions with the order structure in front of you. This procedure is particularly suited to make-to-order production. Refer also to the Information Systems unit.
(C) SAP AG
LO215
4-36
APO as a Planning Tool
R/3 R/3
SAP SAP BW BW
APO APO Supply Chain Cockpit
Historical Historical data data
Demand Demand planning planning Sales and distribution (sales orders)
Shop floor control (prod. orders)
Inventory management
Global Global ATP ATP
Production planning and detailed scheduling
Distribution Distribution
Key Key figures figures Supply Supply Network Network Planning Planning
External External Data Data (for (for example, example, ITEM) ITEM)
© SAP AG 1999
Instead of R/3 requirements planning (MRP), you can use the new SAP product: Advanced Planner and Optimizer (APO). This product is one of the SAP New Dimension products. APO enables a general, comprehensive portrayal, planning and monitoring of all processes in the logistics chain, right down to a detailed level. Open standard interfaces permit seamless integration of SAP Systems (highly-integrated solution for R/3), old systems and systems from external providers. LiveCache, an SAP technology for processing data in the memory, gives APO its high performance level. APO is an absolute planning machine. Inventory management, sales order creation and order execution and control (Manufacturing Execution) are carried out outside of APO, for example in the R/3 System. Orders (planned, production or process) can be created and changed as the result of planning with APO. APO and R/3 are connected by the APO Core Interface (CIF) Data is kept consistent on both sides (APO and R/3). Planning with APO is dealt with in detail in courses AP010 to AP230.
(C) SAP AG
LO215
4-37
Order Creation/Order Change: Summary
You have gained an overview of creating production orders. You can create production orders for various applications and using different resources. The most important creation variant is the conversion of planned orders. All different types of creating orders are needed during production. They come from real-life requirements.
© SAP AG 1999
(C) SAP AG
LO215
4-38
Order Creation/Order Change Exercises Unit: Order Creation / Order Change Topic: Creating an order without basic data (LO215 Exercise 2)
•
Learn about the dialog for creating and changing a production order.
As production manager, production scheduler or supervisor, from time to time you must create production orders for which there is no master data (routing, BOM). This is particularly the case if production has to carry out unplanned work, special requests and other tasks. In this exercise, you will become familiar with the dialog for creating or changing a production order. 1-1
Create an order using the following data: Material
T-MAN
Production plant
1000
Order type
PP01
Total amount
10 piece
Basic finish date
Any
Scheduling type
Backwards
Path: S000 → LO → PP → SFC → ORDER → CREATE
→ WITH MATERIAL A dialog box appears: Routing Selection T-MAN React to the system message: "No routing found" with → GENERATE OPERATION
(C) SAP AG
LO215
4-39
A dialog box appears: BOM Selection. React to the system message: "Do you want to explode a BOM for a different material?" with
→ No
A dialog box appears: Copy reference text? React to the system messages as follows:
→ Yes
1-2
Display the operation overview. Operation 0010 has already been created automatically. → GOTO → OVERVIEWS → OPERATIONS
Path: 1-3
Use the following data to create operation 0020: Work center no.
T-V##
Operation control key PP01 Setup time
1-4
Machine time
10 pieces per 30 mins
Labor time
10 pieces per 60 mins
Save the order.
Order no.:
_________________
→ ORDER → SAVE
Path: 1-5
10 min
Now change the order. Use the following data to enter an additional operation 0030. Work center no.
T-M##
Operation control key PP99 Setup time (C) SAP AG
10 min LO215
4-40
Machine time
10 pieces per 30 mins
Labor time
10 pieces per 60 mins
Path: S000 → LO → PP → SFC → ORDER → CHANGE 1-6
Add material components "T-T1##" and "T-T2##" to operation "0010" in any quantity. Use item category "L" for both.
Path:
Go to the operation overview and select operation "0010". In the menu bar at the bottom of the screen, select the COMPONENTS pushbutton
1-7
To operation "0020", add the production resource/tool "PP-FHMM". with any quantity. Path:
Go to the operation overview and select operation "0020". In the menu bar at the bottom of the screen, select the PRT pushbutton (production resources/tools) A dialog box appears: PRT New Entries Note that this production/resource tool has a material master. The window is set up accordingly. If you want to add other PRT categories, you must select the pushbutton at the bottom.
1-8
Execute a document link, by linking the order with document T-D##. Document no.
T-D##
Document type
DRW
Subdocument
000
(C) SAP AG
LO215
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Document version
00
Assign the document to operation 0010. Path:
1-9
1-11
Check the operation overview. 1-10
Carry out order costing (determine costs).
Path:
→ FUNCTIONS → COST
Display the costing result. Path:
1-12
Go to the document overview → GOTO → OVERVIEWS → DOCUMENTS
→ GOTO -> COSTS -> ITEMIZATION
Save the order. Path:
(C) SAP AG
→ ORDER → SAVE
LO215
4-42
Order Creation/Order Change Exercises Unit: Order Creation / Order Change Topic: Creating an Order with Basic Data (LO215 Exercise 3)
• Routing and BOM selection • Production versions in a production order • Reading master data
As production manager, production scheduler or supervisor, as a rule, you create production orders on the basis of master data (routings, BOMs), which has been created and is maintained in the areas of engineering and work scheduling in your company. This is particularly the case when the production of materials and activities is of a repetitive nature. In this exercise you become acquainted with the way in which the SAP System searches for and selects the master data that is valid for a production order. 2-1
Create an order using the following data: Material
T-F1##
Production plant
1000
Order type
PP01
Total amount
1 piece
Basic finish date
Any
Scheduling type
Backwards
Path: S000 → LO → PP → SHOP FLOOR CONTROL → ORDER → CREATE → WITH MATERIAL 2-2
What is the validity date of the BOM and the routing in the production order?
(C) SAP AG
LO215
4-43
Answer: Path:
2-3
__________________ GOTO → HEADER → Select the tab MASTER DATA
Compare the explosion date with the basic dates of the production order. Which date corresponds to the explosion date? Answer: Path:
2-4
________________________ → Select the tab GENERAL
Release and save the production order. Order number: Path:
2-5
_____________________
→ FUNCTIONS → RELEASE
In operation "0010", change the routing of material "T-F1##". In the operation, enter a minimum wait time of 10 minutes and save the change. Path: S000 → LO → PP → MASTER DATA → ROUTINGS → ROUTINGS → CHANGE
→ GOTO OPERATION OVERVIEW → Select the operation → DETAILS → OPERATION DETAILS → here, see field group INTEROPERATION TIMES 2-6
In your production order, execute the Read PP master data function. Path:
(C) SAP AG
→ FUNCTIONS → READ PP MASTER DATA
LO215
4-44
A dialog box appears: Read PP Master Data Here, you have the option of reading the routing and/or the BOM again and of redetermining the explosion date. Caution: The system resets the status of your production order to Created.
2-7
In your production order, ensure that the change was successful. Ensure that operation "0010" now contains a minimum wait time. → OPERATION → OPERATION DETAIL
Path:
→ Select the tab → INTEROPERATION TIMES 2-8
Create another order using the following data: Material
T-B4##
Production plant
1000
Order type
PP01
Total amount
1 piece
Basic finish date
Any
Scheduling type
Backwards
Path:
S000 → LO → PP → SFC → ORDER → CREATE
→ WITH MATERIAL A dialog box appears: Select Production Version for Material T-B4## ......... You can use a production version to define fixed processes (routing and/or BOM alternatives) according to which production is to be carried out, when required. In the next steps in the exercise, you should find out about the contents of the various production versions before you make a selection. 2-9
Check which production versions are maintained for the material master. Path:
(C) SAP AG
To do so, in the dialog box select the pushbutton LO215
4-45
→ VERSION OVERVIEW 2-10
Display the detail data for the existing production versions and answer the following question: Path:
To do so, in the dialog box select the pushbutton → DETAILS
2-10-1 Why does the system only offer production version 0001 for selection for the production order? Answer: 2-11
_______________________________________________
The order is to be created according to production version "0001", which has been prepared in the material master. Carry out the necessary steps for this. Path: → In the dialog box Selection of Production Versions select production version 0001 and select the pushbutton → SELECT
2-12
Ensure that the production version used in the production order is correct. Path:
GOTO → HEADER → Select the tab ASSIGNMENT
2-13
Save the order
2-14
A production version can be changed afterwards with the READ PP MASTER DATA function. In your order, try to swap Production version ‘0001’ Production version ‘0002’
with the new
You can only carry out this exchange if you enter the number of the production version directly. For the reasons mentioned above, the system offers only version 0001 for selection.
(C) SAP AG
LO215
4-46
Path:
(C) SAP AG
→ FUNCTIONS → READ PP MASTER DATA
LO215
4-47
Order Creation/Order Change Exercises Unit: Order Creation / Order Change Topic: Order Creation with Planned Orders (LO215 Exercise 4)
• Creation of independent requirements • Material Requirements Planning (MRP) • Conversion of planned orders into production orders • Partial conversion of planned orders • Background processing for planned order conversion Your company consistently uses automatic requirements planning in the SAP System. As production manager, MRP controller or production scheduler, you therefore create large numbers of production orders based on planned orders that have been created automatically during the planning run. In this exercise you create planned orders and convert them (in various ways) to production orders. 3-1
In this first step in the exercise, you set up the user interface and functions of the stock/requirements list for the steps to follow. The stock/requirements list is a very important tool in the SAP System for the daily work of the MRP controller and production scheduler. As of Release 4.6, this list has a very flexible design.
Path: S000 → LO → PP → SFC → CONTROL → STOCK/REQUIREMENTS LIST 3-1-1 Select the tab INDIVIDUAL ACCESS and select with
(C) SAP AG
Material
T-F1##
Plant
1000 LO215
4-48
3-1-2 Assign yourself the navigation profile of the production scheduler. ENVIRONMENT → NAVIGATION PROFILE → ASSIGN
Path:
A dialog box appears: Settings for User ..... with several individual screens (tabs). You are immediately on the tab: GENERAL SETTINGS and enter the following values: Checking rule for ATP display Navigation profile
PP
LO215
Save the settings 3-2
Check the stock and requirements situation for the materials 'T-F1##'
finished product
'T-B3##'
assembly
and
Make a note of the current stocks:
3-3
'T-F1##'
_______________________ and
'T-B3##'
_______________________
Use the demand management menu to enter the following planned independent requirement for the next 3 months. Use the following data
(C) SAP AG
Material
T-F1##
Plant
1000
Version
00
Planning period
Copy predefined setting without changing them.
LO215
4-49
Requirements parameter (Select the pushbutton!) Default values Plant
1000
Requirement type
LSF
Display Period split Active
activate Set switch
Overview
Planning table
activate
Material
Quantity (pieces)
Requirements date (month/year)
T-F1##
100
_____ / ______
T-F1##
50
_____ / ______
T-F1##
150
_____ / ______
Path: S000 → LO → PP → DEMAND MANAGEMENT → PLANNED IND. REQMTS → CREATE 3-4
Using the distribution function in the planning table, set the requirements to week format and save the planned independent requirements. Path: Select the tab SCHED.LINES → enter the intended value in the DISTRIBUTION column.
3-5
For product T-F1##, use both of the following paths to create a sales order, each one with an order quantity of 1 piece . Save the sales order and note the order number and item. 3-5-1 Demand management (use the following requirements parameters)
Desired delivery date Any Requirement type
KE
Delivery plant
1000
(C) SAP AG
(make-to-order production)
LO215
4-50
Path: S000 → LO → PP → DEMAND MANAGEMENT → CUSTOMER REQUIREMENTS → CREATE Order no.:
________________________________
____________
3-5-2 Sales (use the following requirements parameters)
Order type
OR
(standard order)
Sales organization
1000
Distribution channel
10
(final customer sales)
Division
00
(cross-division)
Sales office
1000
(Frankfurt)
Sold-to-party
1000
(Becker Berlin)
Goods recipient
1000
(Becker Berlin)
Purchase order number
GR##_001
Desired delivery date
Current date + 1 month
Path: S000→ LO → SD →SALES → ORDER → CREATE If the system suggests a different delivery date, confirm it by selecting the symbol.
Order no.: 3-6
________________________________
____________
For product T-F1##, carry out single item multi-level MRP. Use the following entries to do this: Processing key
NETCH
Create purchase requisition
3
(planned orders only)
Schedule line
1
(none)
Create MRP list
1
(always)
Planning mode
1
(normal mode)
Scheduling
2
(lead time scheduling)
(C) SAP AG
LO215
4-51
Do not activate any of the other switches! Path: S000 → LO → PP → MRP → PLANNING→ SNG-ITEM, MULTI-LVL 3-7
Check the stock and requirements situation for the materials T-B1## to T-B3## T-T1## to T-T4##
and
In the next steps in the exercise, you convert planned orders to production orders using different methods. If there are not enough planned orders available, create more of them yourself. Do not use the planned orders that have been created for the sales orders first. 3-8
For material T-F1##, select a planned order with an order quantity that is more than 1 piece. Number of the planned order. _________________ 3-8-1 Convert this planned order into several production orders with any partial quantities and dates. To do so, use the path via the stock/requirements list. Path: S000 → LO → PP → SFC → CONTROL → STOCK/REQUIREMENTS LIST Double-click the planned order to select it → Select the pushbutton
-> PartProdConvOrder →
Change the proposed target quantity → Select the pushbutton NEW ENTRIES Generate and then save the production order. 3-8-2 What can you say about the "remaining" planned order? Answer:
______________________________________________ ______________________________________________
(C) SAP AG
LO215
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3-8-3 Convert this (remaining) planned order to a production order with the full remaining quantity. To do so, use the path via the stock/requirements list. Path: S000 → LO → PP → SFC → CONTROL → STOCK/REQUIREMENTS LIST Double-click the planned order to select it → Select the pushbutton
-> PRODORDER
Does the converted planned order still exist? Answer:
_______
3-8-4 For the last production orders that you created, check the "Assignment" tab on the header screen. The planned order number is still visible here!
3-9
Select another planned order for material T-F1## . Number of the planned order. _________________ Convert the planned order with the entire quantity. To do so, use the path via the shop floor control menu. Path: S000 → LO → PP → SFC → ORDER → CREATE → FROM PLANNED ORDER
(C) SAP AG
LO215
4-53
3-10
Convert several planned orders simultaneously into production orders. Use the collective conversion path. Restrict the selection date (one month before or after the current date). Select the planned orders to be converted using the following parameters: MRP controller 0## Material
T-F1##
Order type
PP01
Note the numbers of the converted planned orders. Planned order no.: ___________
Production order no. ________________
Planned order no.: ___________
Production order no. ________________
Planned order no.: ___________
Production order no. ________________
Path: S000 → LO → PP → SFC → ORDER → CREATE → COLLECTIVE CONVERSION OF PLANNED ORDERS In the list screen of the planned orders, select the orders that are to be converted and select the CONVERT pushbutton. The next activities in the exercise are optional. Only carry this out if you have enough time.
3-11
Now use the path via the order progress report for collective conversion with reference to the sales-order. Convert all planned orders for the sales order from step 3-5-2 together into production orders . Sales order no.:
_________________________
(You will find the order number in the stock/requirements list) Path: S000 → LO → PP → SFC → INFOSYSTEM → ORDER PROGRESS REPORT Use the overall profile PP0000000001 Use the pushbutton to select the planned orders Convert with (C) SAP AG
LO215
4-54
→ FUNCTIONS → CONVERT PLANNED ORDERS Refresh the report and check that production orders have been created. 3-12
Convert all planned orders still existing for material T-F1## into production orders using background processing. Path: S000 → LO → PP → SFC → TOOLS → SCHEDULE BACKGROUND JOBS → CREATE WITH PLANNED ORDERS Use the following data: Job name
GR##_001
Job category
A
Variant
GR##_PAUF The job variant must be created beforehand using transaction SE38. When you do this, use the same data as for collective conversion in step 3
Start prerequisite
Immediately (Save!)
Print specifications
P542 (Save!)
Save the job and check whether your planned orders have been converted.
(C) SAP AG
LO215
4-55
Order Creation/Order Change Exercises Unit: Order Creation / Order Change Topic: Other Variants for Order Creation (LO215 Exercise 5)
• Explain the basic features and additional variants for creating production orders
Not all orders that are to be executed in production are for maketo-stock production or for the production of material. As production manager, MRP controller or production scheduler, you must sometimes carry out unplanned special orders in varying forms. The SAP System provides you with different options for producing these special cases using production orders. 4-1
Create a new production order with reference to the sales order from the previous exercise (with any quantity and schedule). Use order type PP01. Save the order.
Order no.: __________________
Path: S000 → LO → PP → SFC → ORDER → CREATE → FOR SALES ORDER 4-2
Check the order header data Assignment Settlement rule Path: → GOTO → HEADER → Select the ASSIGNMENT tab and → HEADER → SETTLEMENT RULE
(C) SAP AG
LO215
4-56
4-3
Use a reference production order from the previous exercise (‘copy from’ function) to create a new production order with material. Save the order Order no.: __________________ Path: S000 → LO → PP → SFC → ORDER → CREATE → WITH MATERIAL→ In the "Copy from field", enter the order number only Check: the order header data (master data) operation overview component overview costs overview scheduling result
4-4
Create a new production order for a service without reference to material (any quantity and schedule). Weg:
S000 → LO → PP → FS → AUFTRAG → ANLEGEN → OHNE MATERIAL A dialog box appears: Routing selection. React to the system message: "No routing found" with → REFERENCE OPERATION SET
A dialog box appears: ENTER REFERENCE OPERATION SET Use the reference operation set (task list group) 50000000
4-4-1 Assign the production order to cost center 4220. Set the account assignment category to 100% and select the settlement type full settlement. 4-4-2 Make any changes or additions to the order that you like. 4-4-3 Save the order.
(C) SAP AG
Order no.: __________________
LO215
4-57
Order Creation/Order Change Solutions
Unit: Order Creation / Order Change Topic: Creating an order without basic data (LO215 Exercise 2)
No answers are required for this exercise.
(C) SAP AG
LO215
4-58
Order Creation/Order Change Solutions Unit: Order Creation / Order Change Topic: Creating an Order with Basic Data (LO215 Exercise 3)
2-2
Answer:
__________________ (Select the tab MASTER DATA in the order header and read the Explosion date)
2-3
Answer:
Order start date
2-10-1 Answer: Only this production version has a lot-size range that includes the order quantity.
(C) SAP AG
LO215
4-59
Order Creation/Order Change Solutions Unit: Order Creation / Order Change Topic: Order Creation with Planned Orders (LO215 Exercise 4)
3-8-2 Answer:
3-8-3 Answer:
(C) SAP AG
This planned order is "fixed" and is assigned the remaining quantity as order quantity No
LO215
4-60
Order Creation/Order Change Solutions Unit: Order Creation / Order Change Topic: Other Variants for Order Creation (LO215 Exercise 5)
No answers are required for this exercise.
(C) SAP AG
LO215
4-61
Order Release: Contents
Functional steps for "Releasing an Order" Status Management System status User status
Availability checks Material components Capacity Prod. resources/tools
Missing parts backlog processing
© SAP AG 1999
(C) SAP AG
LO215
5-1
Order Release: Course Objectives
At the conclusion of this unit you will be able to: Describe the different types of production orders and understand why order release is necessary Describe the functional steps involved in 'Releasing an Order' Define status management (system status, user status) and explain how it can be extended Understand availability checks material components, capacity, production resources and tools
Determine and process missing parts Understand backorder processing
© SAP AG 1999
(C) SAP AG
LO215
5-2
Overview Diagram (5)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
(C) SAP AG
LO215
5-3
Order Release Functions
Order header
Order Creation
Operations Operations
Material Material components components
Machine Usage Prod. Prod. resources/tools resources/tools Costs Costs
Planned Planned Target Target Actual Actual
100
20 50
Availability Check
Order Release
Print documents
Material withdrawal
Processing
Confirmation
Goods receipt
Settlement
© SAP AG 1999
Order release is the basis for further processing of the production order (printing order documents, material withdrawal and so on). Production orders are managed using statuses. The corresponding status is set when the order is released. An availability check can be carried out automatically. Single operations, entire orders or several orders can be released simultaneously. There is a corresponding function available for the mass release of operations or orders (refer to the unit "Mass Processing and Automation")
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LO215
5-4
Status Management Application Control of the business transactions in a production order Order, operation, material component, PRT Status type System status User status System status Internal system status Cannot be influenced by the user Fixed quantity of predefined statuses Fixed sequence for the assignment of status User status
Order type
Freely definable, with no limit to the amount Set by the user Linked via status profile © SAP AG 1999
A status can allow, allow with warning or disallow business transactions. A system status is set or deleted by a transactions in relation to an object. System statuses can neither be set nor deleted by a user status. Status management is used similarly in many different applications (CO internal orders, maintenance orders, PS networks and so on). Statuses always refer to a status object (order header, order operation, production resource / tool, component). It is possible to log changes in status (see creation of change documents for order category) System control can be practically enhanced using the user status. There are various transactions for status maintenance: BS02 Status profile (user status) BS12 Object type (only for SAP) BS22 System status (only for SAP) BS32 Business transactions (only for SAP)
(C) SAP AG
LO215
5-5
System Status and User Status
Ord Order er hheader eader
Operations
Materi al components
System status
User status
Prod. resour ces/tools
Costs
Planned Target Actual
100
20 50
Created
Release Printed Confirmed Delivered
Checked
Material availability
Checked
Capacity availability
Checked
PRT availability
Check Release Release
Documented Possible Locked
Final costing Rework
Deleted © SAP AG 1999
User statuses enhance the system's status management capabilities. You can prepare user statuses in Customizing.
(C) SAP AG
LO215
5-6
Availability Check for Material W/H 3
Scope of Check A Material
Order type
A Material
Checking Group
W/H 2
Checking Rules
Requirements qty/ date
A Material
W/H 1
Check Control for Production Orders
A Material
Result of Check Time 1
Creation
Committed qty
Time 2 12 11 1 10 2 9 3 8 4 765
12 11 1 10 2 9 3 8 4 765
Change
Release
Missing parts record (index) MSPT status (missing part)
Processing
Confirmation
Goods receipts
© SAP AG 1999
Availability checks are controlled using multi-part validation rules. You need to define validation rules for the individual applications (requirements planning, sales and distribution order management and so on). This must be done in Customizing. Validation rules incorporate various elements: Checking group Assignment in the material master (MRP data screen 3) Checking rule Assignment to the order type Checking scope Defining the checking details for each checking rule and checking group Checking times can be set manually or automatically for: order creation Order Release Reading master data Save (change) Checking variants Individual components of an order All components of an order Several orders (collective orders or mass processing function) Results of the check Assignment of the confirmed quantity (partial quantities can also be confirmed) Status missing part Missing parts record
(C) SAP AG
LO215
5-7
Check Procedure ATP Receipts
+200 (B) 3 +100 (A) 3
2
1 1 2
-50
-100
1
3 3
2 -200
Issues
Element PRORD RESERV PLORD RESERV DEPREQ
covered by the master production } Not schedule
3
Receipt quantity 100 B 200 -
Issue quantity
A
1 2 3
ATP qty
50 100 200
50 200 -
1
ATP qty 50 100 -
2
ATP qty
3
-50
© SAP AG 1999
A dynamic check of all receipt and issue elements is carried out. Checking procedure: calculation of the ATP quantities (ATP = Available to promise). Checking period: the whole time period. It can, however, be limited to the total replenishment lead time (material master). On the basis of the ATP quantity, the MRP controller can determine whether all issues are covered by the production plan and which part of the warehouse stock or master production schedule is still available for new issues. Planned independent requirements are not taken into account when capacity leveling is performed.
(C) SAP AG
LO215
5-8
Controlling the Availability Check for Material
Check Control for Production Orders
Order type
Order-specific determination of a checking rule Determination controlled by a bus.trans. (creation, release) Activating/deactivating the availability check Controlling the order release option in the case of material shortfall Checking Rules Assigning a checking rule to an application
Checking Group
A
Assigning a checking rule to a material
Material
Scope of Check Limiting the time period for the availability check Determining the elements to be included in the check © SAP AG 1999
You can control availability checks independently of the order type and operation (order creation or release). It is only possible to check materials that are part of a checking group (material master). The scope of the check specifies the elements to be included in the check (planned orders, production orders, purchase orders and so on).
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LO215
5-9
Controlling the Availability Check for Capacity
Check Control for Production Orders Order type
Determining a checking rule depending on order type Determination controlled by a bus.trans. (creation, release) Activating/deactivating the availability check Controlling the order release option in the case of a capacity deficit Checking Rules Basic load checks ( Indicator 'Capacity available') Profile SAPSFCG013 Check only capacities with indicator 'Relevant for finite scheduling' Result of Check Indicator 'Capacity available' Status MSCP (capacity shortage) © SAP AG 1999
Availability checks are controlled using multi-part validation rules. You must specify the multi-part validation rules for production orders in Customizing. Validation rules incorporate various elements: Checking profile Overall profile for capacity evaluation Capacity scheduling indicator Assignment in the capacity (capacity header screen). Checking times are set manually or automatically (on order creation and / or order release). Checking variants An order Checking result Anindicator is set internally, which at the same time indicates that the capacity requirement is part of the basic load. Checking procedure Comparison of the available capacity with the capacity requirements of the basic load If a capacity shortage is determined in a work center for at least one operation, the entire order can be rescheduled using the "Capacity scheduling" function. The basic load is defined with the report RCCYLOAD.
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LO215
5-10
Availability Check for PRT
Check Control for Production Orders Order type
Determining a checking rule depending on order type Determination controlled by a bus.trans. (creation, release) Activating/deactivating the availability check Controlling the order release option in the case of a PRT deficit Checking Rules Material stock and material status checks Document status checks PRT status check (Miscellaneous PRT) Result of Check Status MSPR (PRT shortage) © SAP AG 1999
You can activate the check according to order type and business transaction (order creation, order release). Checking times Set manually or automatically (on order creation and / or order release). No inventory management exists for PRT, therefore it is checked according to the PRT category against the following statuses: Material / PP statuses Document statuses PRT statuses As long as the status is not locked, the PRT is considered to be available. For material-related PRTs, it is possible to run the availability check against the material's unrestricted-use stock. Checking variants All PRTs of an order individual PRTs of an order Checking result Status PRT shortage
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LO215
5-11
Order Release: Summary
You have gained an overview of releasing production orders A production order is controlled by status management You know the availability check options for material components, capacity, production resources/tools Situations where parts are missing can be determined using the missing parts list Backlog processing enables you to change confirmed quantities from reservations
© SAP AG 1999
(C) SAP AG
LO215
5-12
Order Release Exercises Unit: Order Release Topic: Order release, status management, availability checks (LO215 Exercise 6)
• Availability check •
Status Management
• Release of individual operations and orders •
Mass release
As production manager or production scheduler, you must release production orders so that material preparation, printing of shop floor papers and production itself can begin. As a rule, you use the mass release function to do this. In exceptional cases, you release individual orders (operations). Before release, you should execute availability checks (material, capacity, PRT) to ensure that production can proceed without any problems. 1-1
Display all existing production orders for material "T-F1##" with the stock/requirements overview.
1-2
Select an order that has not yet been released for the exercises to follow. Order number: _______________________
1-3
Check the material availability of material T-B1##. Path:
S000 → LO → PP → SFC → ORDER → CHANGE → GOTO → OVERVIEWS → COMPONENTS Here, select the component. Continue with
→ COMPONENT → AVAILABILITY → CHECK AVAILABILITY 1-3-1 Which checking rule and checking group are used for the availability check?
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LO215
5-13
Answer:
Checking Rules
______
Checking group
______
Path: Select the pushbutton → SCOPE OF CHECK 1-3-2 Did the system check availability as per replenishment lead time? Answer: 1-4
________
Check the availability of the production resource/tool "PP-FHMM" of operation "0050". Path:
Go to the operation overview and select operation "0050". In the menu bar at the bottom of the screen, select the PRT pushbutton (production resources/tools)
→ Here, select the PRT and continue with
→ PRODUCTION RESOURCE/TOOL → AVAILABILITY PRT 1-5
In each case, release operation 0010. Save the release. Path: Select the operation and proceed as follows: RELEASE
1-6
→ OPERATION →
Display the status of the production order and the operations. What is the new status of the production order? Answer:
(C) SAP AG
________________________
LO215
5-14
1-7
Check the availability of capacity for the entire order. Path:
→ FUNCTIONS → AVAILABILITY CHECK → CAPACITY AVAILABILITY
1-8
Now check the material availability of the entire order. What is the new status of the production order?
1-9
Answer:
_______________________________________________
Path:
→ FUNCTIONS → AVAILABILITY CHECK → MATERIAL - ATP
Use the user status function in the central header to document that you have carried out all availability checks. Set the status: 1-9-1 Material availability checked 1-9-2 Capacity availability checked 1-9-3 PRT availability checked 1-9-4 Checks documented Caution: Status refers to user status. You must therefore select (set) each status individually and manually.
Path: 1-10
Now release the entire order. Save the order. Path:
1-11
→ Select this symbol (pushbutton)
→ FUNCTIONS → RELEASE
Ensure that the system has released the production order.
(C) SAP AG
LO215
5-15
1-12
Use the missing parts information system to determine whether there are missing parts in plant 1000 for the orders of your production scheduler number 0##. Select the material view profile. Path: S000 → LO → PP → SFC → INFOSYSTEM
→ MISSING PARTS INFORMATION SYSTEM 1-13
Carry out a collective release for all orders of your production scheduler number 0##. If no additional production orders are available, simply create a new production order for material T-F1##. Note the date selection entries that are proposed by the system and change them if necessary.
Path:
S000 → LO → PP → SFC → CONTROL → COLLECTIVE RELEASE
1-13-1 Select the tab Selection and select using the following parameters: Plant
1000
Order type
PP01
Production scheduler
0##
1-13-2 Select the tab Mass processing - release and carry out the following settings: Function
Release Execute function immediately
Function parameter 1-13-3
Path:
(C) SAP AG
Order Release
Select any production orders and start the release (mass processing)
→ MASS PROCESSING → EXECUTE
LO215
5-16
1-13-4 Check the release log for possible errors Path:
→ MASS PROCESSING → LOG of last MP or → pushbutton ORDER
(C) SAP AG
LO215
5-17
Order Release Solutions Unit: Order Release Topic: Order release, status management, availability checks (LO215 Exercise 6)
1-3-1 Answer:
Checking Rules
Checking group
‘PP’
‘02’
1-3-2 Answer:
No
1-6
Answer:
PREL (partially released)
1-8
Answer:
MACM (material committed) or MSPT (material shortage)
(C) SAP AG
LO215
5-18
Printing Order Documents: Contents
Overview of standard documents Overview of print control Sequence of functions for "Printing orders"
© SAP AG 1999
(C) SAP AG
LO215
6-1
Printing Order Documents: Course Objectives
At the conclusion of this unit you will be able to: Describe the control options and variants for printing production documents Explain how to use the print functions
© SAP AG 1999
(C) SAP AG
LO215
6-2
Overview Diagram (6)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
(C) SAP AG
LO215
6-3
Overview of Document Printing Module pool: SAPLCODR
Order header
Operations Operations
Preparing the shop papers
Material Material components components
Prod. Prod. resource resources/tools s/tools Cost Costss
Planned Planned Target Target Actual Actual
100
20 50
Control tables Document Type Lists Layout set Reports Transactions Output devices Print processing
ITAB Layout sets
ABAP Reports ID REPORT LG01 PSFCOBJL
SAPSCRIPT Layout set PSFC_STD_LAYOUT
SPOOL
Report group PSFCxxxx
SP01 Spool control © SAP AG 1999
You can print production order documents online, in the background or during updating (status update). You can control printing in different ways: during processing of the production order using a program (job)using a mass processing function (see the corresponding unit) Two programs are available to you for background processing: Printing flagged orders (PPPRBTCH) (*) Selecting and printing orders (PPPRBSEL) Print formatting is carried out by ABAP reports from the internal buffer tables (ITAB). You predefine the layout sets for the individual documents using SAPSCRIPT (layout set PSFC). SAPSCRIPT provides two editors (graphical and alphanumerical) for designing the forms The documentation for the Form Painter is in the SAP library (online documentation). Choose BASIS COMPONENTS -> BASIS SERVICES/COMMUNICATION INTERFACES -> SAPscript -> STYLE AND FORM MAINTENANCE -> DESIGN TOOLS. Print documents can be triggered automatically upon release via the production scheduling profile. (*) No longer to be found in the menu, because mass processing is provided.
(C) SAP AG
LO215
6-4
List Types for Order Documents
Object list
Reports
Layout sets
PSFC_OBJ_LIST
PSFC_PRINTPSFC_PRINT-LAY
Control ticket
PSFCOPCT
Job ticket
PSFCJOBT
PSFC_STD_LAYOUT
Time ticket
PSFCTIME
PSFC_STD_LAYOUT
Confirmation slip
PSFCCONF
PSFC_STD_LAYOUT
Material staging list
PSFCPICK
PSFC_STD_LAYOUT
Goods issue slip
PSFCGISS
PSFC_STD_LAYOUT
PRT overview
PSFCPRTL
PSFC_STD_LAYOUT
Kanban card
PSFCKANB
PSFC_KANBAN
Document distribution
PSFC_STD_LAYOUT
PSFC_DOCLINK_DIST
DDS_COVER_PLO
© SAP AG 2003
A variety of different standard lists are available. These lists are compiled by list-specific ABAP reports. The user can generate additional lists. A maximum of 20 lists can be generated per order. You use the document distribution to plot document originals.
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LO215
6-5
Print Control Print mode Original print Reprint
Selection Plant MRP controller Order type Order (from/to)
Material Dates (Release and prod.start/finish date from/to) Order status (System/user status) Production scheduler
Control tables Lists Spool parameters Ref. order categories Layout sets Printing programs Transactions Determination of printer Print processing Table access
X X X X X
© SAP AG 1999
The system differentiates between two print modes: original print and reprint Original printing an order prints all released operations and their objects (material components, PRT and so on). If an order has already been partially printed, original printing automatically prints only those objects of the order that have not already been printed. Reprinting an order reprints all operations that have previously been printed. You can maintain the settings in Customizing. The settings marked "x" are dependent on plant and therefore need to be taken into account when the system is installed. You can mask the key to the table settings (exceptions: print variants and reference document type). You can condense numerous external order types into a single internal order type using a reference order type to enable joint control of order types (reports, layout sets, transactions and output devices). Some changes to settings can be made even upon printing. The Customizing settings that are valid for a user and a transaction can be controlled using a report.
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LO215
6-6
Printing Operations
Production order Op. 10
Op. 20
Op. 30
Operation control key CTRL
Print
Time ticket
'
' Do not print ' ' Print
© SAP AG 1999
The operation control key determines the printing output of an operation. You can deactivate operation control checking in Customizing. Operations are only printed as time tickets when: the number of time tickets > 0 the operation control key time ticket = ' '
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LO215
6-7
Printing Confirmation Slips Production order Op. 10
Op. 30
Op. 20
Operation control key CTRL
Confirmation
Print
11
'
' Do not print ' ' Print 1 Milestone 2 Normal
© SAP AG 1999
Confirmation slips are generated for operations whose operation control key has been set to confirmation = '1' , '2' or ' ' and confirmation print = ' ' is selected
(C) SAP AG
LO215
6-8
Printing Order Documents: Summary
You have gained an overview of printing production documents Standard documents are supplied for production orders The user is usually not required to make any special changes to the standard settings for customizing
© SAP AG 1999
(C) SAP AG
LO215
6-9
Printing Order Documents Exercises Unit: Printing Order Documents Topic: Printing Order Documents (LO215 Exercise 7)
Checking print control •
Printing order papers
As production scheduler, you give the work list to the work center in the area that you are responsible for. If the work list is to be given to the employees in the form of printed order papers, then you must use the printing functions of the SAP System. The order papers are often created in the form of a mass print job that is processed in the background. This is usually carried out at night for the following day. If necessary, however, you must also print or reprint individual papers. 1-1
Open an unreleased order for material T-F1## for the following exercises. Order number: ___________________
1-2
Check the individual operations and record the following data:
Operatio Print Operation? n Yes
No
Print Time Tickets? Yes
No. of TT No
Print Confirmations? Yes
No. of C
No
0010 0020 0030 0040 0050 0060 Key: TT = Time tickets C = Confirmations (C) SAP AG
LO215
6-10
Path: Use the operation control key and the detail screens to perform the check. 1-3
Release operation 0010 and save the production order.
1-4
Print the order documents for operation '0010'. Path: Select the printing path for the individual order Path: → FUNCTIONS → PRINT
1-5
Display the status of the production order and the operation 0010.
1-6
Use transaction SP01 to display the print result. Check the list manually. Path: S000 → SYSTEM → SERVICES → OUTPUT CONTROL Select the tab SPOOL ORDERS and start
→ SELECTION → EXECUTE Note that the right-hand scroll bar only works for a single page. If there are several pages, you can reach them using the function (scroll)
→ Select each individual spool number in sequence and display the print result for each one. 1-7
Now release the complete order and print it out in its entirety. Select the same printing path as in the preceding exercise step.
(C) SAP AG
LO215
6-11
1-8
Use the mass processing function to print any other order. Path: S000→ LO →PP→ SFC → ORDER → PRINT 1-8-1 Select the tab Selection and select using the following parameters: Plant 1000 Order type
PP01
Production scheduler 0## Selection profile status
PP00008
1-8-2 Select the tab MASS PROCESSING - PRINT and carry out the following settings: Function
Printing order papers
Execute function immediately Function parameter
Original print
The print function "Original print" prints all released operations in an order that have not been printed.
1-8-3 Use the proposed list selection and definition of the printer.
→ Start the selection. 1-8-4 Select any production orders
→ Start printing.
(C) SAP AG
LO215
6-12
1-8-5 Check the printing log for possible errors Path: → MASS PROCESSING → LOG of last MP or → pushbutton ORDER 1-8-6 Use transaction SP01 to display the print result. Check the list manually. 1-9
Create a copy (reprint) for the order from step 1-1, but only for the job ticket. Print job ticket from the individual production order. Path: → Change the order and carry out the necessary settings by choosing → ORDER → SETTINGS → LIST CONTROL
→ Here, select only the job ticket. 1-10
Use transaction SP01 to display the print result. To do so, carry out the same procedure as in step 1-6.
The next activity in the exercise is optional. Only carry this out if you have enough time.
(C) SAP AG
LO215
6-13
1-11
For the same order from step 1-9, create a copy (reprint) of the time ticket for operation 0010. When you do this, select the printing path using mass printing. Path: S000→ LO →PP→ SFC → ORDER → PRINT 1-11-1 Select the tab Selection and select using the following parameters: List
Operations
Profile
000002
Order
________________
1-11-2 Select the tab MASS PROCESSING - PRINT and carry out the following settings: Function
Printing order papers Execute function immediately
Function parameter
Reprint
→ Start the selection. 1-11-3 Select your production order
→ Start printing. 1-12
Use transaction SP01 to display the print result. To do so, carry out the same procedure as in step 1-6.
(C) SAP AG
LO215
6-14
Printing Order Documents Solutions Unit: Printing Order Documents Topic: Printing Order Documents (LO215 Exercise 7)
1-2 Operatio Print Operation? n Yes
No
Print Time Tickets? Yes
No. of TT No
Print Confirmations? Yes
No. of C
No
0010
x
x
1
x
1
0020
x
x
1
x
1
0030
x
x
1
x
1
0040
x
x
1
x
1
0050
x
x
1
x
1
0060
x
x
1
x
1
Key: TT = Time tickets C = Confirmations
(C) SAP AG
LO215
6-15
Material Staging: Contents
Special material components Picking (warehouse preparation) Default issue storage location in the production order Material withdrawal variants (planned, unplanned, surplus, deficit, backflushing, cancellation)
© SAP AG 1999
(C) SAP AG
LO215
7-1
Material Staging: Course Objectives
At the conclusion of this unit you will be able to: Define the special features of the various material component categories List the different options in the R/3 system (material master, BOM item, work center, automatic stock determination) for defaulting an issue storage location in a production order Describe the different material staging options
© SAP AG 1999
(C) SAP AG
LO215
7-2
Overview Diagram (7)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
(C) SAP AG
LO215
7-3
Material Components in Production Orders: Data and Functions General Data Item categories Quantities Requirements qty Committed qty Issue quantity Reqmts date Reservation data Special indicators Status
Functions Reservation Default storage location Calculation of variable-size item quantity Availability check for material Discontinued parts Batch determination
© SAP AG 1999
You use a range of data to control each material component: Item category status of the component Quantities reservation number and a series of indicators with control functions. Several functions exist for material components.
(C) SAP AG
LO215
7-4
Item categories
Item categories
L
N
R
T
D
I
O
M
Material number
+
.
+
-
-
+
.
+
Inventory management
x
x
Text item
x
Variable-size item
x
Document item
x
Class item
x
Intra material
x
PM structure document
x
(+/-) sign before quantity
.
.
+
Sub-item permitted
x
x
x
Item screen sequence control
1
3
2
+
+
+
+
.
x 1
1
1
1
© SAP AG 1999
The following item categories are accounted for in the standard version: L = Stock item N = Non-stock item R = Variable-sized item T = Text item D = Document item I = Plant maintenance structure element K = Class item M = Intra material (only for recipes PP-PI) The following are relevant for production orders: L, N, R, T, D, K + / sign control: + positive only - negative only . both admissible Item categories are configured in Customizing. Document items are not copied to the production order, instead a document link is created.
(C) SAP AG
LO215
7-5
Item Control Indicators
Screen
Item indicators
Function control
S
Bulk material
Overhead material
G
Discontinued
Discontinued parts
A
Backflush
Automatic withdrawal posting
G
Co-product
Planned co-product
G
Alternative
Alternative item
S
Relevancy ind. (status)
Production, engin./design, costing
S
Material provision, spare part
Material provision, spare parts
G
Phantom
Phantom assembly
G
Fixed quantity
Requirements qty fixed lot size
G
Explosion type
Deactivate matl master control
G
Special procurement
Special procurement per item
© SAP AG 1999
You can combine the different item categories with various indicators. You can therefore control multi-faceted special processes. Screen: S = Status screen G = General data A = Assignment to operation You can predefine most of the control indicators in the material master. In general, they are not copied to the bill of material. The following indicators can deactivate or override material master control per item: do not explode phantom assembly individual requirements indicator direct production (special procurement key SOBSL 52) long-term planning You can control requirements quantities using a lot-size independent indicator. The bulk material indicator defines a material component as indirect material. Special procurement can be controlled per item.
(C) SAP AG
LO215
7-6
Options for Material Withdrawal
IM Warehouse Management
Kanban control
Prod. order
Pick list items
Crate parts
Release order parts © SAP AG 1999
The R/3 System has various procedures for controlling material staging. These are a) Warehouse management with the component MM-IM (Inventory Management) b) Replenishment control with the Kanban component c) Storage location management and replenishment control with the component MM-WM (Warehouse Management System) The Warehouse Managment System has three options, which are described below: Pick list items are provided for the production order in exactly the same quantity as the requirements quantity. These parts can be provided for the production order at a physical storage location or dynamic storage location (production order). With this type of material staging, you can create transfer requirements in two ways: - automatically when an operation is released - manually Typical examples are large, expensive parts such as shafts, housings, ..... Crate parts are requested manually when a crate is almost empty. Typical examples are small parts in containers such as screws, nails, ..... Release order parts are requested manually. The required quantity is calculated using the target quantities of the components in the selected released orders. Thereby, the stock situation is taken into account in the production and the replenishment storage types. Typical examples are laminates, paints, ...
(C) SAP AG
LO215
7-7
Interactive Picking Functionality
Programm 'PPIOM000' Flexible selection of component requirements Control profile '000002' (similar to order info system) Functions Availability check, goods issue posting Grouping, sorting, filtering, field selection Collective and individual entry
Various print views (totals and detail views) Picking in the background (BATCH) Orders not selected (created, locked, technically completed) Components not selected (backflush, phantom assembly, direct production, final issue, bulk material, deleted, text items)
© SAP AG 1999
You can use a picking function to prepare and post material withdrawals. You can use this function to create and print any picking list and post the material withdrawals. You can export the picking list to MS-Excel ® or a PC file.
(C) SAP AG
LO215
7-8
Pull lists
Program 'RMSERI16' Component requirements selection and warehouse stock check Functions Plan replenishment (from storage type for replenishment stocks) Transfer
Background processing (BATCH) Staged from WM storage bins (transport requirements) Various print views (totals, detail and transfer) Orders not selected (created, locked, technically completed) Components not selected (phantom assembly, direct procurement, bulk material, pipeline, finally issued, deleted, text items)
© SAP AG 1999
You can use an interactive material list to request and transfer material stock. You can use this function to prepare any stock transfer, create and print a stock transfer list and then carry out the stock transfer.
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LO215
7-9
Storage Location Default in the Production Order (1) Work center maintained in operation?
Yes
PSA maintained in work center?
No
Yes
No
MM warehouse in BOM item? No PSA in BOM item? No
Yes Is PP/WM interface to be used?
Yes
No
MM warehouse in material master? No
Yes
Yes MM warehouse in PSA?
Yes
PSA in material master?
No
Yes Yes Yes
No PrO created with production version? No
Mat. master maintained for MM warehouse?
Yes No
No automatic warehouse default in production order !
Continued on slide (2)
Yes Yes
Yes Yes Yes
Default MM warehouse
Continued on slide (3)
© SAP AG 1999
Each material component in a production order can be assigned a default issuing storage location (at the point of order creation). This default enables automatic withdrawal postings (for example, backflushing). There are numerous options for the default (work center, bill of material, material master, production version). If the default is to occur via a production version, additional steps must be carried out, as described on the following slide. If materials are to be picked from a Warehouse Management storage bin, additional measures must be taken, as described on the next slide but one. Using notes 123580 and 126881, the procedure pictured above (standard) can be changed by modifying its order of priority. The SAP Enhancement PPCO0005 contains a Customer Exit EXIT_SAPLCOSD_001 for storage location default. Key: PSA production supply area.
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LO215
7-10
Storage Location Default in the Production Order (2) Checks for the default using the production version Yes
A
B
C
© SAP AG 1999
D
No
"Issue storage location selection" filled in the MRP group Yes
No
Issue storage location selection =1 No Does production version contain issuing storage location? No
Yes
Does production version contain receiving storage location?
Yes
Yes
no storage location default
A Material
Does the material master of the product in the PrO have an MRP group? Yes
Default storage location
If a storage location has not been found either via the work center, BOM item or material master, then the MRP group of the product defines whether the issuing storage location is used from the production version of the product in a production order or from the storage location in the material master of the component ("Issue storage location selection" field). This field can be defined for each MRP group in Customizing for Material Requirements Planning. Storage location selection = blank or 1: Issue storage location in the material master of the component is proposed as the issuing storage location (leads to no storage location default in the production order, see above!) Storage location selection = 2: For all components, the default issuing storage location is the one contained in the production version of the production order (see material master of the manufactured product). If this issuing storage location is not maintained in the production version, the system adopts the receiving storage location as the issuing storage location. This can be defined in the production version of the assembly in the Receiving SLoc field or in the material master of the assembly in the Issue storage location field. You should use this type of selection if all components are stored together near the production line, where they are required. Storage location selection = 3: Behaves in the same way as selection type 2 Storage location selection = 4: Behaves in the same way as selection type 2
(C) SAP AG
LO215
7-11
Storage Location Default in the Production Order (3) Checks for default storage location in production order
Mat. Master maintained for WMS warehouse (0088)?
No
Yes Control cycle for material and PSA maintained?
No
Yes Storage bin entered ?
No
Yes Default storage bin (WMS)
Error in WM staging
Transfer requirement/order © SAP AG 1999
If the stocks of the material components are managed at storage bin level using the Warehouse Management System, other requirements have to be fulfilled. The SAP modules KANBAN and Warehouse Management (WM) are responsible for these required measures. Once all settings have been fixed, WM staging can be triggered directly from the production order. This necessitates transfer requirements or transfer orders for the WM System.
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LO215
7-12
Material Withdrawal Variants
From warehouse From storage bin (WM) From consignment
Goods issue From ext. procurement
Issues
Consumption Prod. order Cost center Inspection sample
Asset
Scrap
Sales Project © SAP AG 1999
Goods issues can be both planned and unplanned. The data you need to enter depends on the type of goods issue. Goods issue slips, material staging lists, pick lists, and other similar documents form the basis of material withdrawal for production orders. Material withdrawals can be posted automatically when an operation is confirmed (backflushing).
(C) SAP AG
LO215
7-13
Manual Good Issues
With reference
Planned consumption To an order
To a reservation
Without reference
Unplanned consumption Individual entry
Collective entry
© SAP AG 2003
The reference to a reservation is determined by the planned or unplanned material withdrawal for a production order. You can only carry out planned material withdrawals for components kept in stock. Items that are to be backflushed are not offered. Unplanned material withdrawals are recorded in the goods movements log. Goods movements can vary for each item. You can also make collective entries for various account assignments in a material document. A prerequisite for goods issue is that the goods movement has been allowed for the reservation item. That is, the production order is released. You can restrict material withdrawal according to storage location and proportional quantity default. You have an extended selection with regard to requirements dates and operations. You have the option of setting the final issue indicator. When this is done, the reservation item is deemed completed.
(C) SAP AG
LO215
7-14
Movement Type
Material Document Item
Account Determination
Cost Update
Quantity Update
Movement Type
Consumption Update
Print Indicator
Field Selection
© SAP AG 1999
The movement type enables you to differentiate between goods movements. It incorporates control characters for creating and updating goods movements. You can select the movement type from the Menu or use F4 to display a list of movement types that have already been assigned to the transaction. You can enter the individual items of a material document with various movement types. The reference to a production order is controlled upon material withdrawal using a specially defined movement type (261).
(C) SAP AG
LO215
7-15
Effect of a Goods Issue
A Material
Reservation
Stock Quantity Consumption Stats ...
Consumption to the: Order Cost center ...
Account determination
Goods issue Goods issue slip G/L accounts: Stock account Consumption account Material ...
document
Accounting document
Controlling document
© SAP AG 1999
You can update stock and consumption fields according to storage location. You can reduce the reservation (for planned withdrawals). Only costs are updated for unplanned withdrawals. You can determine actual costs (valuation) and update the order. You give material consumption a value in Customizing using a valuation variant specific to plant or company code. Material, accounting and controlling documents are generated for a goods movement. The material document describes the goods movement from a materials management (warehouse) perspective. The accounting document describes the goods movement from a financial accounting perspective. An accounting document is always related to a company code. You can create one, several or indeed no accounting documents for a goods movement. Displaying a material document enables you to access and display other documents. You have the possibility of printing a goods issue document.
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LO215
7-16
Backflushing Materials
Execution
Backflush Posting
Synchronous with confirmation
Automatic
Asynchronous with Program 'CORUPROC‘
Proportional to the quantity
Reworking of terminated withdrawals with transaction 'COGi'
Control via material master, work center, or material assignment in routing Termination when material stock = 0
12 11 1 10 2 9 3 8 4 7 6 5
Release
Material withdrawal
Processing
Confirmation
Goods receipt
Order settlement
© SAP AG 2003
A materiel component withdrawal can be posted automatically (backflushing), synchronously or asynchronously when an operation is confirmed. You should always use backflushing when you do not want to stage materials from the warehouse for a specific order. During backflushing it is presumed that the material is prepared at the work center. Application areas: flow and assembly lines less valuable materials You can control backflushing in the material master. This can be done according to work center or for each BOM component assignment to an operation. You must rework unsuccessful withdrawal postings (stock = 0). Batch determination can be activated at the point when the backflush posting of the material withdrawal is carried out.
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LO215
7-17
Negative Stocks or Reworks
Negative Stocks
Current Stock Comp. 100-100
Backlogs
50
50
Backlog list
Backflush 100 pieces
GR 120 Pieces
Reworking
50
-50
100
12 11 1 10 2 9 3 8 4 7 6 5
100
12 11 1 10 2 9 3 8 4 7 6 5
0
12 11 1 10 2 9 3 8 4 7 6 5
170
70
N/A
70
© SAP AG 1999
If, for organizational reasons, the goods issue is generated before the corresponding goods receipt and the material already physically exists in the warehouse, two paths are open to you. These are either the function reworking of unsuccessful material withdrawals or negative stocks. It is possible to have negative stocks for standard priced materials in the inventory management. When you are working with negative stocks, you must make sure that: You have no negative stocks on the balance sheet key date and at the time of taking physical inventory. When you run the month end closing program no negative stocks still remain from the previous month. You set the indicator determining the permissibility of negative stocks in the material master (storage screen 2).
(C) SAP AG
LO215
7-18
Material Staging: Summary
This unit gave you information about some special features of the various types of material components There are various ways to default a withdrawal storage location (material master, BOM item, work center) There are 2 picking lists with varying functions available for material staging in the warehouse An automatic stock determination can be used at the time of picking and/or for backflushing
© SAP AG 1999
(C) SAP AG
LO215
7-19
Material Staging Exercises Unit: Material Staging Topic: Material Staging (LO215 Exercise 8)
• Pick material or organize replenishment • Withdraw material from the warehouse for production orders • Post over-withdrawals and under-withdrawals
Material components must be made available for production at the correct time and in the correct quantity. To achieve this end, you take the material withdrawal slip, enter the proposed warehouse and withdraw the material. Another option is that the material is brought to you automatically or by a transport team. The procedure for material withdrawal postings is, however, the same. 1-1
Create an order using the following data: Material
T-F1##
Production plant
1000
Order type
PP01
Total amount
10 piece
Basic finish date
Any
Scheduling type
Backwards
1-1-1 Release the order. 1-1-2 Carry out an availability check for all materials and in the table below, note any shortfall that may arise using the missing parts overview for the production order. Path: (C) SAP AG
→ FUNCTIONS → AVAILABILITY CHECK LO215
7-20
→ MATERIAL - ATP Path: Material
→ GOTO → MISSING PARTS → MISSING PARTS OVERVIEW Missing parts quantity
Inventory
Difference
T-B1## T-B2## T-B3## T-B4##
1-1-3 Save the order. 1-2
Order no.: __________________
Check the current stock level for each material component using the stock/requirements list. Note these in the table above. Calculate the difference between the stock level and the required quantity. Enter this in the table and post at least these difference quantities to the stock level, as described in the following note. Note: In the steps to follow, if your requirements quantities are more than the current stock level or if material withdrawals cannot be carried out because stocks are low, then use transaction MB1C and movement type 561 to execute other goods receipts. Post a sufficient quantity.
1-3
Create a picking list for the staging of the material components for the order in the warehouse. Save the result (picking) to post the goods issues. Path: S000 → LO → PP → SFC → GOODS MOVEMENTS → MATERIAL STAGING → PICK → Use the proposed standard profile 000002 In the list select all components and select the pushbutton PICK To display any errors that occur during the picking process, choose Environment → Errors.
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1-4
Ensure that the system has updated the production order (documented goods movements, withdrawal quantities, actual costs)
1-5
Create another order using the following data: Material
T-F1##
Production plant
1000
Order type
PP01
Total amount
10 piece
Basic finish date
Any
Scheduling type
Backwards
1-5-1 Release the order. 1-5-2 Save the order.
Order no.: __________________
Note: Withdraw the material components for the order in the following steps. (Transaction MB1A, movement type 261)
1-5-3 Determine the reservation and item number of the assembly TB-1## and carry out a withdrawal of material with reference to the reservation. Reservation number:
________________
Document number:
________________
Path: S000 → LO → PP → SFC → GOODS MOVEMENTS → GOODS ISSUE Select the pushbutton FOR RESERVATION 1-5-4 Carry out a withdrawal of material for assembly T-B3## with reference to the production order.
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7-22
Document number:
________________
Path: Select the pushbutton FOR ORDER 1-5-5 Carry out an over-withdrawal with a quantity of 1 for T-B1## with reference to the reservation. Document number:
________________
If you switch on the indicator “Suggest zero lines”, the system proposes components for an over-withdrawal which have already been finally issued.
1-5-6 Carry out an over-withdrawal with quantity 1 for T-B1## without reference to the reservation and order, but for the production order (movement type 261). This is the equivalent of an unplanned withdrawal. Document number:
_________________
1-6
Withdraw the remaining quantities of material that have not been withdrawn so that no unplanned material withdrawals remain open.
1-7
Ensure that the system has updated the production order (documented goods movements, withdrawal quantities, actual costs)
1-8
Use transaction MB51 to display the material documents that have been created. Path: S000 → LO → MM → INVENTORY MANAGEMENT → MATERIAL DOCUMENT → DISPLAY
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LO215
7-23
Material Staging Solutions Unit: Material Staging Topic: Material Staging (LO215 Exercise 8)
No answers are required for this exercise.
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LO215
7-24
Order Control: Contents
Options for detailed control of orders Sequencing Splitting orders Splitting capacity requirements (machine / person) Down and uploading orders to / from PDC Options for earned value analysis
© SAP AG 1999
(C) SAP AG
LO215
8-1
Order Control: Course Objectives
At the conclusion of this unit you will be able to: Define the means and methods of detailed order control in the R/3 system Describe which options there are for sequencing production orders Explain how to split orders and capacity requirements (machine/person) Transfer orders to PDC systems Transfer confirmations from PDC systems to R/3 Check order progress and possible delays in dates
© SAP AG 1999
(C) SAP AG
LO215
8-2
Overview Diagram (8)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
(C) SAP AG
LO215
8-3
Objectives and Methods of Machine Commitment
Objectives Creating a feasible capacity commitment plan to carry out operations Specifying processing sequences, processing quantities and dates
Requirements Medium-term capacity planning has already occurred
Methods Mass planning in the background (capacity planning) Online planning in the planning table (capacity planning) Using the order information system © SAP AG 1999
The capacity planning functions of the R/3 System put extensive planning options at your disposal. The applications of the order information system enable you to compile lists of operations for each individual work center. In addition, a special profile can be compiled in Customizing.
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8-4
Dispatching Operations (Basic Functions) Other available functions
1
Determining operations to be dispatched
2
Sorting operations (sequence)
3
Determining dispatching dates
4
Minimizing setup time
Deallocate Reschedule new date other work center Adjust capacity Dispatch with user exit
Special Notes
5
Execute dispatch
6
Finite scheduling
7
Checking operation dates
8
Midpoint Scheduling
9
Save planning result
"Dispatching dates" are the start dates for an available capacities search Activities 2 to 4 and 6 to 8 can be activated and deactivated as required Dispatching is controlled by a strategy profile Midpoint scheduling is carried out when you save.
© SAP AG 1999
You can use the capacity planning table to plan machine commitment. You can use control profiles to plan production orders in great detail. There are different strategies available for dispatching the operations. Dispatching dates are the start dates for finite scheduling. They can be specified: directly as a manual entry. - by copying the scheduled operation dates (lead time scheduling of the production order). - by drag and drop (mouse-controlled). There are different strategies available for minimizing the setup times. They are all based on a setup time matrix. Finite scheduling is a special type of lead time scheduling with a capacity availability check. Only those operations whose work centers have the "relevant for finite scheduling" indicator are included in finite scheduling. A work center's capacity load can be greater than 100 % ("overload" indicator in the work center).
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Strategy Profile (Capacity Leveling)
Overall profile
Dispatching sequence Planning direction Finite scheduling
(sort profile) (forwards/backwards) (yes / no)
Dispatching at earliest opportunity Strategy profile
View of overall capacity load Inserting the operation / Closing gaps Specifying dates for dispatch Taking order / operation floats into Consideration Determining new queue time (none/minimal/according to reduction strategy)
Dispatching for internal processing Checking operation dates Midpoint Scheduling Discontinuing dispatching when errors occur © SAP AG 1999
Strategy profiles are used to achieve various planning objectives. You can change a profile interactively during planning. Course LO230, "capacity planning", deals with the individual strategies and their settings in greater detail and provides relevant examples.
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LO215
8-6
Midpoint Scheduling
Example: a dispatched operation Before dispatching 10
PS
30
SS
Dispatch operation
Forward and backward scheduling
20
SF
PF
20
10
20
DSPT
SS
30
SF
© SAP AG 1999
A dispatched operation is given the status DSPT and the internal indicator "Capacity is available" If only one operation is dispatched, then all preceding operations are scheduled backwards and all subsequent operations are scheduled forwards. If more that one operation is dispatched, then the scheduling direction between the two dispatched operations depends on the scheduling direction chosen during the lead time scheduling.
(C) SAP AG
LO215
8-7
Order Split Order
Functions
Edit
Goto
Order
Environment
6000767
000006000767 000006001007
Header
Status SPLT General
Assignment Goods receipt
Control
Dates/quantities Master data
000006001105
r de Or ad lo
Parent PrO
Child PrO
Product Cost Collector
Child PrO M E V X G
Status CSPL
1000 100-100 1421 4230 1310 External processing 300900 Additional raw material
12.000 25.000 8.000 12.000 8.500
© SAP AG 1999
You can split production orders that have already begun to be used in the production process into separate production orders. You must define from which operation the orders are to be split. This function should then be used, if Material components are only partly available A work center has a capacity shortage A partial quantity has been produced and the remaining quantity is to be produced at a later date You control the function by selecting an operation in the operation overview and choosing FUNCTIONS -> SPLIT ORDER The original order is described as the parent order and the orders that are split off from this order are called the child orders. The orders are identified by the SPLT status (parent) and the SPLE status (child). You can carry out multiple splitting. All production orders must be (and are) created with reference to the same product cost controller (that is, the function can only be used with a product cost collector!) Serial numbers can be assigned to the split orders. Restrictions: Reading PP master data is not possible No change of material (product) is possible between the parent and child order Only operation confirmations can be carried out (C) SAP AG
LO215
8-8
Splitting Capacity Requirements
Application criteria Planning of individual capacities and personnel Planning within the normal operation (capacity requirements) Planning in greater detail than for work centers or capacities Split capacity requirements for machine commitment or workforce planning in a short-term planning period Implementation at shop floor level and in applications that also use workforce planning (PD, PM, PS)
© SAP AG 1999
(C) SAP AG
LO215
8-9
Levels in a Split
Plant 1000 Cost center 4230
...
Cost center 4220
... Machine group 1904
Machine group 1112
Machine group 1111 Capacity category machine
...
Individual machine -1 Individual machine - 2 ...
Person Person 1 Person 2 ...
Position ...
...
Person A Person B ...
...
Pooled capacity setup
Capacity category Person
Qualification
Checked against HR tables !!
© SAP AG 1999
The capacity in the work center can be subdivided according to the capacity category (machine, personnel). That is, elements can be assigned to the capacity. The assignment options are dependent on the capacity category. Subdividing in this way means that an operation (or, more precisely, its capacity requirement) can be directly assigned to the relevant machine and / or person. You can only make assignments to people, qualifications, and positions if the SAP Human Resources System (HR) is active.
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LO215
8-10
Types of Split Quantity split Various capacities
100
Various times
50 50
50
50
Standard value split
10 h labor time for 100 pcs.
5 h labor time 5 h labor time
Different capacities work simultaneously on the same lot or order, but can also undertake partial jobs.
© SAP AG 1999
You have the option of several types of splits. You can split the quantity or the standard values of the capacity requirements (or split both, if necessary). Quantity splits are useful if partial quantities of the order are to be processed by several individual capacities at the same time or if they are to be processed at different times and gaps exist between them. Standard value splits are useful if an operation is divided into two or more partial tasks (work steps) that are carried out by different individual capacities at the same time and for the total quantity. You can split the quantity as well as the standard values.
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8-11
PDC Systems: Objectives and Concerns RealReal-time process control Production with fewer shop floor papers Decentralized decision making Bar code link Improved transparency in production Availability of production statuses (conditions) conditions) Control of fully or partially automated systems
Relatively high investment Changes in process structure Independent implementation project advised © SAP AG 1999
A constant exchange of information is required between the production planning and control (PP) level and the production level. Production often occurs with automated and partially automated machines and systems.
(C) SAP AG
LO215
8-12
Interfaces: Overview MM PP
R/3
PPPDC HR (CC1)
(CC2)
PM
PS
PPKAN
(CC3)
(CC4)
(CC5)
Plant data collection
Plant maint. data entry
PP
PP
PI
WM
MM
QM-IDI PP-REM PP-CAD PI-PCS WM-LSR MM-MOB interface interface interface interface interface interface
PDC interfaces
Time recording
QM
Project Kanban data entry
Inspection proc. (LIMS)
Material data entry
CAD integration
Process control
Warehouse control
Mobile data entry
Subsystem
CC = Communication channel © SAP AG 2003
PDC interfaces (Plant Data Collection) are used to transfer data between R/3 and subsystems. The PP-PDC interface is the interface that has been designed especially for production control. Starting from Release 3.0A, this interface was called Communication Channel 2 (CC2). (This will only be maintained for two more main releases) As of Release 4.6A, this interface is implemented as an asynchronous SAP R/3 BAPI interface and is called the PP-PDC interface. Subsystems can receive certification from SAP (Complementary Software Program). For further information on this interface see: http://www.sap.com, SAP Partners -> Software Partners -> Integration Opportunities -> Interface Certification -> Interface Reference Look under interface PP-PDC "Plant Data Collection - R/3 Shop Floor Control"
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Requirements for the PP-PDC Interface Maintain subsystem configuration (Customizing) Transfer configuration data to the subsystem Maintain PDC groups (Customizing table 705) Assign PDC group to work center (subsystems) subsystems)
Activate PDC link (Customizing table 399X)
Order type
Order is released ( download) download) Order contains at least on operation with work center with PDC group Relevant changes (quantity, quantity, date, activity type, type, ...) Operations must require confirmation (upload) © SAP AG 1999
When the PDC indicator is activated in the order-type dependent parameters (T399X), released orders are transferred in the download if they contain at least one operation whose work center is assigned to a subsystem (PDC) group. In order for time events to be included in the upload from the PDC system, the operations must require confirmation.
(C) SAP AG
LO215
8-14
Download: Logical View MM PP
R/3 PP
R/3 online
HR
Program
Delta download
Initial download
Master data download Mat. master HR master Reasons for var. Units of measurement
Production orders
Work centers Wage types etc.
Subsystem © SAP AG 1999
You can download data in the following three ways: Master data download Initial download Delta download The master data download enables the transferal of R/3 master data to the subsystem. The initial data download supplies the subsystem with production orders. The delta download supplies the subsystem with changed production orders. In order for the initial and delta downloads to work, you must first release production reports in R/3.
(C) SAP AG
LO215
8-15
Upload: Logical View PP
MM PP
Online
R/3
Update
HR
CO AFRU Analysis
Post PDC records
Update Act. time recording Pair formation
RUECK Request PDC UPLOAD
Original values Time ticket
Time event
Attendance - yes/no
CONF21
Subsystem © SAP AG 1999
The original values provided by the subsystem are processed in an analysis program. The duration (setup, processing) can therefore be determined from the start and end events. In order to calculate the duration successfully, the time events must first be assigned to the maximum of six variable standard values of an operation in the work center.
(C) SAP AG
LO215
8-16
Interface Record Types Operation time events
Operation time tickets
R10 - Setup start
L20 - Time ticket partial finish
R20 - Setup partial finish
L40 - Time ticket finish
Work center events
R30 - Setup interruption R40 - Setup finish
Currently none
B10 - Processing start B20 - Processing partial finish
Personnel times (HR-PDC)
B30 - Processing interruption
P10 - Clock-in
B40 - Processing finish
P15 - Break start
A10 - Teardown start
P20 - Clock-out
A20 - Teardown partial finish
P25 - Break finish
A30 - Teardown interruption
P30 - Off-site work start
A40 - Teardown finish
P40 - Off-site work finish
V20 - Var. activity partial finish V40 - Var. activity finish © SAP AG 1999
Only activities that are not already supplied by R/3 orders can be entered with record type V20 / V40. Furthermore, no quantities can be entered.
(C) SAP AG
LO215
8-17
Order Control: Summary
This unit gave you an overview of the means and methods of detailed order control. For sequencing orders you must use the order information system or the planning table from capacity planning Orders or capacity requirements (machine/person) can be split Orders can be transferred from R/3 to PDC systems Confirmations can be transferred from PDC systems to R/3 An order progress report is available for checking the progress of production orders (see unit 13) Course LO230 provides more information about capacity planning.
© SAP AG 1999
(C) SAP AG
LO215
8-18
Order Control Exercises Unit: Order Control Topic: Order Control (LO215 Exercise 9)
• Machine usage list with order information system • Machine usage with planning table • Order split
As production manager or production scheduler, you are responsible for the continual utilization of the work centers in your area for the days to come (hours or weeks). In this process, the orders should always be assigned to each work center in an appropriate sequence (often one that optimizes setup). For each work center and time period, the scope of the work that you assign should not be too large or too small. Both of these would have a negative effect on the employees in your area. The SAP System provides you with several options for carrying out this task. 1-1
Use the order information system to create a machine usage list for the work centers in the area for which you are responsible. Select using the following entries Selection at header level List
Operations
(Selection object)
Profile 000002
(Workload for each work center)
Production plant
1000
Production scheduler 0## Selection at operation level Work center
T-M##
Plant 1000 Familiarize yourself with the content and functions of this list. (C) SAP AG
LO215
8-19
Path: S000 → LO → PP → SFC → INFOSYSTEM → ORDER INFORMATION SYSTEM 1-2
Use the graphical planning table to carry out machine usage (dispatching) for work center T-E##. 1-2-1 Select the objects Plant 1000 Work center T-E## Capacity category 001 to 002 Path: S000 → LO → PP → SFC → CONTROL → CAPACITY PLANNING → LEVELING → WORK CENTER VIEW → GRAPHICAL PLANNING TABLE When you do this, set the filter to order category 1 and order type PP01 Ensure that you do not set any other filters.
Path:
Select the filter symbol Start the selection.
1-2-2 The system has prepared a planning table for work center T-E##. Use the sort sequence key SAPSFCGS12 (setup group key) to sort the order list according to setup times. Path: Select some orders and choose
→ EDIT → CHANGE SORT 1-2-3 Reduce the setup times of the operations that follow the first order (operation) to "0". Select all orders if possible. Path: → Functions → Adjust setup time → Manually
(C) SAP AG
LO215
8-20
1-2-4 Set up the current planning strategy so that the following functions are carried out during planning:
Dispatching the orders
forwards
for dispatching at the earliest opportunity Check or change the strategy profile:
→ SETTINGS → STRATEGY
Path:
1-2-5 Dispatch all orders automatically for the work center.
→ FUNCTIONS → DISPATCH
Path:
1-2-6 Which status do the dispatched orders and operations now have? To find this out, display an order.
Answer:
_______________________
Path: Place the cursor on one of the dispatched operations
→ GOTO → ORDER → CHANGE or → GOTO → OPERATION → CHANGE 1-2-7 Save the planning result. The next activities in the exercise are optional. Only carry this out if you have enough time.
1-3
Due to a capacity shortage in the next few weeks, you must distribute the total quantity of a production order over two weeks. For this reason, carry out an order split for this production order.
(C) SAP AG
LO215
8-21
1-3-1 Create an order using the following data: Material
T-A
Production plant Order type
1000
PP08 !!!
Total amount 10 piece Basic finish date
Any
Scheduling type
Backwards
This order is released immediately!
1-3-2 Save the order Order no.: ___________________
1-3-3 Split the order at operation 0010, so that you then have two orders with the following parameters: Split quantity 5 piece Child order Order type PP08 Basic finish date one week later than proposed Scheduling type
Path:
Backwards
GOTO → OVERVIEWS →OPERATIONS → Select operation 0010 → FUNCTIONS → SPLIT ORDER Enter the split parameters
(C) SAP AG
LO215
8-22
→ ORDER SPLIT → EXECUTE 1-3-4 Save the order and change it again afterwards. 1-3-5 Which orders can you now find? Answer:
Parent order
Number:
____________________
Child order
Number:
____________________
You can switch between the orders as required.
1-3-6 Which new status and quantity entries can you find in the header screens? Answer: Parent order
Status: ________________________ ________________________
Child order
Status: ________________________
1-3-7 Have the operation and component quantities been created proportionally? Answer:
_____
1-3-8 Has the child order already been released? Answer:
_____
1-3-9 How is cost object controlling executed for both orders? Answer:
Parent order Child order
(C) SAP AG
_________________________________ _________________________________
LO215
8-23
The order split function is currently restricted to this form of cost object controlling!
(C) SAP AG
LO215
8-24
Order Control Solutions Unit: Order Control Topic: Order Control (LO215 Exercise 9)
1-2-6 Answer:
DSPT (dispatched)
1-3-5 Answer:
Parent order Number: Child order
1-3-6 Answer:
Number:
____________________ ____________________
Parent order Status: SPLT (split) Expected yield variance = 5Child order
Status: CSPL (Created by splitting)
1-3-7 Answer:
Yes
1-3-8 Answer:
No
1-3-9 Answer:
Parent order Product-oriented for each cost collector Child order
(C) SAP AG
Product-oriented for each cost collector
LO215
8-25
Confirmations: Contents
Confirmation types Control Parameters for Confirmations Procedures involved in the "confirmation of an order" Confirmation data Confirmation results
© SAP AG 1999
(C) SAP AG
LO215
9-1
Confirmations: Course Objectives
At the conclusion of this unit you will be able to: Define the principles and processes of realtime production order confirmation Describe the different types of order confirmation Recognize the control parameters for confirmations Describe the effects of a confirmation
© SAP AG 1999
(C) SAP AG
LO215
9-2
Overview Diagram (9)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
(C) SAP AG
LO215
9-3
Order Confirmation: Process chain Production order Operation Operation0010 0010 Operation0020 0020 Operation
Upload from PDC interface
Manual Input Operation0030 0030 Operation
Confirmations are saved ...
Confirmations
Orders
. . . Operation9999 9999 Operation
The system is capable of performing a variety of functions when the confirmation data is entered.
Capacity requirements
Material document
Actual
HR data
© SAP AG 1999
Order confirmation is used to enter internal activities generated for the order. The work progress of a production order can be measured based on order confirmations. Confirmations from PDC systems are possible, using the PP-PDC interface (see previous unit).
(C) SAP AG
LO215
9-4
Confirmation Types and Functions Confirmation types Order header
Confirmation for order (3.0) Confirmation for operation (4.5) Fast (preliminary) entry Collective confirmation Time ticket / confirmation slip Time event confirmation (3.0) Progress confirmation (4.0) Milestone confirmation Cancellation
Operations
Material components
Confirmation functions
Prod. resources/tools Costs
Planned 100 20 Target 50 Actual
Confirmation status Partial - confirmation Final - confirmation Final - confirmation when minimum tolerance limit reached © SAP AG 1999
Check operation sequence Monitor activity default values Set status ( user status) Process goods movements Backflush posting Withdraw posting for open reservtns Check delivery tolerances Transfer PDC data Reduce capacity requirements Determine actual costs Quantity calculations (4.6C)
Order confirmation is the confirmation of the entire order at order header level and . An operation confirmation allows you to confirm an order step by step. For this type of confirmation, there are various procedures available. The procedures must be selected to suit the methods of organization within your company and the allowed workload. You can only carry out a confirmation for an order if no confirmations have already been entered for the operations. You can follow a confirmation with an automatic goods receipt. Control is then maintained using the operation control key or the production scheduling profile. A material overview enables you to correct backflushing for postable material withdrawals or to enter any number of unplanned goods movements. There are a whole range of Business Application Interfaces (BAPI) available, which can be used to enhance the standard confirmations to suit specific users.
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LO215
9-5
Requirements for Confirmations Production order Op. 10
Op. 20
Op. 30
Order type Confirmation parameters
Operation Confirmation Confirmation number number
Operation Operation control control key key
Operation control key CTRL
Confirmation
PP01 PP01
11
1 Milestone 2 Normal 3 No confirmation © SAP AG 1999
Confirmations are controlled by confirmation parameters (refer to the next slide). Each operation is automatically given a confirmation number when the order is created. You can then clearly identify it without having to enter any other data. Each operation contains an operation control key. This defines whether the operation requires confirmation. An operation can be marked as a milestone. This means that when the milestone operation is confirmed, the operations that precede it are also confirmed with proportional quantities. An operation that is to be confirmed must first be released.
(C) SAP AG
LO215
9-6
Control Parameters for Confirmations Confirmation function
Final or partial confirmation Final confirmation upon reaching tolerance limits Withdrawal posting of open reserv`ns (on final confirmation)
Screen control
Control of first detail screen (1)
Default time units
Hour, minute, optimized automatically
Checks
Operation sequence Underdelivery Overdelivery Future dates
Selection
Confirmable operations (1) Confirmed operations (1) Open orders in a collective order
Goods movements
Display all movements or just backflush postings
Control
Decoupling of the process
HR update
Data transfer: PP -> HR
Error handling/logs
Actual Goods movements
Display or default data
Data to be confirmed, confirmed data, standard data (1)
Order type Confirmation parameters
(1) inapplicable to single screen entry © SAP AG 1999
You control confirmations using settings in Customizing (fixed parameters). You set the control parameters for order type and plant. There are different confirmation parameters for Time ticket confirmation using single screen entry (new form of the normal operation confirmation) Collective confirmation/fast entry You can change some settings online (variable parameters). You must also enter the reasons for variance. The reasons for variance can trigger statuses that, in turn, control trigger points. The transfer of PDC confirmation data to the HR module is dealt with on course HR490 "Incentive Wages and Plant Data Collection".
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LO215
9-7
Field Groups for Single Screen Entry
Personnel data Quantities Activities Dates Quality checks Comments
© SAP AG 1999
As of Release 4.6, the normal time ticket confirmation of an operation is generally entered on one screen (single screen entry). As a result, the system no longer offers a selection screen (order or operation selection). The data that is to be confirmed is distributed between the different field groups on this screen. The field groups can be set up in different ways in Customizing and they can be expanded or collapsed in the actual confirmation. You can greatly influence confirmations by means of field selection control in Customizing (hiding entries, highlighting entries, mandatory and optional fields). You can use customer enhancement CONFPP07 to create and insert your own detail screens. The transaction that was used up to now, CO11, is still available but is not included in the menu.
(C) SAP AG
LO215
9-8
Determining the Yield
Do confirmed operations, confirmable operations or operations which require confirmation already exist ?
Is it possible to perform the operation in sequence? (See Customizing)
Yield of the last confirmed operation
Which of these operations is last in the sequence ?
The preceding operations preceding operations Yield of the order
Yield of this operation
The preceding operations requiring confirmation Yield of this operation
= Yield to be confirmed © SAP AG 1999
In order to facilitate the confirmation, you can allow the system to propose the yield to be confirmed. You are also required to enter the settings in the fixed parameters (Customizing) for confirmation control. The system takes several factors into account when determining the yield. Rework operations are then subject to special treatment (see documentation).
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LO215
9-9
Determining the Remaining Capacity Requirements
Planned qty 150 pieces
Actual quantity 100 pieces
Forecast value for each type of activity
Standard value
OR
Estimated standard value
Formula for each capacity category KBED = setup + lot size x machine time Remaining capacity requirements 50 pieces x 0.1hrs / piece = 5 hours
© SAP AG 1999
Remaining capacity requirements are calculated according to either the standard values for each type of activity or an explicitly confirmed estimated standard value (forecast screen). The system sets the standard value for setup to zero when the first partial confirmation is executed. You can only set all other remaining capacity requirements to zero by setting the remaining quantity or forecast value to zero.
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LO215
9-10
Progress confirmation
Special type of confirmation
automatic confirmation of preceding operations
"Unplanned milestone"
each confirmable operation behaves in the same way as a milestone when it is confirmed
Special characteristics
Total quantities are always confirmed Combined use of progress confirmation and milestones is possible but with restrictions Operations that have already been confirmed remain unchanged
New status
PROG
© SAP AG 1999
You can also use progress confirmation for collective orders. However, it cannot be applied to finally confirmed operations (only for the correction of preceding final confirmations).
(C) SAP AG
LO215
9-11
Milestone or Progress Confirmation Confirmations Operation
Milestone 1.
2.
3. Actual qty Status (100)
0010 50
0020
Progress confirmation
20
(100)
MILE
50 70
PCNF PCNF
100
MILE
1.
2.
3.
4.
Act. qty
(70) (80) (100) 70 (nn) 50
50
Status PRO G PCNF
Normal 0030
Normal
(100)
100
0040
100
MILE
70
70 (nn) 80 (100) 80 (nn)
PROG
100 100
PROG
...
...
Milestone confirmation (nn) - Update executed
Progress confirmations
© SAP AG 1999
Normal, milestone and progress confirmations can be used in combination. (It is, however, advisable to decide on one type of confirmation) Orders confirmed using progress confirmation react in the same way as if confirmed by a milestone confirmation. They confirm the preceding operations. However, quantity calculation functions differently using progress confirmation. Each confirmed quantity is considered a total quantity. You are no longer able to work on operations using progress confirmation if they have already been partially confirmed using normal confirmation. You are therefore also unable to confirm them. You must at least partially confirm milestone operations that have an impending confirmation time.
(C) SAP AG
LO215
9-12
Confirmation: Decoupling of Processes
Order type Confirmation parameters
"Process control"
Confirmation processes
Backflushing GI Automatic GR Calculation of actual costs
Time procedures
Update task Immediately Online Immediately Background Any
Parameters
Number of parallel tasks Specifying server Maximum number of components permitted per MM posting document
© SAP AG 2003
Within the framework of the parameters for confirmations (Customizing), you can set a "process control" parameter for each plant and order type. This controls the decoupling of the confirmation from its sequence processes.
(C) SAP AG
LO215
9-13
Decoupling of Processes: Function Model
Create confirmations Online / Background jobs
Error records
AFFW/AFRC
Preselection
Confirmations
Target table for process
AFRU
COEP/ MSEG
AFFW/AFRP
Process confirmations in the background
Reprocess error records online
© SAP AG 2003
In order to facilitate the subsequent processing of confirmations, the system temporarily saves the confirmation numbers in several tables of planned changes. AFRP1 Automatic goods receipt AFRP2 Backflushing AFRP3 Actual costs AFRP4 HR activity data The CORUPROZ program posts the previously temporarily saved data. This function needs to be prepared in Customizing (Step CORUPROC). Confirmation processes that cannot be posted successfully need to be reprocessed online or in the background. The following transactions and programs are available to you: CO16N Program RMAFRU03 Reprocessing confirmations COGI Program CORUAFFW Reprocessing goods movements COFC Program CORUCOFC Reprocessing actual costs
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LO215
9-14
Confirmations: Summary
You have gained an overview of confirmation processes. You have several different confirmation procedures at your disposal for production orders. You can confirm entire production orders or individual operations, whichever suits your methods of organization or workload. Confirmations are controlled by "fixed parameters" (see Customizing), which, in turn, can be temporarily modified by "variable parameters".
© SAP AG 1999
(C) SAP AG
LO215
9-15
Confirmations Exercises Unit: Confirmations Topic: Confirmations (LO215 Exercise 10)
• Time ticket confirmation • Collective confirmation • Time event confirmation • Progress confirmation • Milestone confirmation • Effects of confirmations Disciplined, real-time confirmations are a fundamental requirement for checking the progress of production and for correct capacity planning. As supervisor or production operator, you are responsible for entering confirmations. You either use confirmation slips to do this, or enter the confirmations directly onto a PDC terminal (or PC), without any paperwork. The SAP System provides you with various options for carrying out this work and one of these has already been selected for use in your company. 1-1
Create an order using the following data: Material
T-F1##
Production plant
1000
Order type
PP01
Total amount
20 piece
Basic finish date
Today’s date + approx. 2 months
Scheduling type
Backwards
Release and save the order!
(C) SAP AG
LO215
9-16
Order number: ________________ 1-2
For the production order that you have selected, check the confirmation obligation and the confirmation number of the operation.
Operation
Confirmation
Yes
No
Milestone
Yes
Confirmation no.
No
0010 0020 0030 0040 0050 0060 Path: Use the operation control key and the detail screens to perform the check. 1-3
Carry out confirmations as described in the following steps. By doing so, you practice various confirmation options.
1-3-1 Carry out a partial confirmation (quantity = 10 pieces and any activity) for operation '0010' of the production order. When you do this, use the operation-related confirmation "Time ticket confirmation" (Do not confirm the complete quantity!!)
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LO215
9-17
Path: S000 → LOGISTICS → PRODUCTION → SHOP FLOOR CONTROL → CONFIRMATION → ENTER → FOR OPERATION → TIME TICKET As of release 4.6, the only variant available for this type of confirmation is "single screen entry". You must enter all key data yourself during this procedure.
Enter the order and operation number. The system then proposes the data to be confirmed.
→ Pushbutton ACTUAL DATA 1-3-2 Which confirmation profile has been used for the confirmation screen?
Answer:
________________
Path: → USER SETTINGS → CONFIRMATION PROFILE 1-3-3 In the future, you want to enter personnel data in the confirmation screen only when required. For this purpose, hide the personnel data and save the setting. Path: Select the appropriate pushbutton to close the field group.
→ PERSONNEL DATA → USER SETTING → SET USER INTERFACES → SAVE 1-3-4 Carry out final confirmation (quantity and time) for operation '0010' of the production order. To do so, proceed as in step 1-3-1.
1-3-5 Carry out an additional activity confirmation (1 hour labor time and no quantity) for operation '0010' of the production order. To do so, proceed as in step 1-3-1. (C) SAP AG
LO215
9-18
1-3-6 Carry out a partial confirmation (actual quantity 10 pieces) for operation '0020' of the production order. When you do this, use the operation-related confirmation "collective entry" Enter the confirmation number. The system then proposes the data that is to be confirmed (actual data). For this step, you can use the confirmation number of the operation since this type of confirmation is designed for fast entry with a barcode reader. However, you can also switch to the entry option that uses the order number. To do so, select the pushbutton OTHER VIEW
Path: S000 → LO → PP → SFC → CONFIRMATION → ENTER → FOR OPERATION → COLLECTIVE ENTRY PROPOSE ACTUAL DATA 1-3-7 Carry out final confirmation (quantity and time) for operation '0040' of the production order. When you do this, use the operation-related confirmation "progress confirmation" Path: S000 → LO → PP → SFC → CONFIRMATION → ENTER → FOR OPERATION → PROGRESS CONFIRMATION 1-3-8 Now answer the following questions: Does this confirmation have the same effect as a milestone? Answer: Is operation 0040 a milestone?
Answer:
_______
_______
Has the system confirmed already partially confirmed operations? (operation 0020)? Answer: _______ Which status has been given? Status:
_______
Progress confirmation automatically confirms previous operations. You do not have to plan milestones in the operation control key. The system does not confirm operations that have been partially confirmed manually. The system views the actual quantity that you enter as the total actual quantity. (C) SAP AG
LO215
9-19
1-3-9 Carry out a final confirmation (quantity and time) for the complete order. When you do this, use the order-related confirmation "For order". Path: S000 → LO → PP → SFC → CONFIRMATION → ENTER → FOR ORDER 1-3-10 Is this final confirmation possible?
Answer:
_______
1-3-11 Carry out two confirmation as time events for operation '0050' of the order. Use the operation-related confirmation "time event" and select the events Start processing and Finish processing. Path: S000 → LO → PP → SFC → CONFIRMATION → ENTER → FOR OPERATION → TIME EVENT 1-3-12 Has an actual processing time been entered for operation 0050?
Answer:
_______
1-4
In the production order, change the operation control key of operation ‘0060’ to ‘PP98’
1-5
Carry out final confirmation (quantity and time) for operation '0060' of the production order. To do so, proceed as in step 1-3-1.
1-6
Display the last confirmation that was entered in the production order for operation 0060. Path: In the operation overview, select operation 0060 OPERATION → CONFIRMATION → DISPLAY
1-7
Display all the confirmations that you have carried out for the order.
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LO215
9-20
Path: S000 → LO → PP → SFC → CONFIRMATION → DISPLAY Select pushbutton 1-8
Display the updates made to the order (actual quantities, status, and costs).
1-9
Confirm any operations that require final completion. Ensure that you have carried out final confirmation for the complete order.
1-10
Execute the goods issue for all material components in the order.
(C) SAP AG
LO215
9-21
Confirmations Solutions Unit: Confirmations Topic: Confirmations (LO215 Exercise 10)
1-2
Operation
Confirmation
Yes
Milestone
No
Yes
Confirmation no.
No
0010
x
x
0020
x
x
0030
x
x
0040
x
x
0050
x
x
0060
x
1-3-2 Answer:
x LO215_001
1-3-8 Now answer the following questions: Does this confirmation have the same effect as a milestone?
Answer: Yes
Is operation 0040 a milestone?
No
Answer:
Has the system confirmed already partially confirmed operations? (operation 0020) ?
Answer:
No
Which status has been given?
Status:
PROG
1-3-10 Answer:
No
1-3-12 Answer:
Yes
(C) SAP AG
LO215
9-22
(C) SAP AG
LO215
9-23
Goods Receipt: Contents
Executing goods receipts postings Effects of goods receipts Control parameters in the order
© SAP AG 1999
(C) SAP AG
LO215
10-1
Goods Receipt: Course Objectives
At the conclusion of this unit you will be able to: Define the posting methods for goods receipts Describe the effects of a goods receipt Recognize which parameters control goods receipts in an order Explain the valuation process for goods receipts
© SAP AG 1999
(C) SAP AG
LO215
10-2
Overview Diagram (10)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
10
© SAP AG 1999
(C) SAP AG
LO215
10-3
Goods Receipt
Other Initial entry of stock balances
Goods receipt
Without a production order Purchase order
Without a purchase order For purchase order
For production order Order header
Operations Operations
Material Material components components
Prod. Prod. resources/tools resources/tools Costs
Planned Target 100 20 50 Actual
© SAP AG 1999
Goods receipt from production in a warehouse occurs in the same way as for normal goods receipts from a purchase order. Goods receipt from production can be posted either manually or automatically. Automatic goods receipt can be controlled specific to either operation (operation control key) or material (production scheduling profile). If you choose control specific to operation, the goods receipt is posted upon confirmation of the last operation requiring confirmation.
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LO215
10-4
Effects of Posting a Goods Receipt
Order G Material
Transfer requirement WMS
Stock quantity
Account determination Goods receipt slip
Goods receipt posting G/L accounts: Stock account Plant activity
Messages Material document
Accounting document
Controlling document
© SAP AG 1999
When goods are taken receipt of from a production order, you are able to specify: Plant storage location batch stock type final delivery indicator Material and accounting documents are assigned according to their numbers. The delivered quantity can be updated in the order. The inward movement of material is valuated. The order is credited. The plant activity account is updated.
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LO215
10-5
Set "Delivery completed" Indicator
Set "Delivery completed" Indicator
Order header
Operations Operations
Material Material components components
Prod. Prod. resource resources/tools s/tools
Cost Costss
Planned Planned Target Target Actual Actual
100 20 50
Production order
Goods receipt
© SAP AG 1999
The "delivery completed" indicator shows whether an order is deemed completed from a goods receipt point of view. This means that no further goods receipt will be expected for this order. The open quantity is zero. It is still possible to post goods receipts of remaining quantities, although this will no longer have an effect on the open order quantity. If you create a return delivery for an item with the "delivery completed" indicator "X" and are expecting a further delivery, then you must cancel the "delivery completed" indicator.
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LO215
10-6
Underdelivery and Overdelivery
Order quantity 100 Underdelivery tolerance10%
70
80
90
Overdelivery tolerance 20%
100
110
Warning Underdelivery
120
130
140
Error message Overdelivery Within the tolerances no messages
© SAP AG 1999
When dealing with a goods receipt relating to a production order, the system proposes the open order quantity for the goods receipt. You have the option of changing this quantity if it does not correspond with the delivered quantity. When a goods receipt item is created, the goods receipt quantity is compared with the open order quantity. The system is then able to specify whether underdelivery or overdelivery will occur. Underdeliveries are generally permitted in the standard system. It is also possible to set a percentage underdelivery tolerance within the order. A goods receipt quantity smaller than the sum of the order quantity minus the underdelivery tolerance is interpreted as a partial delivery and accepted by the system. The system alerts the user to the underdelivery and takes the underdelivery tolerance into account in the online message. Overdeliveries are not permitted in the standard system. If overdeliveries are to be allowed, then you can define a percentage overdelivery tolerance in the order. The over-delivery tolerance check can be deactivated in the order. Unlimited overdelivery is then possible.
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LO215
10-7
Goods Receipts and Quality Management
Setting the quality inspection indicator (possibilities)
G Material
11 In the material master
Ord Order er hheader eader
Oper ati o ns
Mater ial com po ne nts
22
Prod. res ource s/t ool s
Cost s
Pla nn ed T ar get Act ual
100 20 50
In the production order
33
Goods receipt
During goods receipt
© SAP AG 1999
You are able to post inward movements from production to the stock in quality inspection in the following example cases: 1. The material is in principle subject to a quality inspection before further usage. The employee responsible for data in the material master sets the indicator for the quality inspection in the material master. The indicator is copied to the material master when the order is created. 2. If the material comes from a specific production order, then it should undergo a quality inspection before anything else. This is for example the case when you are dealing with an important order and it is imperative that the quality of the product be checked. The work scheduler then sets the quality inspection indicator in the goods receipt data of the order. 3. You decide whether the material must undergo a quality inspection or not at the point of goods receipt. You set the quality inspection indicator in the goods receipt item.
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LO215
10-8
Updating and Valuating Stocks
Stock valuation Quantity basis Material master Special stocks Stock fields per plant, storage location, special stock
G Material
Value basis G/L accounts in accounting Credit/debit transaction figures per company code; periods
Order
Balance: ??
Stock account SS
Valuation at standard price
Plant activity account
Order credit
A A
Valuation with valuation variant
© SAP AG 1999
As a rule, inventory management is performed just as much according to quantity as it is to value. Subsequent statements are valid for a valuated goods receipt posting. Stock fields are available for the current and the previous period on a storage location level. The price control indicator (S/V) in the material master specifies whether the material stock is valuated at the standard price or according to a valuation variant. When using price control S, the valuation price must be entered in the standard price field of the accounting screen. When using price control V, it must be entered in the moving price field of the accounting screen. The activity account is always booked with a price that is dependent on the valuation variant of the valuation area. The order is always credited at the same level at which the plant activity is posted. You therefore need to set a valuation variant per valuation area for the goods receipt. This is done in Customizing. You can enter the transaction figures of the G/L account again separately according to business area.
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LO215
10-9
Goods Receipt: Summary
You can now describe the process of posting a goods receipt This posting has various effects The posting of goods receipts is controlled by parameters in the order
© SAP AG 1999
(C) SAP AG
LO215
10-10
Goods Receipt Exercises Unit: Goods Receipt Topic: Goods Receipt (LO215 Exercise 11)
• Goods receipt from production orders
After a material has been manufactured using a production order (finished product, assembly, single part), the quantity produced must be posted to the warehouse stock (or another type of stock). This, on the one hand, relieves your production area of the material and on the other hand, ensures that the material is available for follow-on activities (delivery to the customer, withdrawal for a project, ...). As supervisor or production operator, you trigger the goods receipt posting when you send a completion message. The posting itself is created automatically when a confirmation is entered or is carried out by the warehouse manager. Use the production order from the previous exercise to perform a goods receipt posting as described in the following procedure.
Order number: _________________
1-1
First check whether goods receipt is intended for the order.
Answer:
______
Path: S000 → LO → PP → SFC → ORDER → CHANGE → GOTO → HEADER
→ Select the tab GOODS RECEIPT (C) SAP AG
LO215
10-11
1-2
Check the material stock of material "T-F1##" Material stock:
______________
Path: S000 → LO → PP → SFC → INFOSYSTEM → STOCK OVERVIEW 1-3
Perform a good receipt for a partial quantity of one piece of the production order. 1-3-1 First go to the detail screen of the posting. Here, check the proposed data. Path: S000 → LO → PP → SFC → GOODS MOVEMENTS → GOODS RECEIPT Select the pushbutton COPY + DETAIL For information about the movement type of the goods receipt from production, choose Movement type.
1-3-2 Which transaction type does the material document have? To find out, go to the document overview
Answer: Path:
____________________________________
Select the pushbutton COPY
→ GOTO → OTHER FUNCTIONS → HEADER 1-3-3 Save the goods receipt posting.
Material document no.: __________________
(C) SAP AG
LO215
10-12
1-4
Check the updated version of the delivered partial quantity in the order. Which status does the order now have?
1-5
Answer:
________
Now perform a goods receipt for the remaining quantity of the production order.
Material document no.: __________________
1-6
Check the updated version of the production order again (quantity, status, costs). Which status does the order now have?
Answer:
________
1-7
Check the material stock of material "T-F1##" Use the stock overview to do this.
1-8
Check the stock in the stock/requirements list for material "T-F1##" Is the delivered order still in the list?
Answer:
1-9
________
Display the material and accounting documents of the goods receipts that you have performed. Path:
S000 → LO → MM → INVENTORY MANAGEMENT → MATERIAL DOCUMENT → DISPLAY → Document header → Item overview
1-10
Determine the numbers of the respective controlling and accounting documents. Controlling document ____________________ Accounting document ____________________
(C) SAP AG
LO215
10-13
Path:
(C) SAP AG
→ ENVIRONMENT → FI/CO DOCUMENTS
LO215
10-14
Goods Receipt Solutions Unit: Goods Receipt Topic: Goods Receipt (LO215 Exercise 11)
1-1
Answer:
1-3-2 Answer:
Yes
WF (Goods receipt for production order)
1-4
Answer:
PDLV
1-6
Answer:
DLV
1-8
Answer:
No
(C) SAP AG
LO215
10-15
Settlement/Archiving/Deletion: Contents
Order settlement Activities Execution Results
Archiving and Deleting Preparation Archiving deleting
Retrieval
© SAP AG 1999
(C) SAP AG
LO215
11-1
Settlement/Archiving/Deletion: Course Objectives
At the conclusion of this unit you will be able to: Define the purpose of order settlement Explain when and how order settlement is carried out Recognize the important control parameters for this function Describe the results of order settlement Describe the necessary steps for archiving and deleting a production order Deleted orders can be displayed again using a retrieval function. Recognize which control parameters to set © SAP AG 1999
(C) SAP AG
LO215
11-2
Overview Diagram (11)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
(C) SAP AG
LO215
11-3
Crediting and Debiting Costs (Order-Related COC)
Debit
Production order
Material costs Production costs External activities Process costs Overheads on material
Material withdrawal
M E V X G
Processing
1000 100-100 1421 4230 1310 External processing 300900 Additional raw material
Confirmation
12.000 25.000 8.000 12.000 8.500
Goods receipt
12 11 1 10 2 9 3 8 4 7 6 5
Order settlement
Archiving / deleting
Production order credits GR valuation control
Settlement Profile Settlement receiver
Material stock account (Qty. * Standard price/Price from valuation var.) Plant activity account (Qty * Price from valuation variant)
Actual costs for Settlement time © SAP AG 1999
Distribution rule Settlement parameters Settlement account (according to allocation structure) Plant activity account Difference account
The method of crediting and debiting the costs of a production order depends on the Cost Object Controlling variant selected in controlling. It can be executed with reference to the order or with reference to the product Order settlement is carried out to credit an order. In general, settlements are carried out periodically. You control settlements using a settlement profile. You must credit orders according to cost element. Cost element allocation between the debit cost element (production order) and the credit cost element (cost receiver) is performed via an allocation structure. Differences are either posted to the price difference account (expenditure / revenue) or cause the allocation price to be corrected. The use of the order-related cost object controller is beneficial in the following cases: Flexible production environment Flexible product pallet Cost management of individual production lots Costs need to be traced for each order High setup costs Co-production For more detailed information about cost object controlling, see course AC510 or AC515. (C) SAP AG
LO215
11-4
Settlement Profile Permissible settlement receiver - Cost center - Order - Project - Cost object - Asset ......
Allocation structure Assignment of debit cost element to the settlement cost element
Parameters - Document type - Maximum number of distribution rules - Residence time of the documents Indicators - 100% validation - Percental settlement - Equivalence numbers - Variance calculation
PA transfer structure Assignment of debit cost element to the value field of a profitability segment
Source structure
Default values - Settlement schema - PA transfer structure - Account assignment - Source structure
Assignment of debit cost element to the line in an apportionment structure for co-products
© SAP AG 1999
The settlement profile is composed of several elements: Allocation structure Source structure PA transfer structure Permissible settlement receiver and proposed account assignment Special control parameters The settlement profile for a production order is determined by the order type. PA transfer structures are required for the cost distribution of profitability analysis objects. Source structures are required for the cost distribution in co-production.
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LO215
11-5
Allocation structure
Debit cost elements
Settlement cost categories
Material (ext.) 400000 400100 400200
650000
G Material
Material (int.) 400000 400100
650100
G Material
Activities 600000 620000
651000
Text
© SAP AG 1999
The allocation structure controls the conversion of debit cost elements to settlement cost elements. You can save default values in the settlement profile. Similarly, the PA transfer structure controls the conversion of debit cost elements in the value components of the profitability analysis. A PA transfer structure is only required when you settle to a profitability segment (for example to a sales order). You have the option of defining cost element groups instead of entering individual cost elements.
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LO215
11-6
Cost Object Controlling - Product-Related Production Production orders Production orders order
Material costs Labor costs Machine costs
PCCcost collector product
. . . . . . . . .
COCOPC
Tgt Act. WIP Var.
$ $ $ $
product cost collector Actual costs of period = GR + WIP + Variance
Actual costs of period = GR + WIP + Variance
Period 1
Period 2
Actual costs of period = GR + WIP + Variance
Period 3
Time
Period end closing: Process costs Surcharges Goods in process Deviations Settlement © SAP AG 2003
In product-related cost object controlling, all costs are credited and debited to a product cost collector. Individual production orders do not have cost segments or settlement rules. All functions in production and materials management that are relevant to costs (material withdrawal, confirmation, goods receipts for the production order and goods receipt from production) are executed on the basis of the production order. All Controlling functions (process costs, overhead costs calculation, WIP and variance calculation, settlement) are executed at the end of the period on the basis of the production cost collector and the corresponding values are then determined. The costs for a period include: The values of the finally delivered material quantities of the period according to the valuation control of the goods receipt. The values for unfinished products (WIP) according to the level of confirmed operations The values of variances (for example, scrap)
(C) SAP AG
LO215
11-7
Crediting and Debiting Costs (Product-Related COC) Debit
Product Cost Collector
Material costs Production costs External activities Process costs Overheads on material
Material withdrawal
M E V X G
Processing
1000 100-100 1421 4230 1310 External processing 300900 Additional raw material
Confirmation
12.000 25.000 8.000 12.000 8.500
Goods receipt
12 11 1 10 2 9 3 8 4 7 6 5
Order settlement
Archiving / deleting
Credit product cost collector GR valuation control
Settlement Profile Settlement receiver
Material stock account (Qty. * Standard price/Price from valuation var.) Plant activity account (Qty * Price from valuation variant)
Actual costs for Settlement time © SAP AG 1999
Distribution rule Settlement parameters Settlement account (according to allocation structure) Plant activity account Difference account
Settlement is period-oriented and is based on the costs of the product cost collector. Order settlement for individual production orders is not applicable here. In this case, the production order does not have a settlement rule. For the in-house production of material, standard price control is generally recommended. The use of the product-related cost object controller is beneficial in the following cases: Make-to-stock production repetitive manufacturing, mass production sales order controlling, only in the profitability analysis
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LO215
11-8
Archiving and Deletion - Procedure
DLFL
1
Deletion flag
Deletion indicator
R/3 Database Production Production orders Production orders order
DLT
2 3
Archiving
Deletion from the R/3 database
4
Archive file Production Production orders Production orders order
Retrieval
5
Archive management
6
© SAP AG 1999
The deleting and archiving of orders is carried out in stages. Certain conditions need to be checked before an order can be physically deleted and archived. You have the option of individual or mass order deletion. A retrieval function is available for displaying orders that have been archived yet already physically deleted. The deleting and archiving functions for production orders use the central archiving tools of the R/3 System. This makes it possible to apply various archiving systems. In archive management, you can manage and display an index list of the archived production orders.
(C) SAP AG
LO215
11-9
Order Statuses and Transactions Allowed TECO
CLSD
Delivery tolerance time
DLV
Residence time 1
DLFL
Residence time 2
DLT Archive file
Display status
X
Reversible Actual costs = 0 No liabilities
TECO Technically completed CLSD DLV
Closed
Delivered
DLFL Deletion flag
DLT
Deleted
© SAP AG 1999
These are the conditions required for the following statuses: CLSD Order is released or technically completed, no liabilities and there are no future change records from confirmations, cost balance = 0 DLFL Order is delivered or technically completed, no liabilities and future change records from confirmations, cost balance = 0 DLT Order has deletion flag and residence time 1 has gone by The following statuses still allow the following functions: TECO confirmations, goods movements CLSD Set deletion flag DLFL Set deletion indicator DLT Archiving and deletion Residence times are defined with reference to the order.
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LO215
11-10
Order Settlement: Summary
In this unit the functions of order settlement were discussed In general order settlement is carried out periodically. Order settlement is controlled by a settlement profile. As a result of order settlement the order itself no longer has any costs and can be deleted. Orders go through the steps preparation for deletion, archiving and deletion. Deleted orders can be displayed again using a retrieval function.
© SAP AG 1999
(C) SAP AG
LO215
11-11
Order settlement, archiving and deletion Exercises Unit: Order settlement, archiving and deletion Topic: Order settlement (LO215 Exercise 12)
• Order settlement
After the goods receipt for a material has been posted (finished product, assembly, single part), any existing actual costs (debits) must be dealt with so that the order can be deleted at a later stage. This crediting of the production order is a task carried out internally by the controlling department in your company. It is carried out using the "Settlement" function. This function is usually carried out on a monthly basis using a background program. As production scheduler or supervisor, you have no activities to carry out. You should simply know that the function must be carried out before orders are deleted. Use the following procedure to carry out order settlement for the production order that you created in the previous exercise. Order number: _________________
1-1
Check the settlement rule for the order (settlement parameters, splitting rule). How is the recipient, in accordance with the posting rule?
Answer:
Acct assgmt type
___________________
Recipient ___________________ Path: S000 → LO → PP → SFC → ORDER → CHANGE → GOTO → HEADER → HEADER → SETTLEMENT RULE (C) SAP AG
LO215
11-12
1-2
Which settlement profile controls the settlement of the production order?
Answer:
____________
Path: GOTO → SETTLEMENT PARAMETERS 1-3
Calculate the overhead for the actual overheads with dialog display andposting (no test run). Total overheads:
____________________
Path: S000 → LO → PP → SFC → PERIOD-END CLOSING → OVERHEADS → INDIVIDUAL PROCESSING 1-4
Display the Balance function to view the order debit. Which amount must be calculated? ___________
Path: Return to the order header → GOTO → COSTS→ BALANCE 1-5
Perform settlement with posting (no test run). Path: S000 → LO → PP → SFC → PERIOD-END CLOSING → SETTLEMENT → INDIVIDUAL PROCESSING 1-5-1 A pushbutton enables you to trace the values to be posted and the accounting documents that are created.
Path:
→ GOTO → DETAIL LISTS → ADDITIONAL DATA → ACCOUNTING DOCUMENTS Settlement document no.:
(C) SAP AG
____________________ (accounting document) LO215
11-13
1-5-2 Display the settlement document and examine it in detail. Which document type has been posted?
Answer:
Path:
____
→ ORIGINAL DOCUMENT
→ ADDITIONAL DATA → DOCUMENT HEADER 1-6
Display the settlement document in the financial accounting module. Select only a few documents for the latest date of entry Path: S000 → ACCOUNTING → FINANCIAL ACCOUNTING → DOCUMENT → DISPLAY → Select the pushbutton → LIST Select using the document number
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LO215
11-14
Order settlement, archiving and deletion Exercises Unit: Order settlement, archiving and deletion Topic: Archiving and Deleting (LO215 Exercise 13)
• Deletion flag • Archiving • deleting • Retrieval • Archive info system Production orders that have been completed in your area (goods receipt has been posted), must be archived and deleted after a stipulated period that you specify in Customizing. This ensures that the volume of data contained in the database is restricted and prevents it from constantly increasing over time. Archiving and deletion is the task of the system administrator in your company. As a rule, he or she carries this out on a monthly basis in the form of a few background programs. As production scheduler or supervisor, you have no activities to carry out. You should simply know that these functions are necessary and how they are carried out. If orders were deleted once from the R/3 database, there is a function available that enables you to display orders from the archive. Use the following procedure to set a deletion flag, archive, and delete the production order that you created in the previous exercise and also display it from the archive.
Order number: _________________ 2-1
First, set the deletion flag and the deletion indicator for the order. 2-1-1 Maintain a job variant "LO215_L##" with the following program parameters.
(C) SAP AG
LO215
11-15
Order number
________________
Exceeding of delivery date
Blank
Actions
Deletion flag Deletion indicator No test run
Options
No detailed log Path: S000 → LO → PP → SFC → TOOLS → ARCHIVING → ORDERS → Select pushbutton "DELETION FLAG" / DELETION INDICATOR" Maintain the program parameters Go back one step and by doing so, save the values. Name the program variants that you have newly created and save them. 2-1-2 Define the start date of the job. Choose immediate start. After saving, the traffic light must be green! Select the pushbutton → START DATE
Path:
2-1-3 Maintain the parameters for printing the log After saving, the traffic light must be green! Path:
Choose the pushbutton SPOOLPARAMETER
2-1-4 Start the job. 2-2
Check the status that is set in the order. What is it?
Answer: 2-3
______
and
______
Now archive the order. 2-3-1 Maintain a job variant "LO215_L##" with the following program parameters. Order number
(C) SAP AG
________________ LO215
11-16
Create archiving file
activate
Deletion program as test
activate
Path: S000 → LO → PP → SFC → TOOLS → ARCHIVING → ORDERS → Select pushbutton "ARCHIVING" Maintain the program parameters Go back one step and by doing so, save the values. Name the program variants that you have newly created and save them. 2-3-2 Define the start date of the job. Choose immediate start. After saving, the traffic light must be green! Path:
Select the pushbutton → START DATE
2-3-3 Maintain the parameters for printing the log After saving, the traffic light must be green! Path:
Select the pushbutton SPOOL PARAMETERS
2-3-4 Start the job. 2-4
Delete the production order from the R/3 database. Path: S000 → LO → PP → SFC → TOOLS → ARCHIVING → ORDERS → Select pushbutton "DELETE" 2-4-1 Select the archive file that you created in step 2-3. After saving, the traffic light must be green! Path:
(C) SAP AG
Select the pushbutton ARCHIVE SELECTION and select the files archived today.
LO215
11-17
2-4-2 Define the start date of the job. Choose immediate start. After selection, the traffic light must be green! Select the pushbutton → START DATE
Path:
2-4-3 Maintain the parameters for printing the log After saving, the traffic light must be green! Path:
Select the pushbutton SPOOL PARAMETERS
2-4-4 Start the job. 2-5
In the archiving information system, check that your order number is also actually contained in the archive file. Use the archiving step ADMINISTRATION to carry out this check. Path: S000 → LO → PP → SFC → TOOLS → ARCHIVING → ORDERS → Select pushbutton "ADMINISTRATION" 2-5-1 Select the INFO SYSTEM pushbutton and go into the Archive Explorer. Path: → GOTO → INFOSYSTEM → ARCHIVING INFORMATION STRUCTURES → ARCHIVE EXPLORER Enter the following parameters: Archiving object
PP_ORDER
Archiving information structure
SAP_PP_ORDER001
2-5-2 Start the display without any further restrictions. 2-6
Use the normal order menu to try to display the order. Can the system display the order?
Answer:
(C) SAP AG
______
LO215
11-18
2-7
Use the retrieval function to display the order from the archiving file. Use the overall profile ‘000000000005’ and select the archiving file that you have created. Path: S000 → LO → PP → SFC → TOOLS → ARCHIVING → ORDERS → Select pushbutton "RETRIEVAL" In the selection screen, select the pushbutton ARCHIVE SELECTION
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LO215
11-19
Order Settlement, Archiving and Deletion Solutions Unit: Order settlement, archiving and deletion Topic: Order settlement (LO215 Exercise 12)
Answer:
1-1
Acct assgmt type
Recipient 1-2
1-5-2 Answer:
(C) SAP AG
Answer:
MAT
T-F1##
(Material stock) (Material)
FA_ABP
SA
LO215
11-20
Order Settlement, Archiving and Deletion Solutions Unit: Order settlement, archiving and deletion Topic: Archiving and Deleting (LO215 Exercise 13)
2-2
Answer:
DLFL and
2-6
Answer:
No
(C) SAP AG
DLT
LO215
11-21
Information Systems: Contents
Overview of information systems for production orders Order information systems (possible applications, structure, customizing selection profiles)
Multi-level order overview for sales orders Missing parts information systems Shop floor information systems Object overviews (structure) Controlling reports
© SAP AG 1999
(C) SAP AG
LO215
12-1
Information Systems: Course Objectives
At the conclusion of this unit you will be able to: Describe the production order's various information sources Define the following available options: Order Information System Multi-level order overview for sales orders Missing parts information systems Shop floor information systems Object overviews Controlling reports
Describe the special features of these options
© SAP AG 1999
(C) SAP AG
LO215
12-2
Overview Diagram (12)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
(C) SAP AG
LO215
12-3
Information Systems for Order Management Basis
(1) Order information system
Multi-level order overviews for sales orders
Orders
(1)
Order structure and operations
(1)
Missing parts record (index record)
Missing parts information systems
CO object for Orders
Controlling reports Production information system SFIS component of LIS (Logistics Information System)
LIS library
(1) Object overviews
Orders
© SAP AG 1999
There are several information systems for production orders. They differ in terms of how the order database is used (directly and indirectly) as well as in terms of the kind of statements that are offered. A profile controls the preparation of the systems marked with (1). The profiles are set up in Cusomtizing by choosing SHOP FLOOR CONTROL + INFORMATION SYSTEMS. If the systems are used for list preparation in individual production orders, you can control the profile in the order-type dependent parameters (T399X) for each order type. In addition to the above mentioned systems, there are capacity evalauations, batch where-used lists and other lists.
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LO215
12-4
Order Information System
Lists for control purposes Actual start/actual finish > Planned start/planned finish Actual scrap > Planned scrap Workload per work center (profile 00000002) PRT requirements list
Lists as a basis for operative decisions Selection of delayed orders Selection of orders with missing parts
Mass processing (many sorts of functions) See next unit
Records of finished production processes Documentation of goods movements Display of confirmations © SAP AG 1999
The order information system is a tool for controlling production. The system works directly with the order database and offers both evaluation (reporting) and mass processing functions (see the Mass Processing unit). It enables you to display information tailored to your requirements (layout can be adjusted). It combines the logical structure and the graphical user interface of the Logistics Information System with the hierarchical display used in IMG and other R/3 applications. The order information system is integrated into the following components of the Logistics System (MM, SD, PS).
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LO215
12-5
Selection Order objects that can be displayed
Selection criteria Order number Plant Order type Material MRP controller Production scheduler Customer number Sales order Project Work center Operation Operation status Component Component status WBS element
Logical database IOC
Header Item Sequence Operation Component Confirmation Capacity requirements Prod. resources/tools Trigger point Goods movements Error during goods movement Purchase requisition (4.0) Purchase order (4.0) Object overview
© SAP AG 1999
Using the selection profile (that can be called up in customizing), you are able control which objects you want to display and with which: fields grouping sort sequence The purchase requisition and purchase order objects only encompass external processing. Documents are not yet included.
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LO215
12-6
Individual Object List Variable display
Order: 60004573 Plant: 1000 Material Requirements qty
grouping Committed qty
Reqmts date
100-100
120 pc
100 pc
02.06.98
100-200
130 pc
120 pc
04.06.98
100-300
100 pc
100 pc
10.06.98
Order: 60004574 Plant: 1000 Material Requirements qty
field selection / sequencing
Filter Field comparison
Committed qty
Reqmts date
100-100
220 pc
0 pc
04.06.98
100-200
10 pc
10 pc
04.06.98
100-300
100 pc
100 pc
04.06.98
Order: 60004574 Plant: 1000 Material Requirements qty
sorting
Committed qty
Reqmts date
100-100
220 pc
0 pc
01.06.98
100-200
10 pc
10 pc
04.06.98
100-300
100 pc
100 pc
04.07.98
Graphic Refresh completely / partly Call up objects / carry out business transactions Print
© SAP AG 1999
The order information system provides object-related inidividual lists and an object overview (standard list for order headers). The (object) individual list enables you to deal with the individual objects (operation, components and so on) in different ways. You can display detailed data for each selected object. The content and structure of the lists can be determined on an individual basis. As of Release 4.6C, two transactions with the following characteristics or special features are available for the order information system. CO28: Not in the menu, controlled by a profile, all characteristics on the slide apply, list preparation isnot based on ALV COOIS: In the menu, controlled by the layout, no grouping and no field comparison, based on ALV
(C) SAP AG
LO215
12-7
Object overview Order structure in graphical form
Order 1 Order no.
MRP contrllr
Plant
60004574
101
1000
Variable object selection Hide / show objects function
Item Material
Reqrmts qty
Start
P-100
120 pc
03.08.98
Variable field selection and sequencing Header information
Operation
Hide orders Work center 1904 60004575
140
Control key
Refresh completely / partly
PP01 1000
Call up objects / execute business transactions
Item Material
Reqrmts qty
Start
P-200
125 pc
04.08.98
© SAP AG 1999
The object overview displays the objects selected from the production orders in hierarchical form. You can determine the objects to be selected.
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LO215
12-8
Order Information System: Customizing
Overall profile Profile variants Filter order type Object profiles
Object overview
Profile "field selection"
Detail list
Profile "field selection" Profile "group criteria"
Indicator "hide object" Profile "sort criteria" Indicator "expand to object" Additional information
User filter Status filter © SAP AG 1999
You can create order information system profiles in Customizing for production orders (transaction CO28). Layouts of the order information system (transaction COOIS) are set up in the application (4.6C)
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LO215
12-9
Variable Object Overviews
Material or planning group
Sequences
Operations
Standard seq.
Material components
Parallel seq.
Prod. resources/tools
Alternative seq.
Suboperations
Inspct.characteristics Trigger Points
Create overview
Overview ID Overview name Line width
Define objects
Line category (header, title, item) Output characteristics
Define fields Select fields per line Field sequence Field attributes
© SAP AG 1999
Object overviews enable you to create varying displays of routings and production orders. Object overviews can be freely defined in Customizing. In order to create an object overview, you must observe a predefined maintenance sequence. For further information on the topic consult the implementation guide.
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LO215
12-10
Order Progress Report
© SAP AG 1999
An order progress report is available in Release 4.5. It enables you to clearly chart the progress of all business transactions (in-house production and external procurement) that are required when carrying out a sales order or project, and to process them. The current stock situation, future stock level over time and the order progress report from confirmations are all fully included in this report. The report contains a warning system that informs you of date and quantity variances, enabling you to actively manage sales orders and projects. MRP controllers can directly trigger procurement by converting planned orders.
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LO215
12-11
Order Progress Report - Characteristics
Objects
All business transactions settled to a sales order or WBS element, including their current component structure Planned orders, production orders, process orders, networks, purchase orders, purchase requisitions, delivery schedules, contract release orders, deliveries, stock (plant, safety, project, customer, sales order)
Functions
Convert planned orders to PrO or PReq Display and change all objects Refresh Progress determination and warning system for each object (date/quantity variance) Print
Navigation to
Stock overview, stock/requirements lists, MRP list, pegged requirements, sales document flow, purchase order history, material document
© SAP AG 1999
Display all procurement elements created automatically (MRP) or manually which are settled to a sales order and/or a WBS element Dynamic explosion of the component structure for each procurement element. Explosion of the whole structure gives you a quicker overview of the progress of external procurement and in-house production You can actively change individual business transactions Information about adherence to delivery dates or possible delays and about quantity variances Variable list structure (profile-controlled preparation, hierarchical and expandable presentation of the structure, field selection technique) Variable navigation options (expand, collapse, sub-tree presentation, focus on particular levels, expand up to exceptions)
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LO215
12-12
Order Progress Report - Warning System Meaning of the warning symbols Sales order
Execeptions exist for this element
Material P-100 Expected delay >0
Production order
Expected delay in dates is too long Actual
Material 100-100
Plnnd PS
Planned order
SS
SF
PO
Element are settled to the sales order
Material 100-200 Missing quantities are too big
Purchase order
Expected delay = 0
Purchase order
Current delay in dates is too long Actual Plnnd PS
SS
SF
PO
© SAP AG 1999
If the system is to determine variances, then the Progress values indicator must be set in Customizing (T399X Order type-dependent parameters). If the indicator is set, the system writes processing requests in the cases listed below. These can be processed directly in the order progress report or in the background via a program PPORPCRE. Processing requests for variances are only created if the tolerance limits defined in the selection profile (Customizing) are exceeded. In detail, the variances mean Yellow traffic light Basic start date (planned order), release date (PReq) is in the past, latest schedule line date comes after the required delivery date (purchase order), actual date exceeds the planned finish date of the last operation finally confirmed and the float after production is smaller than this exceeded quantity (production order) Red traffic light Basic finish date (planned order), required delivery date (PReq, purchase order) is in the past, production finish date comes after the basic finish date (production order) Yellow bell Expected receipt quantity according to yield of the last finally confirmed operation is less than the planned yield of the order (production order) Lock The material component in the order is a missing part (production order)
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LO215
12-13
Multi-level Order Report
Multi-level information about the status of the sales orders (based on the product's static BOM)
Information about critical situations for sales orders, planned orders, production orders
Progress reports for individual orders Decision-making basis for confirming sales orders The function can be triggered from a sales order item (SD) from the production orders menu ("Information System") from the material requirements planning menu
© SAP AG 1999
The order report facilitates integration between SD, PP and MM. It provides the sales department with comprehensive information concerning the status of materials requirements planning, external procurement and the progress of sales orders.
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LO215
12-14
Control Reports (Report Tree) MakeMake-toto-order production Overview Order hierarchies Sales orders Orders
Order selection and summarization Classification Sales order: 1234 Cost categories
Sales order plan
Actual total
Cost categories 410000 619000
Order hierarchies
3.000 50.000
2.000 30.000
Sales orders Orders
. . .
Line items actual / accruals Costing sales orders © SAP AG 1999
You have a series of controlling reports at your disposal. The basis of these reports is the report writer. You can either use standard reports or formulate your own. You access the controlling reports via Shop floor control + Info system + Controlling reports. Current orders must be classified before you are able to execute order summarization. In addition, the "automatic classification" switch needs to be activated in the order type (table T003O) and the characteristics of the standard class SAP_KKR_CLASS specifically generated (Customizing CO, transaction OKQ3).
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LO215
12-15
SAP Logistics Information System
LIS SIS
PURCHIS
INVCO
PPIS 1988 1994 R1 ------ -----: ------ -----R4 ------ ------
QMIS
PMIS
WMIS
SD
MMMMPUR
MMMMIM
PP
QM
PM
WM
R/3
RIS
© SAP AG 1999
The Production Planning Information System (PPIS) is reached from the logistics controlling menu. SAP Logistics offers a series of application-related information systems. These all have a uniform user interface and a comparable basic functionality. The manner in which data is retained is identical in all logistics information systems. A variety of special tools and working methods emphasize the typical characteristics of a data warehouse in LIS. In Logistics, you are able to distinguish between the following information systems: SIS Sales Information System PURCHIS Purchasing Information System INVCO Inventory Controlling WMIS Warehouse Management Information System PPIS Production Planning Information System QMIS Quality Management Information System PMIS Plant Maintenance Information System RIS Retail Information System PPIS uses its own data basis in the form of various info data structures. The info structures are brought up to date by the production order update program. PPIS enables you to configure your own analysis programs for production orders. Info structure data is not deleted along with the production order but specially reorganized. It is therefore possible to carry out evaluations in LIS even after orders have been deleted. Application options and prerequisites are dealt with in course LO275
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LO215
12-16
Information Systems: Summary
This unit gave you an insight into the various information sources available for shop floor control Order management can be effectively supported by: Order Information System Multi-level order overview for sales orders Missing parts information systems Shop Floor Information System (LIS) Object overviews Controlling reports
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LO215
12-17
Information Systems Exercises Unit: Information Systems Topic: Information Systems (LO215 Exercise 14)
• Order information system • Order process report with warning system
As production scheduler, production manager or supervisor, you need constant reports about the status of individual orders, or about large numbers of orders, that are currently being used in the production process, are already confirmed, delivered or have already been deleted. In particular, you need a quick overview of orders that have not been started or finished on time. It is not only important for this group in your company to have statements about orders for the daily control of production, but also to have an overview of the pool of orders at a work center. 1-1
Call the order information system with the following parameters: List
Order headers
Profile
000001
Production orders
activate
Planned orders
Deactivate
selection" Production plant
1000
Production scheduler 0## Path:
S000 → LO → PP → SFC → INFOSYSTEM → ORDER INFORMATION SYSTEM
1-1-1 Save these settings as selection variant LO215_0##
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LO215
12-18
Path: → GOTO→ VARIANTS → SAVE AS VARIANT 1-1-2 Carry out selection 1-2
Change an order for material T-F1##. 1-2-1 Replace the work center of the first operation with the work center T-L##. 1-2-2 Save the order. Path: Select the order → ENVIRONMENT → CHANGE ORDER → OPERATIONS
1-3
Select the changed order in the list and refresh the changed object Path:
1-4
→ LIST → REFRESH → SELECTED OBJECTS
Use the order progress report to check the situation of the sales order that you created in exercise number 4. Call the report with the following parameters: Element selection Plant 1000 sales order no. _____________
____
Profile PP0000000001 Path:
S000 → LO → PP → SFC → INFOSYSTEM → ORDER PROGRESS REPORT
1-4-1 If you have not already done so, open a second session and execute the following functions parallel to the order progress report
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12-19
1-4-2 In material requirements planning, insert a planned order for material 100-300 with reference to your sales order. Planned order profile KD Order quantity
2 piece
End date
Any
Prod. plant
1000
Sales order no.:
_____________
____
Path: S000 → LO → PP → MRP → PLANNED ORDER → CREATE 1-4-3 Refresh the order progress report and check the appearance of the planned order for material 100-300. 1-4-4 Convert all planned orders to production orders. Path:
Use the pushbutton to select the planned orders Convert by choosing → FUNCTIONS → PLANNED ORDERS CONVERT TO PRODUCTION ORDERS Refresh the report and check that production orders have been created.
1-4-5 Release the production order for material T-B3##. 1-4-6 Confirm operation 0010 of this production order. Use the confirmation type: time ticket confirmation and note the following: Final confirmation Dates Start execution finish execution
one month later one month later
Path: Expand the field group DATES in the confirmation screen and change the entry for the month (C) SAP AG
LO215
12-20
1-4-7 In the order progress report, execute the "Update progress values" function. Path:
→ FUNCTIONS → UPDATE PROGRESS VALUES
Refresh the report and check whether a warning was issued 1-4-8 Carry out an availability check for the order, for material T-F1##.
Check whether a warning message was issued 1-4-9 Find out what the warning means. Path:
→ LIST → KEY The next activities in the exercise are optional. Only carry this out if you have enough time. In the following steps, you create a work center-related order overview.
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LO215
12-21
1-5
Use transaction CO28 to call the order information system with the following parameters: List
Operations
Profile
000001
Production plant
1000
Production scheduler 0## Path:
S000 → LO → PP → SFC → INFOSYSTEM → ORDER INFORMATION SYSTEM
1-5-1 Group the list of work centers in ascending order Path: → View → Group → Field selection → Substitute the proposed group fields with the work center numbers. 1-5-2 For this list, set up the following field selection and sequence for the displayed operations.
Latest start date processing (LatestStDateProc.) Order number Operation quantity Operation short text Path:
→ VIEW → SELECT FIELDS → Substitute the current fields with the given fields and sort the fields into the sequence.
1-5-3 Sort the list in ascending order according to the latest start date for processing (LatestStDateProc). Path:
Place the cursor on the required column
→ VIEW → SORT → COLUMN ASCENDING 1-5-4 Add up the total operation quantity for each work center.
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LO215
12-22
Path:
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→ VIEW→ TOTAL
LO215
12-23
Informations Systems Solutions Unit: Information Systems Topic: Information Systems (LO215 Exercise 14)
No answers are required for this exercise.
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LO215
12-24
Mass Processing and Automation: Contents
Mass processing (HVOM) Automatic creation, release and printing Automation options for confirmations Automation options for goods movements (material withdrawal and goods receipts) Later import of reference operation sets Trigger points (variable operation related automation) Generation of transport requirements and inspection lots Selection of workflow © SAP AG 1999
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LO215
13-1
Mass Processing and Automation: Course Objectives
At the conclusion of this unit you will be able to: Describe the automation options for more streamlined production order management Recognize the advantages and effects of these solutions Explain how to control and apply the individual options
© SAP AG 1999
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LO215
13-2
Overview Diagram (13)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Material Staging
7
Mass Processing and Automation Collective Orders
13 14
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LO215
13-3
Automation Options Operation to be automated
Event
Control
Mass Processing
Any
Transaction COHVOMPP
Create prod. order (assembly order)
Create sales order
Planning strategy 82
Create rework order
Confirmation (set status)
Trigger points
schedule order
Release production order
Production Scheduling Profile
Changes to production order
Schedule param. for order type
Availability Check
Prod. order creation / release
Parameters for order type
Release entire prod.order
Create production orders
Production Scheduling Profile
Release operations
Confirmation (set status)
Trigger points
Print
Release production order
Production Scheduling Profile
WM requirement (transport reqmts)
Release production order
Production Scheduling Profile
Post goods issue (backflush)
Confirmation
Master, work center, or BOM component assignment
Operation confirmation
Milestone confirmation
Operation control key
Plant data collection
PDC interface
Post goods receipt
Confirmation
Operation control key Production control profile
Variable automation (such as workflow, insert operations)
Confirmation (set status)
Trigger points
Multi-level collective orders
Create production orders
Special procurement key 52
Process multiple production orders
Any
Order Information System
© SAP AG 2003
The R/3 System comprises a number of automation options for rationalizing and saving time in order management. In addition to the above, the following functions should also be noted: Batch creation (production scheduling profile) Batch determination (batch search strategy) Stock determination (stock determination profile)
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13-4
Mass Processing in the Order Inf. System (HVOM)
Mass Processing
Function
No function Close Set user status / delete Print Release Costing Picking Material availability Log display Confirmation Technical completion Scheduling Increase capacity requirements WM material staging
Immediate execution Background processing Create proc. request
+
Function-specific parameters
© SAP AG 1999
Mass processing of production orders has been redesigned as a standardized concept. It has been integrated into the order information system (COOIS) and works quickly and without a dialog. Advantages of mass processing (HVOM) are: Execution online or in the background Separation into "requests for processing" and "processing" Parallel processing Enhanced, standardized selection criteria Standardized, adjustable display (field selection) Enhanced functions for release and scheduling Log book for background processing (application log) Mass processing can be started with the options: immediate execution, create function request or background processing. If function requests only are created for orders, these must be processed later with the COWORKDISPATCH program. Transactions from earlier releases (CO04,CO05, CO44) have been taken out of the menu but are still available.
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13-5
Mass Processing Functions (HVOM) PRT Close Set user status / delete Print Release Costing Picking Material availability Log display Confirmation Technical completion Scheduling Increase capacity requirements WM material staging © SAP AG 1999
The selected object determines whether or not individual functions can be used. The scheduling function can also be used specifically for rescheduling orders. Committed quantities from the material availability check can be released.
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13-6
Production scheduling profile Assignment options Production scheduler
Mat. master
Production scheduling profile Control options at creation
Automatic release Create document link (mat., BOM)
Control options at release
Automatic printing of document Rescheduling Create document link (mat., BOM)
Control options at confirmation
Automatic GR, adjustment of follow-up operations
Additional control options
Confirm partial quants (mat. availability check ) Overall profile for capacity leveling Activate capacity scheduling Basic load switch for capacity availability check Update surplus/deficit receipts Batch creation and classification Create transport requirements
© SAP AG 1999
Automatic functions can be triggered immediately at the time of order creation or at a later date. You control these functions with a production scheduling profile. The profile can either be assigned to a production scheduler (Customizing) or a concrete material master (Work scheduling screen). In both cases, the result is material-related control. In the production scheduling profile, default order types can be proposed for CO01 Make-to-stock production CO08 Make-to-order production CO10 Engineer-to-orderCO07 Without material
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13-7
Efficient Actual Data Entry
Backflush Posting
Manually per material
Backflush
Confirmations
Manually per operation
Milestones
Goods receipt posting
Manually per order
Automatic
© SAP AG 1999
There are a number of available options for optimizing actual data entry, which have already been dealt with in the preceding units. Confirmations can be simplified by using milestones (planned in the operation control key) or progress confirmations (unplanned milestone). Milestone or progress confirmations can also be used for entire collective orders (or sub-trees). Backflush postings can be executed automatically by confirmations. The indicator has to be set accordingly in the material master for the affected material components. Automatic goods receipts can be executed automatically with a confirmation. This must be set up in the operation control key of the operation in question or in the production scheduling profile.
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13-8
Event-Triggered Automation
Functions triggered by events at operation level
Functions triggered
Automation functions
Set and / or remove status
Release subsequent operations Release up to next "release point"
System and / or user status Define a "release point" Manually and / or status-triggered
Release previous operations Include a reference operation set
One time or always
Create a production order by copying
Combinations of options
Start a workflow task
© SAP AG 1999
You can control a number of business operations with trigger points. You can maintain trigger points in a routing or production order. You can maintain standard trigger points. It is possible to combine trigger points in groups. These can be set up in Customizing. Application examples: to create rework operations to create rework orders to send messages to release operations when the preceding operations have been confirmed and so on
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13-9
Mass Processing/Automation Summary
Order management can be highly automated. As of Release 4.6, there is a standardized concept for fast, variable and dialog-free mass processing. Using the production scheduling profile, orders can be automatically released, scheduled and printed. Backflush postings and milestone confirmations reduce the work involved when entering data to an absolute minimum. Other effects can be achieved by using trigger points.
© SAP AG 1999
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LO215
13-10
Mass Processing and Automation Exercises Unit: Mass Processing and Automation Topic: Mass Processing (LO215
Exercise 15)
• Use of mass processing of orders for selected functions (for example, release, print, confirm)
In the previous exercises, you have always processed individual orders (released, printed, confirmed). As a rule, this is not the way you work in your company. This work is carried out routinely and in the same manner for many orders using a background program. Usually, the mass processing program for orders is executed at night. The system administrator in your company is responsible for controlling mass processing. As production manager or supervisor, you must monitor this transaction and in particular, check it for errors. 1-1
Carry out mass processing of complete orders using the functions RELEASE and PRINT. When you do this, select all orders for your material that have not been released. If no production orders have been created for this material, then create more orders yourself.
Path: S000 → LO → PP → SFC → CONTROL → MASS PROCESSING
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13-11
1-1-1
Select the tab Selection and select using the following parameters: Material
T-F1##
Production plant
1000
Order type
PP01
Production scheduler 0## 1−1−2 Select the tab MASS PROCESSING and carry out the following settings: Function
Release Execute function immediately Execute change of data
Function parameter
Path:
Order Release
PROGRAM → EXECUTE
Select all the orders proposed by the system 1-1-3 Carry out mass processing
Path:
MASS PROCESSING → EXECUTE Depending on the situation, it is possible that the system may issue messages about material, capacity or PRT availability shortages. Release the orders despite this.
1-1-4 Check the release log for possible errors (C) SAP AG
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→ MASS PROCESSING → LOG of last MP
Path: or
→ pushbutton ORDER 1-2
Now print the orders from 1-1 using mass processing.
1-3
Check the printing log for possible errors
1-4
Now confirm some of the orders from 1-1 using mass processing.
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LO215
13-13
Mass Processing and Automation Exercises Unit: Mass Processing and Automation Topic: Automation Options (LO215
Exercise 16)
• Automatic release of the order • Automatic print of order papers • Backflushing • Milestone confirmation • Automatic goods receipt In your company, orders are immediately released and printed, so that work can begin quickly in the production department. Material withdrawals are usually posted automatically at the time of confirmation. Each individual operation should not be confirmed because this involves too much work. Therefore, you use milestone confirmations, which are the only operations that have to be confirmed. 2-1
In the material master (work scheduling screen) of material T-F1##, enter the production scheduling profile 000002. Path: S000 → LO → PP → MASTER DATA → MATERIAL MASTER → MATERIAL→ CHANGE → IMMEDIATELY → Select the Work Scheduling view
2-2
In Customizing, find out about the current control parameter of production scheduling profile 000002 for plant 1000 Path: SPRO → PP → SFC → MASTER DATA → PRODUCTION SCHEDULING PROFILE
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LO215
13-14
2-3
Create a production order using the following data Material
T-F1##
Production plant
1000
Order type
PP01
Total amount
1 piece
Basic finish date
Any
Scheduling type
Backwards
and save the order. Order no.:
___________________
2-4
Check the status of the order.
2-5
How do you ensure that the goods issue postings are performed automatically?
Answer:
___________________________________________________ ___________________________________________________ ___________________________________________________
2-6
Set all the material components in this order to backflushing. Path: In the component overview, activate the "Bf" indicator for all material components.
2-7
How do you ensure that only the last operation must be confirmed and despite this, all preceding operations are confirmed with proportional quantities?
Answer:
___________________________________________________ ___________________________________________________
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LO215
13-15
2-8
How do you ensure that goods receipts are performed automatically?
Answer:
___________________________________________________ ___________________________________________________
2-9
Check whether the last operation of the order is set for automatic goods receipt and milestone confirmation. If necessary, replace the operation control key of the last operation with the value PP99.
2-10
Execute a final confirmation of the last operation for the order. During the processing procedure, ensure that all control parameters are active and that functions are performed automatically.
2-11
In the material master of material T-F1##, delete the production scheduling profile 000002.
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LO215
13-16
MassProcessing and Automisation Lösungen Unit: Mass Processing and Automation Topic: Mass Processing (LO215 Exercise 15)
No answers are required for this exercise.
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LO215
13-17
MassProcessing and Automisation Lösungen Unit: Mass Processing and Automation Topic: Automation Options(LO215
Exercise 16)
2-5
Answer: Backflushing must be activated in the material master, work center, component assignment to the operation or lastly, in the production order itself.
2-7
Answer:
By using milestones (switch in operation control key) or
by progress confirmation 2-8
Answer: You must activate the automatic goods receipt function in the production scheduling profile or in the operation control key
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LO215
13-18
Collective Orders: Contents
How individual orders are linked over multiple levels to create collective orders Areas of application and advantages Structure of collective orders Functions of collective orders Integration options
© SAP AG 1999
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LO215
14-1
Collective Orders: Course Objectives
At the conclusion of this unit you will be able to: Understand how several individual orders can be linked over multiple levels to create a collective order Ascertain where collective orders can be applied, and understand their advantages and limits Describe the structures and functions of collective orders Determine how collective orders can be integrated into different applications
© SAP AG 1999
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LO215
14-2
Overview Diagram (14)
Introduction
1
Order Control
8
Overview
2
Confirmations
9
Order Structure / Processing
3
Goods Receipt
10
Order Creation / Order Change
4
Settlement, Archiving and Deletion
11
Order Release
5
Information Systems
12
Printing Order Documents
6
Mass Processing and Automation
13
Material Staging
7
Collective Orders
14
© SAP AG 1999
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LO215
14-3
Advantages of Collective Orders
Minimal planning, management and maintenance effort
Optional automatic goods movements postings Execution of business transactions for collective order Date and quantity changes Availability checks Order Release Confirmations
Graphic display of all individual orders in the collective order Greater transparency of complex order structures Clear overview of relationships between orders Access to all orders belonging to a finished product with the leading order number Simple access to individual orders by double-clicking © SAP AG 1999
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LO215
14-4
Master Data for Collective Orders
Special procurement key "52" on MRP 2 screen MASTER DATA
Bills of material and routings at each assembly level Any structure possible
Pump
Pressure cap
Spiral casing
Revolution counter
Shaft
Thermostat
© SAP AG 1999
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LO215
14-5
Requirements Planning with Collective Orders
REQUIREMENTS PLANNING
Planned order 1
Planned orders created manually or by requirements planning
Pump
Planned order 2
Planned order 3
Pressure cap
Spiral casing
Revolution counter
Conversion and availability checks occur centrally via the finished product / assembly Changes to quantities and dates automatically change dependent orders during the next planning run
Shaft
Option of visible stock movements between the levels in Thermostat the stock/requirements list
© SAP AG 1999
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LO215
14-6
Production with Collective Orders
Prod. order 1
Warehouse
Pump
Production orders generated manually or from planned orders Conversion, release, availability checks occur centrally via the finished product/assembly
PRODUCTION
Prod. order 2
Pressure cap
Changes to quantities, dates and so on automatically lead to changes in dependent orders Shaft Option of stock movements between levels
Prod. order 3
Spiral casing
Costing of orders per assembly Revolution counter
Thermostat
Overall costs are the result of all levels
Warehouse © SAP AG 1999
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LO215
14-7
Requirements (1)
Order 1 Component Component Assembly
Material master, 2 MRP screen
Finished product
Special procurement key 52
1 2 1
52
E - In-house production E - Special procurement Direct production
Assembly
2 Bill of material, Item data Explosion type
Order 2 Component Component Assembly
Can be deactivated
Assembly 2 3 4 3
© SAP AG 1999
A separate subordinate order is created for each bill of material component whose material master has special procurement key 52 (direct production). You can deactivate the special procurement key in the material master using the Explosion Type field in the bill of material item. Other special procurement types, for example "production in another plant", can be combined with direct production (collective orders).
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14-8
Requirements (2)
Bill of material structure
Order Structure
Finished Product
Order 1
52
Component 1 52
Assembly 1
Component 2
Assembly 3
Component 3
Assembly 4
Component 5
Order 2
52
Assembly 2
Order 3
Order 4
52
Component 4
Order 5
Component 6
© SAP AG 2003
All orders of the collective order have the same order type. You can create the leading order with either an internal or external number. You can only create subsequent orders with internal numbers. The lot size indicator (from the material master) is not taken into account when individual orders are created. It is possible to add and delete individual orders. You can make every component of an order into an order (be it with or without special procurement key "52"). Production versions are passed down from the leading order to subsequent orders.
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LO215
14-9
Collective Order Views
Overview of the entire collective order
Entire Collective Order
Order 1
Order 2
Order 6
Individual orders
Order Order11
Order 3
Order 4
Subtree
Order 5
Order 7
Order Order21
Order 3
Order 4
Order 6
Order Order11
Order 5
Order 7
Order Order21
Order Order31
Order 4
Order61 Order
Order51 Order
Order71 Order
© SAP AG 1999
In a collective order, you have the option of managing single orders, subtrees, or the entire collective order. This has an effect on the functions that you are able to carry out within each of these views. You will need to closely examine all individual functions of the normal (single-level) production order in the corresponding view. The orders to be processed together must first be accessed (that is, read from the database). They can either be read from the database for the view in question when you initially enter the change transaction or dynamically during the dialog.
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LO215
14-10
Function Overview (1)
Maintenance can be carried out in... (read from DB) Function to be executed
Collective order
Subtree
Individual order
Coll. ord. overview
Create manually
CO
Convert planned order
CO
Graphic network overview
CO
ST
Delete assembly
CO
ST
IO
(1)
Add assembly
CO
ST
IO
(2)
Read in master data
CO
ST
IO
(3)
Scheduling
CO
ST
IO
Determine costs
CO
ST
IO
Availability Check
CO
ST
IO
Release
CO
ST
IO
Lock order
IO
IO
IO
Generate inspection lot
IO
IO
IO
Print
IO
IO
IO
WM staging
IO
IO
IO
CO, ST
CO, ST, IO (6) CO, ST, IO
© SAP AG 2003
Key: CO Function across entire collective order ST Function across subtree IO Individual order function FA Function can be controlled (exists), only has an effect per individual order OI Can be executed via the order information system (1) Deleting individual orders leads to the entire collective order being recreated. (2) Materials, whether with or without special procurement key 52, can be made into a new order within the collective order. (3) When the BOM is read, the entire collective order is recreated. The routing is only read for an individual order. (4) Goods receipts only occur on the level of the leading order (product). (5) Individual orders can only be confirmed using a milestone. (6) Only applies for materials and production resources / tools. You can only check the capacity per individual order.
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14-11
Function Overview (2)
Maintenance can be carried out in... (read from DB) Function to be executed
Collective order
Subtree
Material withdrawal Confirmation
CO
ST
Goods Receipt
IO
FA
IO
FA
(5) (4)
IO from 30F
IO
Settlement
IO
Set TECO
CO
ST
Set deletion flag
CO
ST
from 30E
from 30E
Set deletion indicator Archiving
Coll. ord. overview
IO
Determine surcharges Determine variances
Individual order
FA
IO from 30E
© SAP AG 1999
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LO215
14-12
Scheduling
Types of sceduling Forward scheduling Backward scheduling
Range of scheduling Individual orders Subtree Whole order
New data Outlining dates (manually) Scheduling outline dates
Interoperation time Relationships or Transport time © SAP AG 1999
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LO215
14-13
Outline dates S
E
Collective order
S
E
Operation 1 S
S
Operation 1 S
S
S
Operation 3 E
Leading order 1
Operation 1 S
Operation 2
E
Operation 2 E
Order 2
E
Operation 2 Operation 3 E E
Order 3
S
E
Outline dates
(collective order)
S
E
Scheduled dates
(collective order)
S
E
Basic order dates
(order)
S
E
Scheduled dates
(order)
© SAP AG 1999
A collective order has additional sets of dates. Outline dates must be specified manually. This can be done at collective order or subtree level. Lead time scheduling tries to schedule the entire collective order (or subtree) within the outline dates. The basic dates of the individual orders are automatically adjusted according to the outline dates. The production (scheduled) start date of the earliest order and the production (scheduled) finish date of the latest order determine the production (scheduled) dates of the entire collective order. No additional floats (floats before / after production) are scheduled for the total lead time of a collective order. If the calculated (scheduled) lead time exceeds the total lead time that was specified with the basic dates, then all orders in the collective order can undergo reduction or only those orders that require it according to their lead time (critical path). You must set this up in the scheduling parameters for the order type (table TCX00).
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14-14
Interoperation Times Between Individual Orders
Relationship (2 days)
Order 2
(no move time)
Operation 30 Operation 40
A
Order 1
Operation 10
Operation 20
Operation 30
t
Order 2 Operation 30
Move time (2 days) Operation 40
A
Order 1 B
Operation 10
Operation 20
Operation 30
t A = float before production, B = float after production © SAP AG 1999
There are two procedures for specifying interoperation times between assemblies. They are: Floats defined as a relationship, or Floats from move time. When you assign components to an operation (routing or BOM maintenance), you can maintain a relationship. These relationships then enable you to specify a float. This float lies between the staging and subsequent processing of an assembly. You must enter the type and offset (duration) for such a relationship. If you do not specify a float or any units of measurement, the move time of the subordinate order's last operation is taken as the interoperation time. You can overlap individual operations. If you do this, you must maintain the parameters for overlapping in the last operation in the subordinate assembly.
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14-15
Collective Orders: Change Options
Evaluation
Collective order
Subtree
Individual order
Coll. ord. overview
Order quantity
CO
ST
IO
CO, ST, IO
Order dates
CO
ST
IO
CO, ST, IO
IO
IO
Assignment
Changes made to a collective order affect all orders within that group The effects of these changes can be viewed before saving The collective order view is also important when making changes
© SAP AG 1999
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LO215
14-16
Date Changes
Start date
05.05.98 20.05.98
Assembly 1 Reqmts date20.04.98 15.05.98 Assembly 2 Reqmts date22.04.98 18.05.98
Order 2
Start date
20.04.98 15.05.98
Order 3
Start date
22.04.98 18.05.98
Compon. 3 Reqmts date10.04.98 12.05.98
Compon. 5 Reqmts date16.04.98 15.05.98
Compon. 4 Reqmts date10.04.98 12.05.98
Compon. 6 Reqmts date16.04.98 15.05.98
Changes to dates automatically cause dependent orders to be updated during the next scheduling run. You can view the effects that the changes have had on the dependent orders before saving.
© SAP AG 1999
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LO215
14-17
Quantity Changes
Order 1
Total qty
10
15
Assembly 1
Reqmts qty
20
30
Assembly 2
Reqmts qty
40
60
Order 2
Total qty
20
30
Order 3
Total qty
40
60
Component 3
Reqmts qty
40
60
Component 5
Reqmts qty
50
75
Component 4
Reqmts qty
30
45
Component 6
Reqmts qty
60
90
Changes to quantities automatically cause dependent orders to be updated You can view the effects that the changes have had on the dependent orders before saving.
© SAP AG 1999
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LO215
14-18
Availability check Order 3
Order 1
Availability Availability check check for for order order
Display only
Missing parts list
Order 2
Miss. parts overview
Order 3
Order 3
Component 1 Component 7 Component 8
Component 1 Component 7 Component 8
Order 3
Order 4
Order 5
Order 4 Component 4 Component 6
Order 5 Component 11 Component 13
Change Change material material Change Change quantity quantity
Availability Availability check check for for component component
© SAP AG 1999
When you carry out an availability check, all orders within the collective order or partial collective order are checked. The missing parts overview lists all missing parts. You can make changes to the missing parts. The list is always saved with the results of the last check. The missing parts list shows all missing parts and components that cannot be checked. This list is not saved.
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Order Release
To release an order / operation, you must first access the entire collective order or subtree of the collective order
Order 1
Order Release Operation 5
When order 2 is released, orders 4 and 5 are released automatically.
Order 3
Releasing an operation
Order 2
Operation 4
You can only release operation 3 if both operations 2 and 1 and order 5 have already been released.
Operation 3 Operation 2
Operation 1 can be released at any time.
Operation 1
Order 4
Order 5
© SAP AG 1999
(C) SAP AG
LO215
14-20
Shop Floor Papers
Inventory
Shop floor papers with information about goods movements
Order 1
Goods receipt (product) Operation 2
Materials and assemblies yet to be completed are managed by means of a goods receipt list
Operation 1
Operation 2 Operation 1
Order 2
Order 2
Order to order (assemblies)
Operation 2 Operation 1
The receiving order (order number, work center, operation number) is printed on the operation control ticket and job ticket Goods withdrawal (stock material) Materials are printed on the pick list
Inventory
Inventory
© SAP AG 1999
Shop floor papers must be printed by order.
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Confirming Collective Orders
Confirmations cannot be carried out over several production levels when being performed at order header level.
Order 1
You use milestone or progress confirmations to confirm the whole collective order.
Operation 3 Operation 2
A milestone set at operation 3 in order 1 would confirm the whole collective order.
Operation 1
Order 2
Order 3
Operation 2
Operation 2
Operation 1
Operation 1
© SAP AG 2003
(C) SAP AG
LO215
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Inventory Management with Collective Orders Individual orders
Collective Orders Goods Receipt
Goods Receipt Finished product
Assembly 3
Order 1
Interim storage Assembly 3
Finished product
Assembly 4
Order 1 Assembly 3
Assembly 4
Order 2
Order 3
Component
Component
Interim storage
Order 2
Order 3
Component
Component
Assembly 4
Material withdrawal
Material withdrawal
Receipt/issue postings are not needed between production levels If inventory postings take place they are automatic (see next slide) © SAP AG 1999
In the order types table (T003O) you can decide whether or not material accounts documents are to be created.
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Goods Movements (Goods Issue / Goods Receipt) From order to warehouse (GR) Goods Receipt
Confirmed yield is posted as goods receipt Order 1
Possibility of correcting goods movement errors
Operation 2
Similar to normal production orders
Operation 1 Component 1
From order to order (GR/GI)
Assembly 1
Withdrawal quantity of 10 pcs is updated for assembly 1 when operation 1 is confirmed
Order 2
Confirmed yield is posted in the superior order as a withdrawal quantity Optional: material accounts documents!
Confirmation of order 3 with yield of 10 pcs for assembly 1
Order 3 © SAP AG 2003
If only part of the confirmed yield needs to be processed in the superior order, then you must post the surplus quantity to interim storage as an unplanned (miscellaneous) goods receipt. It must be designated as movement type 531 (goods receipt by-product) referring to the superior order. A cost credit is executed for this order. The value of the GR/GI that is posted depends on the use of inventory accounting documents (yes/no). See T0030.
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Order 1
Inventory
Assembly
Order 1 Assembly
Inventory
Rollup of Actual Costs by Confirmation
Order 2
Order 3
Order 2
Order 3
Component
Component
Component
Component
Inventory
Inventory
Inventory
Inventory
Actual
Valuation price
Actual costs occur at every production level Actual costs are transferred to the superior order The valuation price of the assemblies in the material master has no influence over the cost calculation of assemblies in the collective order
© SAP AG 1999
The actual costs for the subordinate assembly "material consumption" in the superior assembly order are calculated as follows: a) Confirmation time Material consumption costs = Confirmed yield * Projected order costs per item b) Settlement time Material consumption costs = Actual costs of order
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Settlement
Cost center
Material
Sales order
Project
Network
Asset
Internal order
Settlement profile
100%
Order 2
Order 1
100%
100%
Order 3
Order 4
90%
10%
Cost center
Order 5
© SAP AG 2003
Each order in a collective order (except the leading order) is assigned to its superior order or to the material stock (depending on how you set the indicator Collective order with Goods Movement in the T0030 table. Settlement always takes place according to cost element and from order to order or to the material stock. You can change the account assignments of the individual orders (for example, partial scrap to cost center). Only the leading order settles the total costs to the actual receivers.
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Collective Orders: Evaluation Options
Collective order IO
Subtree IO
Individual order IO
Comp. overview
IO
IO
IO
IO
PRT overview
IO
IO
IO
IO
Object overview
IO
IO
IO
IO
Graphics
CO
ST
IO
CO, ST, IO
Missing parts
CO
ST
IO
CO, ST, IO
Display costs
IO
IO
IO
CO CO CO
ST ST ST
CO CO
ST ST
CO
ST
IO IO IO IO IO IO IO IO
Evaluation Operation overview
Coll. ord. overview IO
Logs Scheduling Release Deletion flag WM staging Read master data Material availability PRT availability Determine costs
CO, ST, IO CO, ST, IO CO, ST, IO IO CO, ST, IO IO IO
© SAP AG 1999
(C) SAP AG
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Integration of MPS, MRP and SFC
Sales order Plnd Indep. reqmts
Multi-level MRP run
Planned Order 1
Planned order 2
Planned order 3
Convert planned order 1 (or 2 or 3)
Goods Receipt
Production order 1 Production order 2
Production order 3
© SAP AG 2003
Collective orders are fully integrated into SAP R/3. You can use them in the following applications: Sales (SD) Project systems (PS) Materials management (MM) Controlling (CO) Quality management (QM) Warehouse management (WM) Human resources (HR) Multi-level requirements planning must be carried out in order to be able to create planned orders for direct production. Converting any planned order within the collective order results in the entire collective order being fully converted. Collective orders cannot be planned in SAP APO.
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Collective Orders: Summary
Collective orders make it possible for you to link individual orders over multiple production levels. Collective orders' multi-level structure enables you to reduce stock movement postings for subassemblies. Some order functions are valid for the entire collective order, while others are only applicable for individual orders. Collective orders are fully integrated in a number of their applications. This is the concluding unit of the LO215 training course
© SAP AG 1999
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Collective Orders Exercises Unit: Collective Orders Topic: Collective Orders (LO215 Exercise 17)
•
Create collective order
•
Change collective order
•
Carry out production using collective order (entire range of functions for production orders with multi-level collective orders)
Your company manufactures complex products, usually with relation to a sales order. As production manager or production scheduler (supervisor) you require a good overview of the production orders for the individual assemblies and individual parts that make up the finished product (sales order). You use collective orders to ensure that you achieve this overview and to dispense with unnecessary goods movements. Collective orders guarantee that dependent orders are changed directly. In this way, your daily work is simplified. 1-1
Determine which assemblies of the BOM for ‘T-F1##’ are included as components. Path: S000 → LO → PP → MASTER DATA → BOMS → BOM → MATERIAL BOM → CHANGE →
Select the pushbutton ITEM
→ Select the tab GENERAL → Note here the indicator in the "Assembly" field Answer:
Material no.: ________
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1-2
Change the material master records of components T-B1## and T-B3## so that they are subject to direct production (special procurement key ‘52’). Save the change. Path: S000 → Logistics → Production → Master data → Material master → Material → Change → Immediately → MRP 2
1-3
Use the following information to create a production order for material T-F1##. Use the following entries to do this: Plant
1000
Order type
PP01
Total amount
10 ST
End date
Today’s date + approx. 1 month
Save the order.
1-4
In change mode, display the order overview. Path: S000 → LO → PP → SFC → ORDER → CHANGE 1-4-1 Make a note of the created order numbers.
Material T-F1##
____________________
Material T-B1##
____________________
Material T-B3##
____________________
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1-4-2 On which levels can you change or display the order? You can find the answer to this question in the three pushbuttons for the collective order overview (above the display of the collective order).
Answer:
______________________________ ______________________________ ______________________________
1-4-3 Are all order management functions equally available on all three levels?
Answer:
_______
1-4-4 Change the overview graphic of the collective order so that the system displays the following sequence of fields: Number of the leading order Number of the superior order Number of the individual order Number of the production plant Scheduled end date Order quantity Confirmed quantity System status Production scheduler → EDIT → SELECT FIELDS → Select the desired fields and put them in the given sequence
Path:
1-4-5 Execute the function “Read collective order”. Path: (C) SAP AG
→ Select the pushbutton READ COLL. ORDER LO215
14-32
1-4-6 Which changes can you see on the overview?
Answer: ______________________________________________ ______________________________________________ 1-5
To which account assignment are the orders for materials T-B1## and T-B3## billed?
Answer: Acct assgmt type
____ Recipient
_______________
To which account assignment is the order for material T-F1## billed?
Answer: Acct assgmt type
Path: 1-6
____ Recipient
_______________
→ Place cursor on the order → HEADER → SETTLEMENT RULE
Perform the material availability check function for the order of material T-F1##? Which orders does the system check?
Answer:
_______ Read the protocol of the availability check to answer this question.
Path:
(C) SAP AG
→ Place cursor on the order → FUNCTIONS → AVAILABILITY CHECK → MATERIAL ATP
LO215
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1-7
In your collective order, an additional component 400-100 should be produced as a subtree order. In the order for material T-F1## add the material component 400-100 as a subtree order and assign the components to operation ‘0010’. Ensure that the material 400-100 has a special procurement key 52.
Path: Select the order for material T-F1## and choose ...→ GOTO → OVERVIEWS → COMPONENTS → Insert component "400100" here and then answer the questions asked by the system accordingly. 1-8
Component T-B4## should be produced as a subtree order, and not withdrawn from the store. In the order for material T-F1##, create the respective subtree order. Ensure that the material T-B4## does not have a special procurement key 52.
Path: → GOTO → OVERVIEWS → COMPONENTS → Choose component T-B4## and create a subnetwork
→ COMPONENT → CREATE SUBTREE Save the collective order. 1-9
By changing the order again, check whether or not all subtrees were correctly created.
1-10
In the order for material T-F1##, increase the order quantity by 10 pieces (without saving). Do the order quantities of the subordinate orders also change?
Answer:
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1-11
Check system status. 1-11-1 What important information about the dates does the system provide by way of a new status?
Answer: ______
____________________
1-11-2 Schedule the complete collective order and re-check the system status and the calculated dates. Path:
→ FUNCTIONS → SCHEDULE → COLLECTIVE ORDER
1-12
Change the operation control key of operation 0010 in the order for material T-F1## so that it stipulates milestone confirmation without automatic goods receipt (PP98). Save the order.
1-13
Without explicitly reading the individual order, release the first operation of the order for material T-F1##. Can you release this order?
Answer: 1-14
______
From the collective order overview screen, release the complete order for material TF1##. Does this release all subordinate orders?
Answer:
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1-15
Print the production documents of the complete collective order. At present, you must print orders individually. In the collective order overview, you can choose → FUNCTIONS → PRINT to print out orders step by step. When you save the collective order, the system prints all orders. Save the collective order. Path: → Place cursor on the order → FUNCTIONS → PRINT
1-16
Enter a final confirmation for operation 0010 of the order for material T-F1##. 1-16-1 Is this final confirmation possible?
Answer:
______
1-16-2 Which condition prevents confirmation? (true/false)
Answer: The operation is not released
_________
Previous milestone exists and has not yet been confirmed _________ Operation 0010 is not a milestone 1-17
_________
Perform complete order processing for the production order of assembly T-B3##. 1-17-1 Material withdrawal 1-17-2 Confirmation of the last operation 1-17-3 Settlement 1-17-4 Check the order quantities and costs (planned and actual) in the superior production order (material T-F1##) and in the individual orders.
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1-18
Perform complete order processing for the production order of T-F1## Before you do so, change all milestone operations (except for the last operation of the order for material T-F1##) to normal confirmation (PP01) so that you can completely confirm the collective order.
1-18-1 Material withdrawal 1-18-2 Confirmation of the last operation 1-18-3 Settlement 1-18-4 Check the order quantities and costs (planned and actual) in the production order (material T-F1##). 1-19
Check the availability of the product T-F1##.
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Collective Orders Solutions
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_ _
Unit: Collective Orders Topic: Collective Orders Exercise 17)__
(LO215
Answer:
1-1
T-B1##
Material no.:
T-B2## T-B3## T-B4## Answer:
1-2
Collective order (Read entire collective order) Subtree
(hierarchy)
Individual order (read order) Answer:
1-3
1-4
No
Answer:
New symbol
Menu bars for order functions are now active and can be used. Answer:
Acct assgmt type
ORD Recipient
_______________
Answer:
Acct assgmt type
MAT Recipient
T-F1##
1-6
Answer:
All
1-10
Answer:
Yes
1-5
1-11-1 Answer:
NTER
1-13
Answer:
No
1-14
Answer:
Yes
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dates are not up-to-date
LO215
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1-16-1 Answer:
No
1-16-2 Answer:
The operation is not released
False
Previous milestone exists and has not yet been confirmed True Operation 0010 is not a milestone
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Appendix: Contents
Customizing overview and sequence Information on follow-on courses Technical details: Shop Floor Control (SFC) Data structure of the production order Planning and managing scrap and rework Serial number management
© SAP AG 2003
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Appendix: Course Objectives
This appendix supplements course LO215, providing you with further ideas and information about: The structure of Customizing (IMG) for shop floor control The implementation steps (sequence of procedures) for successfully using production orders Further courses or documentation Other special functions in Shop Floor Control (overview) Planning and managing scrap and rework Serial number management External processing
© SAP AG 1999
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Appendix: Course Overview Diagram
1
Info on Further Courses Customizing Overview and Sequence
2
Special Functions (Overview) Overview)
3
Technical Details and Data Structure
4
Scrap and Rework
5
Serial Number Management Ext. processing
6 7
© SAP AG 1999
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Implementation Guide (IMG)
IMG Project "Implementing Production Planning and Control"
Project status
1 2
Project dates
1 2 1 2 1 2 1 2 1 2 Project documentation
Customizing transaction execute
Project notes
Read SAP documentation (R/3-Library)
© SAP AG 1999
You can use the implementation guide (IMG) to make settings for production reports. The IMG also contains a description of the necessary activities. The ASAP Roadmap describes the sequence of procedures. Business Navigator describes the business processes modeled in the R/3 System. The following courses provide background information as to how to use the implementation tools: Course CA090 ASAP Course CA091 ASAP (abridged)
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Customizing Production Orders - Overview Order type Master data
CO parameters (T003O)
PP parameters (T399X) Production scheduling profile
Operations
Integration
Print control
Routing selection BOM selection
Confirmation control
Status management
Stock determination
Availability check
Batch determination
Scheduling control
Change management
Order costing Valuation of goods received
Variance calculation
Settlement control
Info system
Order info system Picking list Missing parts list Missing parts info system Doc. goods movements Progress report
Archiving / deleting © SAP AG 1999
Fundamental control information for management is assigned to the order type. Some settings are specific to a plant.
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Configuration Sequence for Order Management 1 M M M M
Create order type Scheduling control Routing selection BOM selection
R Status schema and selection schema O Availability check O Stock determination O
Batch assignment / determination
© SAP AG 1999
Key:
M = Mandatory activity O = Optional activity D = An activity completed by default settings. A = An activity to be completed by other applications. R = Recommended activity (rationalization effect) A Knowledgeware Product (CD) is available on the topic of availability checks. (Order No. 500 15 300)
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Configuration Sequence for Order Management 2 O
Print control for order documents
O Confirmation parameters D M
M
Allowed material movement type
G Material
Valuation variant for goods receipt Settl em ent Settl em ent
Settlement control
M Archiving / deleting O
Information systems ( order, missing parts and so on)
O Controlling interfaces © SAP AG 1999
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Configuration Sequence for Order Management 3 O
Document integration
R Automation of order management R R
Change management Production scheduling profile
R Trigger Points D
Screen sequence / field selection / tab pages
O Program enhancements (user exits)
© SAP AG 1999
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Information on Further Courses
PP
LO230 Capacity Planning LO235 Kanban LO275 Special Features of LIS in Prod. LO955 Batch Management LO990 / LO991 Variant Configuration
CO
AC505 Product Cost Planning AC510 Cost Object Controlling for Production AC515 Cost Object Controlling/Sales Order
MM
LO020 External Procurement LO510 Inventory Management LO530 Warehouse Management
QM
LO720 QM in Production
BC
BC600 ... Business Workflow Introduction
© SAP AG 1999
The above diagram lists a selection of other courses relating to production orders that may prove of interest to you. The SAP training course brochure provides a comprehensive run-down of all courses on offer. You can obtain quick and relevant information about all available courses from the R/3 Online Service System (OSS) for example in SAPNet.
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Special Functions in the Production Order
Serial numbers External processing / external procurement Planning and managing scrap and reworks Discontinued material components Cross-plant production Assembly orders Co-products Producing configurable materials Batch creation (order header) and batch determination (components)
© SAP AG 1999
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Technical Details - Shop Floor Control Development class(es) Function group(s) Logical database(s)
CO CO_XX_(at the moment, approx. 50) ODC,OFC,OHC,OPC,POH
Number range object(s) MC element MC group table MC group(s) Authorization class Authorization object(s)
Order AUART (T003O) Free choice Production planning C_AFKO_ATY, C_AFKO_AWA C_AFKO_AWK, C_AFKO_DEL, CO, RU, C2, C6, C8, C=, COTU, GOODSMOVEMENT
Message class(es) Lock object(s) Change document object
ORDER Own change log
Match code object(s) Archiving class Archiving object
ORDE, ORDN, PSFC CO PP_ORDER
Profile
Production scheduling profile
© SAP AG 1999
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Data Structure Database Tables View
Document Tables
Index Tables
Online (Data table)
AUFK CAUFV CAUFVDB
Online Tables
Online
CAUFVD
AFKO AFPO
(AFPOB)
(AFPOD)
AFFLB
AFFLD
Order Order head head er er
AFFL
Oper ati o ns
AFVU
AFVGB
ITAB
AFVC
DTAB
Mater ial com po ne nts
Pr od. r es our ce s/t ool s
Cost s
Pla nn ed T arget Act ual
100
20 50
AFVGD
AFVV AFRU AFFH
(AFRUB)
(AFRUD)
AFFHB
AFFHD
RESBB
RESBD
RESB
PLAF
CRHD
KAKO
KBED
COSP COSS COSL
COBRA COBRB
© SAP AG 1999
The individual tables contain the following data: PLAF Planned order CRHD Work centers KAKO Capacities KBED Capacity requirements COSP Primary costs COSS Secondary costs COSL Activities COBRASettlement object COBRB Settlement object AUFK Order header AFKO Order header AFPO Order item AFFL Work sequence AFVC Operation (general values) AFVV Operation (quantities/values/dates) AFVU Operation (user fields) RESB Material components AFFH Production resource/tool AFRU Confirmations ITAB Index table (C) SAP AG
LO215
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Appendix: Scrap and Rework
Overview of planning options for scrap Entering scrap Triggering rework Cost settlement for rework/scrap Proof of rework/scrap
© SAP AG 1999
(C) SAP AG
LO215
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Scrap and Rework: Business scenario
Scrap and rework can occur when processing materials. Scrap and rework that occur as a result of the technical process should be pre-planned to ensure that the desired yield and quality is available at the end of the production cycle. Scrap or rework that cannot be planned have to be disposed of using additional production processes and material.
© SAP AG 1999
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Rework Methods Activities Define the operations and material components for the rework Calculate the costs (planned and actual) Separate cost settlement Determine dates and capacity requirements Document those activities requiring rework Obtain status information
Methods Pre-planning options for scrap (material master, BOM, routing) Inserting rework operations (from the reference operation set) Creating separate rework orders Triggering workflows
Control Events triggered by confimation status © SAP AG 1999
Supplementary steps required to make improvements to products of substandard quality or to badly manufactured material components is described as rework. Rework can be either planned or unplanned. Unplanned rework Manually inserting operations into the production order. Manually creating a separate rework order. Planned rework Modeling trigger points in the routing. These are intended to automatically incorporate a standard routing or to create a rework order.
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Types of Scrap and their Effect Component scrap increases the required quantity of a component maintained in the BOM or material master of a component
Assembly scrap increases the required quantity of all components maintained in the material master of an assembly
Operation scrap, scrap, net ind. ind. refined overplanning using assembly scrap maintained in the BOM
Operation scrap lowers the operation qty of subsequent operations maintained in the routing © SAP AG 1999
You can provide for scrap in the master data (material master, BOM and routing). These scrap values affect the scrap-adjusted quantity for scheduling, the material costs and the cost of production activities in the production order. The different types of scrap have varying effects. Scrap in the material master or BOM increases the requirements for one or all components in the production order and thus also the material costs. Scrap in an operation of the routing reduces the operation lot size of subsequent operations and thus also their production costs. The production order costs increase for every element of the yield. Planable scrap is integrated in requirements planning, the production order and product costing.
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Planable Scrap - Example
10
Turn blank
5%
Blank
20
Screws
Washer
7%
30
Drill holes
Assemble casing
5% Routing
3%
Material master / BOM
11% Mat. master Casing for pump
© SAP AG 1999
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15-17
Trigger Points
Order type Confirmation of Operation 2
Status
Status profile Operation 1
Trigger point
Status
User status System status
Operation 3
© SAP AG 1999
Trigger points are assigned to the operation in either the routing or production order. Possible reworking functions are: Adding a reference operation set Creating a separate order Triggering a workflow Releasing predefined operations Triggered via status changes Planned using standard trigger points
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Confirmation
User status 1-n for the operation, activate manually Confirmation of the operation
User status is active in the operation Table Plant
Give reason for variance
TRUGS Reason for variance
User status 1 User status n
© SAP AG 1999
In the case of scrap or necessary rework, you are able to stipulate a reason for variance in the confirmation screen. In Customizing you can assign a user status to the reason for variance. You can then use this user status to trigger a trigger point function. For further information on this topic, consult the following examples on inserting rework operations and creating rework orders (in the following slides).
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Insert Reference Operation Set
Production order Sawing Turning Trigger point
Reference operation set
Checking Turning
Turning
Checking
Component 1 PRT
Polish
Checking
Define operations for rework
Determine the capacity requirements
Define components for rework
Document those activities requiring rework
Calculate costs
Obtain status information
Determine dates
Separate cost settlement
© SAP AG 1999
(C) SAP AG
LO215
15-20
Creating an Order Reference operation set Production order Turning Sawing
Component 1 PRT
Turning Trigger point
Checking
Checking
Production order (rework) Turning
Polish
Component 1 PRT
Checking Define operations for rework
Determine the capacity requirements
Define components for rework
Document those activities requiring rework
Calculate costs
Obtain status information
Determine dates
Separate cost settlement
© SAP AG 1999
(C) SAP AG
LO215
15-21
Rework costs
Production order 1
Production order 2
Cost categories
Cost categories
Raw material
Raw material
External procurement
Internal activity allocation
Internal activity allocation
Rework costs
Order 2 (rework) is automatically settled to order 1 All cost categories in order 2 can be posted to a cost category in order 1 in order to display the rework costs (settlement schema) © SAP AG 1999
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Activities
Customizing settings Create a user status schema Link reason for variance and user status Create order type for rework orders (optional) Create settlement profile for rework orders (optional)
Master data Create reference operation set Create standard trigger points (optional) Define trigger points in the routing
© SAP AG 1999
(C) SAP AG
LO215
15-23
Appendix: Serial numbers
General concept of serial number usage in R/3 Create serial number profile and assign to material master records Create master records for serial numbers Working with serial numbers in SAP R/3 Generating serial number listings and history reports
© SAP AG 1999
(C) SAP AG
LO215
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Serial numbers: Business scenario
In practice, serial numbers are used in order to manage each individual piece of a lot size Serial numbers can be used in connection with production orders Serial numbers can be created at different points within the system and this ensures that you can choose the best approach for controlling the production process
© SAP AG 1999
(C) SAP AG
LO215
15-25
Integration
Production Production orders orders
Repetitive Repetitive manufacturing manufacturing
Sales Sales
Serial number management
Quality Quality management management
Plant Plant maintenance maintenance
Plant Plant maintenance maintenance © SAP AG 1999
Serial number management is an integral part of the SAP R/3 System. Serial numbers can be used in conjuction with the following business transactions and objects: Goods receipt/goods issue and other inventory postings Original value recording of inspection lots Sales order, delivery note Access from repetitive manufacturing Production and refurbishment orders Maintenance orders Extension to the equipment master record and use of maintenance processing and maintenance history
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Serial Numbers and Batches
48 pc of material xyz Batch no. 0025
Material xyz Serial no. 0002358
384 pc of material xyz
© SAP AG 1999
Serial number management and batch management are different functions in the SAP R/3 System, which can be used in conjunction with each other. A batch represents a subset of the total quantity of a material held in stock, which is managed separately from other subsets of the same material. Examples of batches: Different production lots (for example, paints, wallpapers, pharmaceutical products), delivery lots or quality grades of a material A serial number is a number that you give to an individual item of material in addition to the material number, in order to differentiate between this individual piece and all other items of the material. The material number/serial number combination is unique. It is not necessary to use the batch management function to use serial number management.
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Serial Number Management: Procedure
Serial Number Profile
Mat. Mat. master master
Create serial number profile Assign profile to material master Create master records for serial numbers
Serial Serial number number master master 0001 0001
© SAP AG 1999
To be able to assign serial numbers to individual items of material for particular business transactions (for example, goods receipt), you must first create a serial number profile in Customizing. You specify serial number profiles in the material master records for which you want to create serial numbers. You can create and maintain individual master records for serial numbers in the system. You can create configuration data for serial numbers. You can assign serial numbers to business transactions. From a technical viewpoint, the master record of a serial number is stored as an equipment master. If the equipment master functions are activated, then you can use the SAP R/3 Classification System to further enhance the serial number master. The equipment master functions can be activated by default if specified in the customizing of the serial number profile, or can be activated by the user during the creation or maintenance of the serial number master.
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Serial Number Profile
Serial Number Profile
Profile text Existence requirement Equipment category Stock check rules Serializing procedures
© SAP AG 1999
The serial number profile defines the conditions and operations for assigning serial numbers to materials. It must be assigned at plant level in the material master. Serial number profiles are defined in configuration under Customizing for Plant Maintenance. The profile defines: The business operations for which a serialization can be performed, must be performed, is performed automatically, or is not performed. Whether for a particular business operation serial number masters must already exist, or serial numbers for which no master record exists can be assigned. That is, the serial number can be created during the transaction. Information about whether a stock validation is made for stock-relevant operations and how the system should deal with inconsistencies. Whether an equipment master record must or must not be created for each serial number The equipment category which the system should propose for the automatic assignment of serial numbers in the case of equipment records
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Business Transactions with Serial Numbers
MMSL PPAU PPRL PPSF QMSL SDAU
Use: 01: None 02: Optional 03: Obligatory 04: Automatic
Serial number profile
SDCC SDCR SDLS SDRE © SAP AG 1999
Business procedures may be assigned in configuration to a serial number profile. Each procedure refers to a specific application component. The assignment to the serial number profile determines if serial numbers are required, can be assigned, must be assigned or are assigned automatically. The following lists the procedures and their business meaning: MMSL: Goods receipts, issues, stock transfers, stock transport orders and physical inventory PPAU: Use of serial numbers when production orders are created PPRL: For the assignment of serial numbers when production orders are released PPSF: For the assignment of serial numbers in repetitive manufacturing QMSL: For the assignment of serial numbers when entering the original value in an inspection lot SDAU: For the use of serial numbers in sales orders, inquiries and quotations SDCC: For the assignment of serial numbers when performing completeness checks for deliveries SDCR: For the assignment of serial numbers when performing completeness checks for returns deliveries SDLS: For the assignment of serial numbers for deliveries SDRE: For the assignment of serial numbers for returns deliveries
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Serial Number Usage with Movement Types
Usage: 01 Optional MMSL MMSL
Serial number profile
Movement Movement type type Usage: 03 Obligatory group group 0001 0001
Movement Movement types: types: 561 561 561 561 E E … … 562 562 562 562 E E ... ... © SAP AG 1999
Under certain conditions, the business procedure assigned to the serial number profile may not be restricitve enough for some of the associated movement types. For example, it may be specified for the procedure MMSL that serial number usage is optional since the serial number is assigned at a later time. However, existing inventories have to be loaded into the R/3 system during implementation. This would be done using movement type 561; entry errors would be corrected using movement type 562. Since this is existing stock, the serial numbers have already been determined in the legacy systems and procedures, and thus they would be required when using movement type 561 or 562. It is therefore possible to assign a movement type group to the profile and indicate that serial number usage is obligatory. The movement type group is then assigned to the specific movement type. As a result, all materials with this particular profile specified in the material master require a serial number to be specified whenever a good movement using movement type 561 or 562 is transacted.
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Serial Number Master
Material Material master master
Serial Serial number number master master
Obtain status information Stock information Partner data Configuration data Optional equipment master with: Plant maintenance data Location data Classification data
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A serial number master record contains the following information: Status information: You can specify which system and user statuses are valid for the master record. If necessary, you can set or delete the user status, display the authorized business procedures and set particular system statuses. Stock information: This records in which plant or storage location the material item is located or to which batch it belongs. You can also see what type of stock or special stock is involved. The stock information is updated automatically when goods movements are performed and cannot be changed manually. Partner data: You can use freely definable partner functions and partners to specify in Customizing which companies are responsible for the maintenance of the serialized material. Configuration data: You can configure an item of material according to its characteristics or make reference to a configured object. Further data and functions, such as maintenance data, location data, and classification data are available if you add to the serial number master record to make it an equipment master record.
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Creating Serial Number Masters Directly
Internal Internal or or external external assignment assignment of of serial serial number number
Serial number masters created directly
llyy iidduuaall v i v i d d n i attee in C Crreea
Serial Serial number number master master xxxx xxxx
C Crreeaatte e uussiinn gg lliisst t pprroocce essssiinng g
Internal Internal or or external external assignment assignment of of serial serial number number
Serial Serial number number master master xxxx xxxx
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Serial number master records can be created directly, in advance of any business transactions. This would be appropriate if it is necessary to have serial numbers already in the system so that these can be assigned during a business procedure. Depending on how the serial number profile is configured, it may be necessary to have the serial numbers already in existence prior to the business transaction taking place. Serial numbers can be created individually or several at a time, depending on the transaction chosen. In either case, depending on the serial number profile configuration, it is possible to have the serial numbers assigned internally or externally. If internal number assignment is chosen, the first serial number created is the next sequence from the last one assigned to this material at this plant.
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Serial Number Masters in Production Orders
Create Create order order
Assign Assign
Assign Assign
Order Order Release Release
Goods Goods receipt receipt
Assign Assign
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Serial numbers can be assigned for individual pieces of material when creating, changing or releasing production orders. The serial numbers can already exist, or can be created during the assignment. The serial numbers that are assigned to the production order are transferred to the goods movement document on goods receipt. The serial numbers that are assigned to the production order are transferred to the goods movement document on goods receipt. The PPAU procedure makes possible the use of serial numbers in production and refurbishment orders and defines how they are assigned. The PPRL procedure makes possible the assignment of serial numbers when production and refurbishment orders are released. You can control the assignment of serial numbers in production control. If PPAU specifies usage "03- obligatory", then the order cannot be saved unless all serial numbers have been assigned. If PPAU specifies usage "02- optional", then the order can be saved without serial numbers but cannot be released unless all serial numbers have been assigned. If PPAU and PPRL specify "02" and MMSl "03", the serial numbers must be assigned on goods receipt.
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Serial Number List
Detailed Detailed selection selection options options
Documents Documents -- Orders Orders -- Material Material documents documents
Serial Serial Number Number List List -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Serial number history
Serial Serial Number Number Master Master
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Serial number masters can be created, changed or displayed individually. There is extensive list editing capabality for creating, changing and displaying serial number masters. If used to create masters, a large number of masters can be created with internal and/or external number assignment. If used to change or disply serial number masters, the list editing capability has extensive and detailed selection options. The resulting listing can be used to drill down to individual serial number master records. From the individual master record, a detailed history record for the serial number masters and associated documents can be called.
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Appendix: Summary
You use Customizing (IMG) to configure Shop Floor Control. The sequence of implementation steps that you require to successfully use production orders are contained in the appendix. The LO215 course covers the basic features of Shop Floor Control with production orders. There is a range of further courses and documentation that supplement this course and are to be recommended. The appendix contains an overview of other special functions within Shop Floor Control. In the appendix, you will find slides about the special topics scrap planning, management, rework, serial number management and external processing.
© SAP AG 1999
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