Bom Nd Routing

Andersen Consulting 2000 1

PP02 - Master Data in PPNovember 2000


• Topic 1: PP Master Data Overview• Topic 2: Material Master• Topic 3: Bill of Material (BOM)• Topic 4: Work Center• Topic 5: Routing

Contents


Master Data is a building block of the whole systems.

It describes the basic situation about the organziation business practices, including:

• What are the end products of the company?

• What are the materials required in order to make the finishe goods?

• Where does the production take place?

• How does the production go on?

The accuracy of the master data is of utmost importance. Any mistakes would cause the

big problem in the day-to-day operations.

What is Master Data


Material Master (MRP, Work Scheduling Data)• WHAT are the end products and components, raw materials

BOM, Bill of Material• WHAT are the end products consist of

Work Center (Machines, Labor)• WHERE the production takes place

Capacity (Available hours)

Routing (List of Operations)• HOW the production goes on

Calendar (Factory Calendar)

What does it include?



Contents


General Concepts for Material Master Record

The material master contains information about thematerials an enterprise buys, produces, stores, and sells.

Information is stored in a database that is used as acentral repository for material data.

Material data is used throughout the R/3 System.Applications related to Production include:

Sales Forecast

Production Planning

Production Execution MaterialMaster

Data


Organizational Levels in Material Master

General data

Material numberDescriptionUnits of measureTechnical data

Plant-specific data

MRP dataPurchasing data

Storage location data

Stock quantities

Client

Plant

Storage Location

• The Material master has a hierarchical structure , which covers the following organizational levels:

Client plant storage location

• Organizing materials hierarchically allows easy management of information and prevents redundant storage of material data.


Primary Views

Material master record

Materialplanning

St

t Purchasing

Sales and distribution

Storage

Qualitymanagement

Stocks in plant-warehouse

AB

Warehousemanagement Classification

Forecast

Accounting

Each user department has its ownview of the material master containingdepartment-specific data.


Material Master View Selection Screen

• Changes are recorded in history

• The MRP 1-4 views and the Work Scheduling view are where Material Master data relevant for MRP and Production are maintained

• The R/3 System allows selection and maintenance of the data that is relevant to a particular department

• To create a view, the view must be selected on this screen before material data is entered

• Users are responsible for creating and maintaining the view(s) of the material that are relevant to their department(s)


Levels in material master record maintenance

MaterialInitia

l leve

l

Purchasing

St

t

Engineering MRP SalesForecast Accountingdepartment

Main w

ork l

evel

Units of measureAdditional data level

Texts

Managementdata

Consumption

Addi

tiona

l dat

alev

el


Material Types and Industry Sectors

Semi-finishedproducts

Raw materials

Raw materials

Semi-finishedproducts

Finished products Finished products

Others Others

Mechanicalengineering

Chemicalindustry

Material master records aregrouped according toindustry sector material

Industry sector informationdetermines the industry-specific data that will appearon the material master record.

Material type informationdetermines whatdepartmental views aremaintained and howinventory will be handled(quantity and value updates).


Industry Sector

Industry sector determinesthe type of industry towhich the material will be

assigned.

Industry sectorinformation determines:

which screens will appearand in what sequence.

what industry-specific datawill appear.


Material Type

Material types groupmaterials with the samebasic attributes.

Material type informationdetermines: Which departmental views are

maintained.

Whether changes in materialquantities are updated.

Whether internal or externalprocurement is allowed.

Which general ledger accountsare updated (e.g., inventory

account).


Material Type - default parameters

Account assignment

Can material be configured?Quantity / value update

Price control

Variances per plant

MaterialA

Materialtype

Data views / screen sequenceNumber range / assignmentDescriptionField referenceItem category groupPrice controlInternal / external purchase ordersValuation / account assignment


Material master record - data areas

General data

Material numberDescriptionUnits of measureTechnical data

Plant-specific data

MRP/typePlanned delivery timePurchasing groupBatch indicator

Valuation

Valuation priceValuation procedureValuation quantity

Sales-specific data

Delivering plantSales texts

Unit of measurePalleting instruction

Storage location-specific data

Storage timeStock fields

Forecast data

Consumption data

Warehouse Manage-ment system data


Units of measure

Base unit: Piece (ea)

Box(unit of issue)

Crate(order unit)

Pallet(sales unit)

4 9616


Material creation - Accounting

...

MART Allowed values

ROH 3000 3010HALB 7920HIBE 3000

. . .

Mat. stock account

300000300100790000300000

Valuation class


Material creation - Accounting

Price control

Standardprice control:Valuation at standard price from the material master record

Moving average price control:Landed price (e.g. order price) influences thevaluation price

?

S V


Display options for material data

Display Stock overview List of materials

Data for thismaterial

Material

List of selectedmaterial

Stocks per plant/storage location


Additional functions

Change Flag for deletion

Change document

Material


Changing / extending the material

Material master record

Purchasing

Sales and distribution

Stocks in plant-warehouse

AB

Engineering

Accounting

Requirementsplanning

St

t Classification

Data view to be “created”


MRP group defines many of the parameters effecting how MRP calculations will take place

MRP type determines how the material is to be planned

Lot size data determines how MRP will calculate replenishment

General MRP data controls basic parameters of MRP planning

Example: MRP 1 View


Material Master Summary

A material has different organizational levels Material processing is controlled by the material type , the industry sector and

the material status The data in a material master record is divided between different views

(departments) In addition to data pertaining to the organizational levels , a view usually

contains data for more general organizational levels The material master record can be maintained centrally or can be maintained

on a decentralized basis according to the organizational levels and views


Exercise for Material Master Records

Now it’s time for you to do exercise:

PP02 - Exercise 140 Minutes



Contents


A bill of material is a complete, formallystructured list of the components whichmake up a product or assembly. The list

contains the description and object numberof each component together with the

quantity and unit of measure.

BOM

Definition of a Bill of Material


BOM Categories

Document

Material BOM Equipment BOM Document BOM

Materialmasterrecord

Equipmentmasterrecord

Documentinfo record

Material


MaterialBOM

Plantmaintenance

Location data

Design

Technical data

Production

Operations

Costing

Price

Sales

Order quantity

Productionorder

Salesorder

BOM Usage


BOM Integration

Material Equipment Document Bill of material Routing Class

Basic data

PRT Work center

Sales & Distribution

Production

Controlling

Sales order

Requirements planning

Planned order

Production order

Product costing

Material management

Plant maintenance

Purchasing Warehouse

Maintenance plan Maintenance order


Requirements

Material

Material

MaterialMaterial BOM

Plant


Area of Validity

Material

Material

Material

Material BOM

PLANT 2Material

Material

Material

PLANT 1


Validity Period

12

9

6

3

11 1

7 58 4

210

Valid-from date

12

9

6

3

11 1

7 58 4

210

Valid-to date

2


Technical Types / Summary

Alternative 1

Alternative 2

Multiple BOMSimple BOM Variant BOM


Design drawing and corresponding bill of material

Example: Bicycle

Saddlesupport

Saddle

Pre-assembledframe and forks

Gears

Handlebarassembly

Bearings

Pre-assembled frame and forks

Handlebar assembly

Gears

Bearings

Saddle

Saddle support

PP-FRAME01

PP-HBAR

PP-GEARS

PP-BEAR

PP-SADDLE

PP-SADSUP

1 PC

1 PC

1 PC

1 PC

1 PC

1 PC


Multi-level BOM

0

1

2

Low-level code

Men's racingbike PP-BIKE01

Gears

PP-GEARS

Handlebarassembly

PP-HBAR

Pre-assembledframe and forks

PP-FRAME01

Chromeforks

PP-FORKS

Blueframe

PP-MB01

Handlebar

PP-HAND

Handlebargrip

PP-GRIP

Gearcassette

PP-CASS

Rear arm

PP-REARARM


Item Categories

Stock item

Non-Stock item

Variable-sized item

Document item

Text item

Phantom item

Class item


Non-stock Item/Item Category N

BOM PP-GEARS

Item Component Quantity Item cat. 10 PP-CASS 1 pc L 20 PP-REARARM 1 pc L 30 1 pc N

Item 30: Purchasing data

- Price - Product group - Price unit - Purchasing group- Cost element - Delivery time

MRP and costing fields


Document Item/Item Category D

BOM

Document info record

MaterialA

DocumentMaterial

Material


Sub-items

Item 0030PP-Grip: 2 pieces

Sub-item00101 piecesLeft grip

Sub-item00201 piecesRight grip


Exercise for BOMNow it’s time for you

to do exercise: PP02 - Exercise 2

40 Minutes



Contents


Work Center together with the Material Master, BOMs and Routings is fundamental for production planning.

Work centers specify where or by whom an operation is carried out.

Work centers contain scheduling and capacity data needed for lead time scheduling and capacity planning.

Work centers contain costing data which enable you to cost operations

DefinitionWork Center is a Single/group of machines or personnel area in the plant


Primary Functions of a Work CenterWork center

Default valuesfor task lists

Costingdata

Scheduling dataand available

capacity

21

Tasklists

2724.00 1200.00 124.00 4048.00

CostingLead time

schedulingcapacity planning


Basic dataScheduling

.

.

.

ProductionPlant maint.

.

.

.

Usage Standard values

Control of field and screen selection

Work center category

Work Center Category


Work Center Usages

Qualitymanagement

Plant maintenanceCapacity planning

Task lists

StatisticsProduction

Routing

Sales andoperations planning

Repetitive manufacturing


Work Center Data

General data Name and description Standard value key Performance efficiency rate

Basic data

Default values fortask lists

Control key Standard text key Wage data

Default values

Capacitydata

Available capacity Formula key

Capacity

Schedulingdata

Scheduling basis Queue and move times Formula key

Scheduling

Costing dataand

HR system data

Cost center Activity types Formula key

Assignment


Activity typesOperation 10

Default values

Standard value key Std. value verification

Relationship Between Work Center & Operation


Work Center Capacities

Work center

Pooledcapacity

Energy

Scrap

Machine

Labor Transport

Work center


Maintaining Available Capacitywith Shift Sequences

Day 1 Day 2 Day 7

Shift 1

Work start

Work finish

Breaks

Shift 2

Shift 3

Shift definition

Shift 2

Shift 1

Shift 2

Shift 1

Shift 3 Shift 3

Shift sequence

Work centers


8:00 9:00 10:00 11:00 12:00 13:00

Available capacity

Overload factor• Capacity means the ability to perform a

certain task. • R/3 separates between different type of

capacities, labor or machine. This is done by choosing Capacity Category for the Work Center.

• It is possible to define number of capacities in a Work Center. For example 3 persons or 5 machines in a Work center. In addition the efficiency of these capacities can be defined in percent.

• The below formula is stated in the work center for calculation of available capacity:

Available time = (Work hours - Break hours) x No of capacities x Efficiency

Overload Factor


Order dates Capacity requirements

Standard Costing Operating Availablevalues data time capacity

PPS Basic data

Work center

Lead time scheduling

Routing

Capacity planning

10 20 30 40

232221

Work Center and Lead time Scheduling


Assignments

Cost centerWork center

Positionn

Qualification

nPerson


Calculating Production Costs

Cost center

Work centers

Formula constants Formula key

Activity types

Activity price

Internal processing costs

Routing

Operations Work centers Standard values

Formula


Exercise for Work CenterNow it’s time for you

to do exercise: PP02 - Exercise 3

30 min.



Contents


Routing

Operation 20

Work center Texts Control data Times

Operation 10 Material components

PRTs

Material

Routing group


Routing Types

Reference operation setRouting

Operation 10 20 30 . . .

Operation 10 20 30 . . .

Material

S1


Default Values in Routings

From work center

From PRT master

From material master

From profile


Origin of Default Values in Routings

Profile Work center

Material master

PlantHeader UnitUsageStatusOperation increment

Description Base unit of measure Planner group

Reference

Control key xStandard text key x Std. value verification Units of measure for

the standard values Activity types x Wage type x Wage group x No. of time tickets x Qualifications x Setup type key x


Sequences in Routings

Operation 10

Operation 20Operation 30Operation 30Operation 30

Std. sequence0000

Alternativesequence

0002

> 20 25< 30

Alternativesequence

0001

> 10 15 20 25< 30


Parallel Sequences

20 25 30

Operation

10 20 30 40

20 30


Float before Lead time scheduling Float afterproduction production

Scheduling direction

Scheduling OverviewDetermining the planned order dates

Determining the planned order dates

Incorrect in-house production time in material master?

In-house production time from material master

10 20 30 40 50

In-house production time is longer than in routing

In-house production time is less

PS PF


Operation Lead Time

10 20 30

Operation lead time

Interoperation timeExecution timeInter-

operationtime

Queue Setup Processing Teardown Wait Move


Execution Time

Standard values Setup time Processing time Teardown time

Number of splits ...

Formula key Formula constants

Work center Operation

Lead time scheduling

Formulas


Example of a Standard FormulaOperation qty. : 200 pcBase qty. : 10 pc Set-up time : 0.25 hProcessing time (mach./labor) : 12 minTeardown time : 6 min

Standard value

Setup time = Setup timeProcessing time = Processing time x operation qty.

base qty.Teardown time = Teardown time

Formulas

Setup time = 15 minProcessing time = 12 x 200 = 240 min

10Teardown time = 6 min

Results


Material Allocation to Routings

Group Groupcounter

AMaterial

Plant

2 01

02

1 1

2

3

2 1

3 1

1 01

02


Planning ScrapComponent scrap

Assembly scrap

Operation scrap

affects specific components in the BOM

maintained in the BOM or the material master

affects the complete assembly

maintained in the material master

affects a specific operation

maintained in the BOM (for components)maintained in the operation (for standard values)


Stickers

Welding wire

Planning Scrap (Example: Bicycle Frame)

Bars

100g

PaintComponent

scrapOperation Result

10

10

10

Weldbars

Paintframe

Checkframe

Attachsticker

10and 5%

100g+ + 10%

+

Netindicator

2%

Assemblyscrap


BOM ExplosionE 1 E 2

T 1 T 3T 2

B 1

Product E 1 BOM level by level Multi-level BOM Summarized BOM

Material Quantity Material Quantity Material Quantity

T 1 2 .1 T 1 2 B 14T 2 3 .1 T 2 3 T 1 2B 1 4 .1 B 1 4 T 2 19'T 2 16 .. 2 T 2 16 T 3 8 T 3 8 .. 2 T 3 8

2 34 5

3

24


Reference operation setcheck

Reference Operation Set

6054

Reference operation setcheck

Reference operation setXY

Routingwith referenceRouting

10

20

30

40

50

34

38

32


Trigger points are allocated to operations in the routing or in the production order

Functions possible with trigger points include:

Trigger Points

• inserts a reference routing• create an order using existing order as reference• trigger workflow• release operations

Operation 1

Operation 3

Triggerpoint

User status

System status

Status profile

Order type

Confirmationof

operation 2

Status Operation 2


Sub-operation

Operation 10

Operation 20

SOp 10/20 Processing 1

SOp 10/10 Setup

SOp 10/30 Processing 2


Exercise for Routing

Now it’s time for you to do exercise: PP02 - Exercise 4

30 min.


Question & Answer

Q & A


Congratulations !Congratulations !

Bom Nd Routing

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Transcript of Bom Nd Routing