Rc SCM310 ProductionOrders

SCM310 Production OrdersSCM310

Release 640 04/06/2006

0

SAP AG 2003

SCM310 Production Orders

THE BEST-RUN E-BUSINESSES RUN SAP

© SAP AG 2003

SCM310Production Orders

SAP R/3 Enterprise, System Landscape Fx3 2003/Q3 50063195

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SAP AG 2004

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.

Copyright

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Target Group

Members of the project team 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

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Course Goals

Course Objectives

Course Content

Course Overview Diagram

Main Business Scenario

Course Overview: Contents

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At the conclusion of this course, you will be able to:

Course Goal

SAP AG 1999

Use production orders.

Create, release and fully implement production orders. You will be able tomake system settings and also understand production orders in context.

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Classify production orders in the production planning and execution environment (demand management, requirementsand 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 functionsin detail

Use the information systems for production orders Take into consideration the integration relationships within

the production order Teach yourself additional special functions

Course Objective(s)

At the conclusion of this course, you will be able to:

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Course Overview: Course Content

Unit 8 Order Control

Unit 9 Confirmations

Unit 10 Goods Receipt

Unit 11 Settlement, Archivingand Deletion

Unit 12 Information Systems

Unit 13 Mass Processing andAutomation

Unit 14 Collective Orders

Unit 1 Course Overview

Unit 2 Introduction

Unit 3 Order Creation /Order Change

Unit 4 Integration for Planning

Unit 5 Order Release

Unit 6 Printing Order Documents

Unit 7 Material Staging

Appendix

Preface

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Course Overview: Overview Diagram (1)

Goods ReceiptGoods Receipt 1010

ConfirmationsConfirmations 99

Information SystemsInformation Systems 1212

Settlement, ArchivingSettlement, Archivingand Deletionand Deletion 1111

Collective OrdersCollective Orders 1414

Mass ProcessingMass Processingand Automationand Automation 1313

Material StagingMaterial Staging 77

111

Order Creation /Order Creation /Order ChangeOrder Change 33

Order ControlOrder Control 88

Printing ofPrinting ofOrder DocumentsOrder Documents 66

Order ReleaseOrder Release 55

Integration for PlanningIntegration for Planning 44

Course OverviewCourse Overview 22

Course Overview

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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

Classification of order production in the organizational structures of SAP System components

Master data prerequisites for production orders

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At the conclusion of this unit you will be able to:

Overview: Unit Objectives

Recognize the different steps in the process chain for order-related production

Recognize the essential characteristics of order-relatedproduction

Understand how production orders in production planning and control and organizational structures are positioned

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Overview Diagram (2)


22


Course OverviewCourse Overview

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Application Areas of Production Orders

P R O D U C T S T A B I L I T Y

Mechanical engineering, vehicle construction and contractors and engineering companiesConsumption goods, building, woodwork and electronic industriesAviation, astronautics, ...

Typ. IndustriesTyp. Industries

P R

O D

U C

T

C O

M P

L E

X I

T Y

Production by LotsProduction by Lots

MTO ProductionMTO ProductionSpecial ProductionSpecial Production Assembly Production/Assembly Acc.to Catalog

Period-OrientedProduction

Mass Production

Production orders are used in diverse branches of industry and their industry sectors. Production orders can be used in a wide range of production types that occur in practice. These production types are essentially dependent of the product stability,

product complexity and the manufacturing processes used.

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mySAP Supply Chain Management (mySAP SCM)

ExternalProcurement

Source Delivery

OrderFulfillment

Production

Production

Supply Chain Design

Strategy

Sales &Delivery Planning

Plan

Supply Chain Performance Management

Supply Chain Event Management

Partner

Customer

Partner

Su

pp

ly C

hain

Co

llabo

ration

Su

pp

ly C

hai

n C

oll

abo

rati

on

Supplier

mySAP Supply Chain Management (SCM) is a comprehensive solution that allows a company to efficiently plan, regulate and control complex delivery, procurement and production networks.

This solution supports a synchronized and close interaction between all affected departments (and people) of a supply chain.

This complete solution includes customers, Sales and Distribution, Production Planning, Production, Inventory Control, Purchasing and vendors.

Particular emphasis lies on the processing of cross-company or cooperating planning and procurement processes that also enable a connection to open marketplaces.

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Cross-Application Functions

Material forecast Sales & Distribution

Stock

E

A C D

B

Cap

acit

y R

equ

irem

ents

Pla

nn

ing

Cap

acit

y R

equ

irem

ents

Pla

nn

ingDemand program Customer req.Plnd ind. req.

Material requirements planning

Production preparationProduction preparation

Production executionProduction execution

Goods receiptGoods receipt

Goods issueGoods issue

SettlementSettlement

Planned orderPlanned order

SC

M P

lan

nin

gS

CM

Pla

nn

ing

SC

M P

rod

uct

ion

SC

M P

rod

uct

ion

Purchase requisition

Purchase order

Goods receipt

Invoice receipt

SC

M E

xter

n. P

rocu

rem

ent

SC

M E

xter

n. P

rocu

rem

ent

Co

stin

gC

ost

ing

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 by production versions (for example, production lines)

Production of configurable materials

Order Change Management (OCM)

Multi-level collective orders

Assembly orders

Serial numbers / as-built configuration

Order splitting

External processing of operations / external procurement of components

Cross-plant production (planning and production plant)

Order-Based Production: Characteristics (3)

Enhanced Functions of the Production Order

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Enhanced Functions of the Production Order

Order-Based Production: Characteristics (4)

Trigger points (workflow, create prod. order, ...)

Planning and managing scrap and reworks

Discontinued material components

Quality inspections during production

Batch number assignment (product)

Batch determination (component)

Batch where-used list

Co-production

Transport and packaging units (HU)

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Production Planning and Control Data

Confirmations

CO object (cost collector)

Material movements (goods receipt / issue)

Production orders

Factory calendar

Mat. master

Work centers

Bills of material

Routings

Prod. resources/tools

CAPP formulas

Documents

MasterMaster datadata

TransactionTransaction datadata

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

Order

Assignmentto a

material

OrderOrder Order

Overheadcost

orders

Capitalinvestment

orders

Goods for the market Internal company goods and services

Sales-Related

Goods sold

Goods instock

Company Internal

Cannot beactivated Can be activated

Customer Warehouse Cost center Asset portfolio

Logistic functions (quantities and values) Cost accounting functions (values)

Assignmentto a

sales order

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 in-house 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 MaintenanceNetwork -> PS Project SystemOverhead cost order -> CO ControllingCapital investment order -> CO Controlling

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Document Type, Order Category, Order Type

Material accounting documentsFinancial accounting documents

Orders

PP process orderPS networkCO internal orderCO production orderCO model orderPM plant maintenance order

Production order (external number range)Production order (special types)

Production order (internal number range)

PP production order

Document typeDocument type

Order categoryOrder category

Order typeOrder type

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 assignmentSetting default valuesUser-specified status managementUser-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

WhatWhat isis being producedbeing produced??

WhenWhen isis it beingit beingproducedproduced??

How much hasHow much has toto bebeproducedproduced??

For whom are we producingFor whom are we producing??((costcost object)object)

Which resourcesWhich resources andand methodsmethodsare being usedare being used in the in the productionproduction??

Which costs are incurred byWhich costs are incurred by thetheproductionproduction??

ProductsActivity

Planned order datesBasic order datesCalculated datesConfirmed dates

ReleaseStartFinal

Planned order quantityProduction order quantityConfirmed quantity

MaterialCost center

OrderAsset

Material usageProd. resources/toolsChecks

PlannedActual

The production order is determined by a series of definitions for manufacturing a product.


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Production Orders and Organizational Structures

Organizational unitsOrganizational units

Production order

Shop floor control

Demand management

Requirements planning

Inventory management

Company

Controlling areas

Sales organizations

Company codes

Valuation areas

PlantsPlants

Storage locations/batches/special stocks

Purchasing organizations

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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Demo Scenario: Pump Production in Plant 1000

0001 Material storage Plant 1000 (Hamburg)

Pre-assembly I

Work center R-V##

Pre-assembly II

0002 Finished goods warehouse

Goods receipt

Work center R-F## Work center R-E##

Confirmations

Final assembly II Final assembly I

Confirmation

Work center R-M##

Material stagingfor stock transfer

Storage bin PROD-1300

Delivery

Delivery

Sold-to party

SDSD

Demonstration example: Production with production orders:In plant 1000, pumps and their assemblies (casing, shafts, ... ) are produced. Final and pre-assembly and assembly production take place in storage and as make-to-order production. Production is organized according to the shop floor principle. The individual parts for assembly production are transferred by picking or via material staging lists from the material storage into production. When assembly is confirmed, the goods receipt for the assembly is booked directly to the storage location to which the final assembly production line is assigned. Components for final assembly that are not produced on the assembly production lines are transferred via the material staging list from the material storage.

The most important data in the course system is:Material numbersR-F1## Pump (Make-to-stock and make-to-order production)R-B1## Casing (Make-to-stock production)R-B2## Storage (Make-to-stock production)R-B3## Shaft (Make-to-stock and make-to-order production)R-B4## Drive electronics (Make-to-stock production with production version)

Work centersR-V## Pre-assembly 1R-M## Pre-assembly2R-E## Final assembly1R-L## Paintshop


R-F## Final assembly2 R-P## Inspection


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Production Order - Symbol Overview

Order header

Detail screen (operation, component, PRT, ...)

Sequence overview

Component overview

Operation overview

Document overview

Status overview

Key

Collective order overview

Log

Trigger point overview

Change

Display

Save

Deletion

Schedule (order, collective order)

Cost

Check availability (material, capacity, PRT)

Release (order, operation)

Print

Enter long text (text editor)

Generate object (for example, order)

Execute program (function)

Update

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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Overview: Summary

You have gained an overview of the process chain for order-related production and the role it plays in the SAP System.

You have been informed about the role of order management in the organizational structures of the SAP System.

The orders are assigned to an application using the order category.This determines the scope of the functions.

The order types help control special functions for each order category.

You have learned about the prerequisites for master data.


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Order Creation / Order Change: Contents

Life Cycle of a Production Order

Creation variants

Normal, with production version, with variant configuration, ...

No reference to material (any activity)

With reference order (copy order)

Function procedure "Creating an order"

Order data structure

Production order screens

Number assignment

Automatic follow-on postings

Bill of material and routing selection

Reading master data


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Order Creation /Order Creation /Order ChangeOrder Change

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Creation Variants 1

2050

100

Activity

Directly (manually)

From planned order

Copy from order

For sales order

From SD (assembly order)

From confirmation(rework)

As collective order

With variant configuration

Order headerOrder header

Operations

Material components


PlannedTargetActual

Costs

With reference to material

Without reference to material

There are numerous possibilities for creating production orders.

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Creation Variants 2

Order

Order

Planned

Planned Order

Material BOM

OrderPlanned order

Planned

Create without routing andbill of material

Create with routings

Create with routingand bill of material

Create with planned order

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.

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Creating Production Orders

FridayJuly

27 1992

TuesdayDecember

18 1992

ManualManual Requirements planningRequirements planning AutomaticAutomatic

Specify order type

Define order item

Copy routing

Copy bill of material

Lead time scheduling

Optional (Customizing)

Availability check

Add, change

Save production order

Various functions (1)(1)

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).

((11)) Other functions that can be executed automatically are:

Batch creation, determination, order classification, serial number assignment, document integration.

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Elements of a Production Order (SAP R/3)


Operation sequencesOperation sequences

OperationsOperations

Capacity splitsCapacity splits

Material componentsMaterial components

Prod. resources/toolsProd. resources/tools

Trigger pointsTrigger points

ConfirmationsConfirmations

Order numberPlantProd. scheduler

Standard sequenceOther sequences

Work centerControl keyStandard values

Individual machineIndividual person

Settlement ruleSettlement rule

Settlement profileSettlement receiver

Material numberQuantityRequirements date

PRT numberPRT categoryNumber

Functions

QuantitiesTimes

CostsCosts

PlannedActual

Document linksDocument links

Order-related Cost Object Controlling (COC)

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

Doc. number

Doc. type

Document linksDocument links

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, submitted at order header level, and a settlement rule created for

the order, only in the case of order-related cost object controlling.

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Production Order - Header

1000767

General Assignment Goods receipt Control Dates/quantities Master data

Order typeOrder numberPlantMaterial or activityQuantities dates

To RoutingTo BOMTo Costing

Entered by / Changed byPlantsAssignmentsMRP controller

Control of goods receiptMovement type

Settlement ruleSettlement receiverPercentages

Deadline monitoringQuantity monitoring

Product (activity) to bemanufactured with the order

ManualPlanned order

Definition Origin

Order Edit Goto HeaderFunctions Environment

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

1000767

Stand. values Ext. processing Interoperation times Standard value calc.

Operation 0010

Operation overview

Single step inOrder

ManualRouting

OperationSuboperation

Definition Origin Types General Data

Standard values

Ext. processing

Interoperation times

Standard values calc.

Splitting

Overlapping

Operation dates

User fields

Quantities/activities

Confirmed dates

Order Edit Goto OperationFunctions Environment

General Data

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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Own scheduling for planned orders

To the day

Calculated basic dates Basic start dateBasic finish dateCreation date

Base in-house production time or replenishment lead time

Advantageous for performance

No capacity requirements are determined

Used

To the second

Starts from basic dates Requirements planningManual

Determined production dates (scheduled dates)

Start dateFinish date

Release date

Base operations

Determined capacity requirements

Material requirements planning

Lead time scheduling

Periods

Order head erOrder head er

Operati o ns

Mater ial com po ne nts

Prod. res ource s/t ool s

Cost s Pla nn edT argetAct ual

2050

100

for orders and routings

Scheduling in Production Planning

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

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 schedulingRouting schedulingScheduling 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.

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Order dates Operation dates Time concepts

PS Planned start date (basic start date)

SS Production start date (scheduled start date)

SF Production finish date (scheduled finish date)

PF Planned finish date

AD Planned availability date

LT Loading time

GI Goods issue date

RDD Requested delivery date

ES Earliest start date

LS Latest start date

EF Earliest finish date

LF Latest finish date

Lead time of order oroperation

Execution time of operation

Interoperation times

Processing times insales

Float bef.prod.

Op.0010

Op.0020

Op.0030

Op.0040

........ Op.0099

Float afterproduction

GRproc.time

Pick/packtime

Loadingtime

Transittime

PS SS

Queuetime

Setuptime

Proc. time Teardown Wait time Move time

SF PF RDDGILTAD

ES LS EF LF

Float times for order/operation

SAP R/3 Order: Scheduling / Time Elements

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

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 planningFloat 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 under "Scheduling".

The duration of an operation is made up of a maximum of five time elements.Queue timeSetup timeProcessing timeTeardownMinimum 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.


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Production Order - Material Components

1000767

Purch.data VarSzeltmDta Co-product Text item

Compon. 0010

Material numberMaterial descriptionRequirements qtyReqmts date

ReservationItem categoryBulk mat. indicatorAvailable quantityIssued quantityMissing parts quantity

Text editor

OriginDefinition

Materials required for an operation or for manufacturinga product

Manual

BOM

Planned order

Order Edit Goto ComponentFunctions Environment

General data

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

Definition

1000767

General Quantities Dates

Item 0010

TypesOrigin

PRT numberPRT control keyPlant

Requirements qty

Usage valueFormulas

Usage dates

Document (graphics)PRT text

Production resources/tools requiredto execute an operation

Manual

Routing

Material

Equipment (as of 3.0)

DocumentOtherOrder Edit Goto PRTsFunctions Environment

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

P-100

Order Processing Go to DocumentFunctions Environment

Doc. Data Additional Data Descriptions Object Links Original

Document

Document no.SubdocumentDocument version

Assignmt to operationOriginFormat

Object link

Original appl. file(s)Storage data

Definition

Production resources/tools requiredexecute an order

Origin

Manual

Material MasterBill of Material

Prod.Version

000 00

Originals

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 diagramsInspection instructions and certificatesWork instructionsStorage and transportation regulationsSpare parts listsMaintenance regulations


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1000767


Receiver of order costs

Definition


Production Order - Settlement Rules

Manual

Automatic

Origin

Material

Cost center

CO order

Asset

WBS element

Production lot

Sales order and so on

Account assignment categoriesAccount assignment categories

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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Automatic Postings

Material reservationsMaterial reservations

Purchase requisitionsPurchase requisitions

Costs (CO object)Costs (CO object)

Capacity requirementsCapacity requirements

Transport requirementsTransport requirements

Inspection lotsInspection lots

PRT requirementsPRT requirements

Inventory management

Purchasing

Controlling

Capacity planning

Warehouse management

Quality management

PRT management

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 SAP R/3 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 that 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.


3.16

SAP AG 1999

Number Assignment for a Production Order

. . . .

1000000100000019999991999999

2000000200000029999992999999

3000000300000039999993999999

PP02PP02PI02PI02..........

XX

PP01PP01IDESIDESPP06PP06........

PI01PI01............

Number rangeNumber range objectobject forfor anan orderorder ((generalgeneral))

Range fromto

Assignment internalexternal(x)

Assignment of the order types(element)

Number range -Group 1



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.


3.17

SAP AG 2003

Order dates Operation dates Time concepts

PS Production start date

PF Production finish date

AD Planned availability date

LT Loading time

GI Goods issue date

RDD Requested delivery date

OS Start date

OF Finish date

Lead time of order oroperation

Activity duration (from SAP R/3)

Activity duration (SAP APO)

Processing times insales

Op.0010

Op.0020

Op.0030

OP.0040

........ Op.0099

Safety days'supply

ActivityGR

Pick/packtime

Loadingtime

Transittime

PS

ActivitySetup

ActivityProduction

ActivityTeardown

PE RDDGILTAD

OS

ASOF

AF

Relationships

SAP APO Order: Scheduling / Time Elements

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

Activity dates

AS Start date

AF Finish date

AS AFAF AS

Rel. Rel. Rel.

The slide shows all possible elements of the total lead time of an SAP APO production order. The SAP APO production order is always scheduled with dispatching within capacity scheduling

using the selected planning strategies.For that reason, the lead times of an operation and of the entire order, are always dependent on the respective planning situation.

The duration of an operation is made up of individual activities with a duration and relationship (Rel.) between the activities, with a minimum or maximum duration.

Three activities can be transferred from the SAP R/3 routings.Setup (setup duration), production (processing duration), teardown (teardown duration)

The goods receipt processing time (SAP R/3) is mapped as an activity (Transport type). A safety days' supply (product master, Lot Size tab page) is available exclusively as order float time. The SAP APO production order does not have operation-related float or interoperation times (work

center and operation-related queue times, process-related wait times), because a philosophy of "exact planning" is assumed in the SAP APO PP/DS module.

Process-related wait times can be implemented within a relationship between two activities (manual PPM maintenance required).

Move times can be mapped as a separate activity (manual PPM maintenance required). If the 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 through the SAP R/3 component.


Calendar-dependent scheduling does not take place for relationships.


3.18

SAP AG 2002

Routing Selection - Criteria (SAP R/3)

Selection type (T399X) "With / without routing""Routing required / optional""Manual / automatic selection""With / without ref. operation set""P" (Production)"N" (Routing)"S" (Reference Operation Set)

ApplicationTask list type

Routing selection IDUsage

Material no.Plant

"Alternative selection" indicator (MRP screen 4)

Production version

GroupGroup counterStatusValidityLot-size rangeDeletion flag = = "X"

"Order quantity""Basic start/finish date""Released"

(in reference operation sets)

CustomizingCustomizing

Routing

Material

A

"Production version" indicator (T399X)

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

You define the routing selection options in Customizing. The most important tables are:

T399X order-type dependent parameters andTCA43 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 the validity with which the routing should be selected, is dependent on the setting in table

T399D ( Customizing Requirements Planning).


3.19

SAP AG 1999

BOM

Stage

0

1

2. . .

. . .

20

50

100

HEADERHEADER

ITEMITEM

ITEM

Pump P-100

Pre-assembled casing

100-100

Pre-assembled shaft

100-300

Casing

100-110

Support base

100-700

Shaft

100-301


Operations

Material components


PlannedTargetActual

Costs

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.


3.20

SAP AG 2002

BOM Selection - Criteria (SAP R/3)

BOM itemBOM item

CustomizingCustomizingBOM application (T399X)BOM selection IDBOM selection priorityBOM alternativeBOM usage

"Alternative no."

BOM statusValidity

Lot-size range

Deletion flag

"Released""Basic start/finish date"

"Order quantity"

= = "X"

StatusValidity

'Production'

BOM headerBOM header

Material no.

Plant

"Alternative selection" indicator (MRP screen 4)

Production version

Material

A

BOM

"Production version" indicator (T399X) "Automatic/manual"

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

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 status 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 material number of the product to be manufactured).Refer to "Parameter Effectivity" in change management


3.21

SAP AG 1999

Item Categories in the Production Order

2050

100

Reservation

Purchaserequisition

Find object

for class


Operations

Material components


PlannedTargetActual

Costs

Stock item

Variable-size item

Non-stock item

Text item

Class item

Item categories control the data scope and functions of a material component. Typical examples are:

Stock itemNon-stock itemVariable-size itemText itemClass 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)


3.22

SAP AG 1999

Reservation

1

MaterialA

Reservation

Header

ItemItem

ItemItem

ItemItemMaterial

Plant / Storage location

Reqmts date

Movement allowed

Committed qty

Base date

Check calendar

Assignment

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).


3.23

SAP AG 1999

Material Assignment

Item 20

Item 10

Op.30

Op.20

Op.10

Material

B

Material

A

Routing BOM

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.


3.24

SAP AG 1999

Assignment of Production Resources / Tools

Production order

Op.10

Op.20

Op.30

PRT1

PRT2

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.


3.25

SAP AG 2003

Document Integration in Production Orders

Production order

Routing

BOM

DMS

MaterialB

Master DataDocument Management

System (DMS)

Material item 10

Document item 20

Document item 30

Operation 10

Operation 20

Document 1

Document 2

Document 3

Prod. res./tools Production res/tools

Order item

Overview of documents in PrO

Document 4

Document 5

Document link 4

Document link 5

Document link 1

Material item 10

Operation 10

Operation 20

Document link 2

Document 6

Fri

Fri

Fri

Fri

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 masterDocument 2 Link created manuallyDocument 3 No link to production orderDocument 4 and 5 Link created from BOM itemDocument 6 does not appear in the document overview of the production order


3.26

SAP AG 2003

Parallel Sequences

20 25 30

30

20 30

40 50 60

45 55

IIIII

IIIIIIIII

IIIIIIIII = Floats

IIIIIIIII

Parallel sequence 1

Parallel sequence 2

Parallel sequence 3

Operation 10 Operation 20

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.


3.27

SAP AG 1999

Read Master Data

2050

100

Routing 2

BOM 1

BOM 2

Routing 1

Material components


Operations


PlannedTargetActual

Costs

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)


3.28

SAP AG 2003


Aims of change management for production orders

Provision of a system-supported tool for automated change of production orders that 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?

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

12

9

6

3

11 1

7 58 4

210

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: ECM = Engineering Change Management OCM = Order Change Management

ECM concentrates on the preparation and execution of changes to product master data. OCM concentrates on the execution 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, 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 SAP R/3 provides functions for the controlled change of orders.

Change management for production orders (OCM) is dealt with in course PLM150.


3.29Order Creation / Order Change: Exercises

Unit: Order Creation / Order Change

Topic: Order Structure and Processing(SCM310 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 Create an order using the following data:

Material R-F1##

Production plant 1000

Order type PP01

Total quantity 1 pieces

Basic finish date Any

Scheduling type Backward

Path: R/3 → LO → PP → PC → ORDER → CREATE → WITH MATERIAL

1-2 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: → GOTO → HEADER

Select the corresponding tab page for the respective screen.

General assignmentGoods receiptControl dataDates/quantitiesMaster dataLong text

Also, look at the settlement rule for the order

Path: → HEADER → SETTLEMENT RULE

1-2-2 Overview of the operation sequences

Path: → GOTO → OVERVIEWS → SEQUENCE OVERVIEW

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: → OPERATION → OPERATION DETAILS



GeneralStandardValsExt.processingInterop.timesStd val.calculationSplittingOverlapDatesUser fieldsSO datesQty/activitiesConfirmed datesQualificatsLong text

1-2-6 Material components - Overview

Path: GOTO → OVERVIEWS → COMPONENTS

1-2-7 Material component screens (select component 0010)

Path: COMPONENT → COMPONENT DETAILS


Position “0010” General data

Long Text

1-2-8 Overview of production resources/tools for operation 0010

Path: Go to the operation overview and select

operation 0010.

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 0010)


Path: PRODUCTION RESOURCES/TOOLS → PRODUCTION RESOURCES/TOOLS DETAILS


Position “0010” GeneralQuantitiesDates

1-2-10 Document overview

First return to the header screen.

Path: GOTO → OVERVIEWS → DOCUMENTS

1-2-11 Display of the document information record (select the first document)

Path: DOCUMENT → DISPLAY DOCUMENT INFO RECORD


Document data

Descriptions

Object links

Originals

1-2-12 Display of the original document (display both originals from the document overview for the order)

Path: DOCUMENT → DISPLAY ORIGINAL DOCUMENT

First return to the header screen.


1-2-13 Costs

Itemization

Analysis (Cost categories)

Cost comp. structure (Cost components)

Path: GOTO -> COSTS -> ITEMIZATION

→ ANALYSIS

→ COST COMP. STRUCTURE

1-3 Save the order. Order no.: _________________

Path: → ORDER → SAVE

1-4 Now change the order.

Path: R/3 → LO → PP → PC → ORDER → CHANGE

Insert an operation 0025.

Select the operation 0030. Path: → EDIT → INSERT → ΟPERATION

Use the following data to enter the operation:

Work center no. R-V##Operation control key (CTRL) PP01Setup time 10 minMachine time 10 pieces in 30 minutesPersonnel time 10 pieces per 60 mins

1-5 Add material component R-T1## to operation 0030 in any quantity.

For this, use item category ‘L’.

Path: Go into the operation overview and select the operation 0030.

Choose the COMPONENTS pushbutton at the bottom of the screen.


1-6 Save the order and check your changes.



Topic: Order Creation Without Basic Data(SCM310 Exercise 2)

This exercise is optional.Only do the exercise if you have enough time.

• 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 the case in particular 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.


Material T-MAN


Order type PP01




Path: R/3 → LO → PP → PC → ORDER → CREATE

→ WITH MATERIAL

A dialog box appears: Routing Selection T-MAN

React to the system message: "No routing found" with

→ GENERATE OPERATION


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

2-2 Display the operation overview. Operation 0010 has already been

created automatically.

Path: → GOTO → OVERVIEWS → OPERATIONS

2-3 Use the following data to create operation 0020:

Work center no. T-V##Operation control key (CTRL) PP01Setup time 10 minMachine time 10 pieces in 30 minutesPersonnel time 10 pieces per 60 minutes

2-4 Save the order. Order no.: _________________


2-5 Now change the order.Use the following data to enter an additional operation 0030.

Work center no. R-M##Operation control key (CTRL) PP99Setup time 10 minMachine time 10 pieces in 30 minutesPersonnel time 10 pieces per 60 mins

Path: R/3 → LO → PP → PC → ORDER → CHANGE


2-6 To the operation 0020, add the material components:

R-T1## and R-T2## in any quantity.

Use item category "L" for both.


operation 0020.

Choose the Components pushbutton at the bottom of the screen

2-7 To operation 0030, add the production resource/tool "PP-FHMM". with any quantity.


operation 0030.

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.

2-8 Execute a document link, by linking the order with document T-F1##Dokument type DRWSubdocument 000Document version 00.

Assign the document to operation 0020.

Path: Goto the document overview

→ GOTO → OVERVIEWS → DOCUMENTS


2-9 Delete the operation 0010.

Path: → EDIT → DELETE

Can the system renumber the remaining operations?

Answer: ______

Number the operations manually.

2-10 Check the operation overview.

2-11 Carry out order costing (determine costs).

Path: → FUNCTIONS → COST

2-12 Display the costing result.

Path: → GOTO -> COSTS -> ITEMIZATION

2.13 Save the order.


2-14 Check your changes again in the order.



Topic: Creating an Order with Basic Data(SCM310 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 SAP R/3 searches for and selects the master data that is valid for a production order.


Material R-F1##


Order type PP01




Path: R/3 → LO → PP → PC → ORDER → CREATE → WITH MATERIAL

3-2 What is the validity date of the BOM and the routing in the production order?

Answer: __________________

Path: GOTO → HEADER→ Select the tab MASTER DATA


3-3 Compare the explosion date with the basic dates of the production order.Which date corresponds to the explosion date?

Answer: _____________________

Path: → Select the GENERAL tab page

3-4 Release the order and save it.

Order number: _____________________

Path: → FUNCTIONS → RELEASE

3-5 In operation 0010, change the routing of material R-F1##. In the operation, enter a minimum wait time of 10 minutes and save the change.

Path: R/3 → LO → PP → MASTER DATA → ROUTINGS → ROUTINGS → STANDARD ROUTINGS → CHANGE

→ GOTO OPERATION OVERVIEW→ Select the operation

→ DETAILS → OPERATION DETAILS→ here, see field group INTEROPERATION TIMES

3-6 In your production order, execute the Read PP master data function.

Path: → FUNCTIONS → READ PP MASTER DATA

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.

Note: The system resets the status of your production order to Created.


3-7 In your production order, ensure that the change was successful. Ensure that operation 0010 now contains a process-related wait time.

Path: → OPERATION → OPERATION DETAIL

→ Select the tab page → INTEROPERATION TIMES

3-8 Save the order.

3-9 Create another order using the following data:

Material R-B4##


Order type PP01




Path: R/3 → LO → PP → PC → ORDER → CREATE

→ WITH MATERIAL

A dialog box appears: Select Production Version for Material R-B4## plant 1000

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.


3-10 Check which production versions are maintained for the material master.

Path: To do so, in the dialog box select the pushbutton

→ VERSION OVERVIEW

3-11 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

3-11-1 Why does the system only offer production version 0001 for selection for the production order?

Answer: ____________________________________________

____________________________________________

3-12 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

3-13 Ensure that the production version used in the production order is correct.

Path: GOTO → HEADER→ Select the tab ASSIGNMENT

3-14 Save the order.

3-15 A production version can be changed afterwards with the READ PP MASTER DATA function.

In your order, try to exchange the production version 0001 you originally selected with the new production version 0002.


You cannot do this, because, for the reasons given above, the system only offers you version 0001.

Path: → FUNCTIONS → READ PP MASTER DATA



Topic: Other Variants for Order Creation (SCM310 Exercise 4)

• Explain the basic features and additional variants for creating production orders

Not all orders that are to be executed in production are for make-to-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 component SAP R/3 provides you with different options for producing these special cases using production orders.

4-1 Create a new production order with reference to a sales

order. Your instructor will give you the sales order.

Use the following data to do this:

Sales order number: ____________________ Item 10

Material R-F1##


Order type PP01




Save the order. Order no.: ____________________

Path: R/3 → LO → PP → PC → 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

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: R/3 → LO → PP → PC → ORDER → CREATE → WITH MATERIAL→ In the "Copy from field", enter the order number onlyCheck:

Order header data (master data)Operation overviewComponent overviewCost overviewResults of scheduling

4-4 Create a new production order for a service without reference to material (any quantity and schedule).

Path: R/3 → LO → PP → PC → ORDER → CREATE → WITHOUT 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. Order no.: _________


3.30Order Creation / Order Change: Solutions



Topic: Order Structure and Processing(SCM310 Exercise 1)

No answers are required for this exercise.



Topic: Order Creation Without Basic Data(SCM310 Exercise 2)




Topic: Creating an Order with Basic Data(SCM310 Exercise 3)

3-2 Answer: __________________ Select the MASTER DATA tab page

in the order header and read

the Explosion date)

3-3 Answer: Order start date

3-10-1 Answer: Only this production version has a lot-size range

that includes the order quantity.



Topic: Other Variants for Order Creation(SCM310 Exercise 4)



3.31

SAP AG 2003












44


Integration for PlanningIntegration for Planning




3.32

SAP AG 2002

SAP R/3 as a Planning Tool

PP - MRP

PP - MPS

Insertion of sales orders

Requirements planning

Scheduling of planned orders

Conversion of planned orders into

production orders

PP - SOP / MPS

Demand plan

Demand program

Capacity leveling

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

Demand program

Production plan

Capacity leveling

PP - CRP

Capacity evaluation

Capacity leveling


3.33

SAP AG 2003

Multilevel Materials Planning

PlannedPlannedssalesales

Independent Independent reqmtreqmt

PLANNED ORDER

PLANNED ORDER

PLANNED ORDER

Dependent requirementsDependent requirements

Dependent requirementsDependent requirements

E1E1

B1B1 B2

R1R1 R2R2 R3R3

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

Requirements planning covers a whole product structure. It runs in the following steps for each material. Checking the requirements coverage Generating the planned order BOM explosion (single-level) Determining the dependent requirements Entering the components into the planning file


3.34

SAP AG 2003

Planned Order Structure

1000767

Header Assignment Master Data

Plnd order Processing Goto Extras

MaterialA

Required material

- Quantity- Requirements date

Items

Order type

Quantity

Dates

Detailed sched.Components

Capacity reqmts

- Operation- Work center- Reqmts date

PeriodsPeriodst

Capacity req. records

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 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.


3.35

SAP AG 2002

Conversion of Planned Order to Production Order (SAP R/3)

Prod. order

No new routing selection,same routing read

Planned order has capacity requirements (scheduling "2")

Dependent requirements in planned order

"Reservation" indicator set

Capacity requirements are scheduled(DSPT)

No new scheduling with unchanged routing

Planned order

Planned order has "conversion" indicator

Make-to-order production is intended

Change to planned order through simultaneous MRP run during conversion

Leads to Termination when you save

Conversion Planned order deleted

Partial conversion Planned order firmed

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

You can convert planned orders online either individually, collectively, completely or partially. 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 firmed.


3.36

SAP AG 2002

Collective Conversion - Time-Oriented

2050

100

Operations

Materi al components

Production res/too ls

Costs plannedtargetactual

Purchase requisition

Planned orders

PL

PS

PE

PL

PS

PE

t

x days later

Today

x days earlier

Production orders

Opening period

Material reqmtsplanning

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


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. You can perform a collective conversion that is dependent on the outcome of a material availability

check (analogous to the order release).


3.37

SAP AG 2002

Collective Conversion - Structure-Oriented

Prod. order 2

Prod. order 1

Preq

Prod. order 4

Prod. order 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

R/3

List Edit Goto Settings System Help

Stock/requirements MRP Sales Profile

Target qty Receipt/requirementPlant stock Customer stock

PlantORTypeBecker Berlin

OrderSold-to party

SalesOrd

Mat.

SalesOrdPlOrd

Mat.Mat.Mat.

PlOrdDepRqmt

Mat.

DepRqmtPlOrd

Mat.Mat.Mat.

DepRqmtPlOrd

Mat.

Mat.Mat.

DepRqmtPlOrd

Mat. Blank for shaft

Blank for shaft

Pressure coverHollow shaft

Spiral casingSteel sheet ST 37Fly wheel GG

Ball bearing

NutSupport baseW'hse support

Pump GG I

Qty varianceProject stock

Qty unitBase quantity Standard pr.Pr

P-100 PC

PC

PCPC

PC

PCPC

PC

PC

PC

PC

Order Progress Report: Object Structure

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 as of 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.


3.38Integration for Planning: Solutions


Unit: Integration for Planning

Topic: Order Creation with Planned Orders (SAP R/3)

(SCM310 Exercise 5)

1-8-2 Answer: This planned order is "firmed" and is assigned the remaining quantity as order quantity.

1-8-3 Answer: No


3.39

SAP AG 1999

Describe the different types of production orders andunderstand why order release is necessary

Describe the functional steps involved in 'Releasingan 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

At the conclusion of this unit you will be ableto:

Order Release: Course Objectives

SAP AG 1999


3.40

SAP AG 2003











55




Order Release



3.41

SAP AG 2002

Order Release Functions

Order release



Production res/toolsProduction res/tools

Costs PlannedTargetActual


2050

100

Availability check

Machine usage


Order creation

Printdocuments

Materialwithdrawal

Processing Confirmation Goodsreceipt

Settlement

The order is released in SAP R/3. The 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")


3.42

SAP AG 2002

System Status and User Status

Operations

Materi al components

Production resource s/too ls

Ord er headerOrder h eader

Costs Planned

TotalActual

2050

100

Created

Release

Printed

Confirmed

Final Costing

Deleted

Delivered

Checked

Checked

Checked

InspectionReleaseRelease

Rework

Materialavailability

Capacity availability

PRT availability

documentedpossible

locked

User StatusSystem Status

User statuses enhance the system's status management capabilities. User statuses can be prepared in the form of a user status profile (Customizing). This status profile is assigned to the order category.


3.43

SAP AG 2002

Availability Check for PRT

Order typeCheck control for production ordersCheck control for production orders

Checking ruleChecking rule

Result of checkResult of check

Status MSPR (PRT shortage)

Material stock and material status checks

Document status checks

PRT status check (Miscellaneous PRT)

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 PRT deficit

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

You can activate the check according to order type and business transaction (order creation, order release).

Checking times 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 orderIndividual PRTs of an order

Checking result Status PRT shortage


3.44

SAP AG 1999

Order Release: Summary

You have gained an overview of releasingproduction orders

A production order is controlled by statusmanagement

You know the availability check options formaterial components, capacity, production resources/tools

Situations where parts are missing can bedetermined using the missing parts list

Backlog processing enables you to changeconfirmed quantities from reservations


3.45Order Release: Exercises


Unit: Order Release

Topic: Order release, status management, availability checks

(SCM310 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 'R-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 R-B1##.

Path: R/3 → LO → PP → PC → 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?


Answer: Checking group _________

Checking rule _________

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 production resource/tool T-D06 DRW 000 000 ofoperation 0010.

Path: Go into the operation overview and select the operation 0010.

In the menu bar at the bottom of the screen, select the PRTpushbutton (production resources/tools

→ In the screen that appears, select the production resource/tool PP-FHMM and proceed as follows:

→ → PRODUCTION RESOURCE/TOOL → AVAILABILITY PRT

1-5 In each case, release operation 0010.

Save the release.

Path: Select the operation and proceed with:→ OPERATION → RELEASE

1-6 Display the status of the production order and the operations.What is the new status of the production order?

Answer: ___________________


1-7 Check the availability of capacity for the entire order.

Path: → FUNCTIONS → AVAILABILITY CHECK → AVAILABILITY CAPACITY

1-8 Now check the material availability of the entire order.

What is the new status of the production order?

Answer: _________________________________

Path: → FUNCTIONS → AVAILABILITY CHECK → MATERIAL - ATP

1-9 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

Note: Status refers to user status. You must therefore select (set) each status individually and manually.

Path: → Select this symbol (pushbutton)

1-10 Now release the entire order. Save the order.

Path: → FUNCTIONS → RELEASE

1-11 Control the release of the order in the order and in the stock/requirements list.


1-12 Use the missing parts information system to determine whether there are missing partsin plant 1000 for the orders of your production scheduler number 0##.Select the material view profile.

Path: R/3 → LO → PP → PC → INFORMATION SYSTEM→ MISSING PARTS INFO SYSTEM

1-13 Carry out a collective release for all orders of your production scheduler number 0##.

If no additional production orders exist, simply create a new production order for material R-F1##.

Note the date selection entries that are proposed by the system and change them if necessary.

Path: R/3 → LOGISTICS → PRODUCTION → PRODUCTION CONTROL → CONTROL → COLLECTIVE

RELEASE

1-13-1 Select the Selection tab page and select using the following parameters:

List Order Headers

Profile Standard profile

Plant 1000

Order type PP01

Production scheduler 0##

System status FREE (Exclusive)

1−13−2 Select the tab Mass processing - Release and carry out the following settings:

Function Release

Execute function immediately

Function parameter Order Release

1-13-3 Select any production orders and start the release(mass processing)

Path: → MASS PROCESSING → EXECUTE


1-13-4 Check the release log for possible errors

Path: → MASS PROCESSING → LOG OF LAST MP

or

→ ORDER pushbutton


3.46Order Release: Solutions


Unit: Order Release

Topic: Order Release, Status Management, Availability Checks

(SCM310 Exercise 6)

1-3-1 Answer: Checking rule ‘PP’

Checking group ‘02’

1-3-2 Answer: No

1-6 Answer: PREL (partially released)

1-8 Answer: MACM (material committed) or MSPT (material shortage)


4

SAP AG 1999

Overview of standard documents

Overview of print control

Sequence of functions for "Printing orders"

Printing Order Documents: Contents

(C) SAP AG SCM310 1

4.2

SAP AG 1999

Printing Order Documents: Course Objectives

Describe the control options and variantsfor printing production documents

Explain how to use the print functions


SAP AG 1999

(C) SAP AG SCM310 2

4.3

SAP AG 2003










66





Printing ofPrinting ofOrder DocumentsOrder Documents


(C) SAP AG SCM310 3

4.4

SAP AG 2003

List Types for Order Documents

Object list

Control ticket

Time ticket

Confirmation slip

Material staging list

Goods issue slip

Job ticket

PRT overview

Kanban card

Reports Layout sets

PSFC_OBJ_LISTPSFC_OBJ_LIST PSFC_PRINTPSFC_PRINT--LAYLAY

PSFCOPCTPSFCOPCT PSFC_STD_LAYOUTPSFC_STD_LAYOUT

PSFC_STD_LAYOUTPSFC_STD_LAYOUT




PSFCJOBTPSFCJOBT


PSFCPRTLPSFCPRTL PSFC_STD_LAYOUTPSFC_STD_LAYOUT

PSFCKANBPSFCKANB PSFC_KANBANPSFC_KANBAN

PSFCGISSPSFCGISS

PSFCPICKPSFCPICK

PSFCCONFPSFCCONF

PSFCTIMEPSFCTIME

Document distribution PSFC_DOCLINK_DISTPSFC_DOCLINK_DIST DDS_COVER_PLODDS_COVER_PLO

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.

(C) SAP AG SCM310 4

4.5

SAP AG 1999

Print Control

Original print

Reprint

ListsSpool parametersRef. order categoriesLayout setsPrinting programsTransactionsDetermination of printerPrint processingTable access

PrintPrint modemode

PlantMRP controllerOrder typeOrder (from/to)

MaterialDates (Release and prod.start/finish date from/to)Order status (System/user status)Production scheduler

SelectionSelection

ControlControl tablestables

X

X

XXX

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.

(C) SAP AG SCM310 5

4.6

SAP AG 1999

Printing Order Documents: Summary

You have gained an overview of printingproduction documents

Standard documents are supplied forproduction orders

The user is usually not required to make anyspecial changes to the standard settings forcustomizing

(C) SAP AG SCM310 6

4.7Printing Order Documents: Solutions

(C) SAP AG SCM310 7

(C) SAP AG SCM310 8

Unit: Printing Order Documents

Topic: Printing Order Documents(SCM310 Exercise 7)

1-2 Answer:

Operation

Print Operation? Print Time Tickets? No. of TT

Print Confirmations?

No. of C

Yes No Yes No Yes 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

0070 x x 1 x 1

Key: TT = Time tickets C = Confirmations

(C) SAP AG SCM310 9

5

SAP AG 1999

Special material components

Picking (warehouse preparation)

Default issue storage location in the production order

Material withdrawal variants (planned, unplanned, surplus, deficit, backflushing, cancellation)

Material Staging: Contents

(C) SAP AG SCM310 1

5.2

SAP AG 1999


Material Staging: Course Objectives

Define the special features of the variousmaterial component categories

List the different options in the R/3 system(material master, BOM item, work center,automatic stock determination) for defaultingan issue storage location in a productionorder

Describe the different material stagingoptions

SAP AG 1999

(C) SAP AG SCM310 2

5.3

SAP AG 2003







77







Material StagingMaterial Staging



(C) SAP AG SCM310 3

5.4

SAP AG 1999

Material Components in Production Orders: Data and Functions

Item categories Quantities

Requirements qty Committed qty Issue quantity

Reqmts date Reservation data Special indicators Status

Reservation Default storage location Calculation of variable-size item quantity Availability check for material Discontinued parts Batch determination

General DataGeneral Data

FunctionsFunctions

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 SCM310 4

5.5

SAP AG 2003

Item Categories

Item CategoriesItem Categories LL NN RR TT DD II KK MM

Material number

Inventory Management

Text item

Variable-size item

Document Item

Class item

Intra material

PM structure document

(+/-) sign before quantity

Sub-item permitted

Item screen sequence control

+ . + - - + . +

x x

x

x

x

x

x

x

. . + + + + + .

x x x x

1 3 2 1 1 1 1

Item categories are configured in Customizing. The following item categories are accounted for in the standard version:

L = Stock itemN = Non-stock itemR = Variable-sized itemT = Text itemD = Document itemI = Plant maintenance structure elementK = Class itemM = 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

Document items are not copied to the production order, instead a document link is created. The material status of a component (in the material master) has to allow the usage in the production

order.

(C) SAP AG SCM310 5

5.6

SAP AG 2002

Options for Material Staging

Crate parts

Release order parts

Pick list items

Kanban control

Warehouse Management

Prod. order

SAP R/3 has various procedures for controlling material staging.These area) Warehouse management with the component MM-IM (Inventory Management)b) Replenishment control with the Kanban componentc) Storage location management and replenishment control with the component MM-WM (Warehouse Management System)

The Warehouse Management 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- manuallyTypical 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. Thus, the stock situation is taken into account in the production and the replenishment storage types. Typical examples are laminates, paints, ...

(C) SAP AG SCM310 6

5.7

SAP AG 1999

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)

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.

(C) SAP AG SCM310 7

5.8

SAP AG 2002

No automaticwarehouse default inproduction order !

Yes

Is PP/WM interfaceto be used?

MM storage location from PSA

No

Yes

No

No

MM storage location in BOM item?

MM storage loc. in material master?

Default MM storage location

No

Yes

NoYes

Work center maintained in operation? PSA maintained in work center?

No

Go to slide (3)

Yes

PrO created with production version?

No

Go to slide (2)

Storage Location Default in the Production Order (1)

Yes

PSA in material master?

No

Yes

PSA in BOM item?No

Yes

Mat. master maintainedfor MM warehouse?

Yes

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 slide after the next 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. The default logic also applies to production orders planned in SAP APO and converted from APO

planned orders. Container resources used in the production process model (PPM) are an exception. These are adopted

during the conversion (note 488270).

(C) SAP AG SCM310 8

5.9

SAP AG 1999


No

Yes

Yes

No

No

"Issue storage location selection" filled in the MRP

group

Does the material master of the product in the PrOhave an MRP group?

Issue storage location selection = 1

Yes

Does production version contain issuing storage location?

Does production version contain receiving storage location?

NoB C D

A

no

storag

e locatio

n d

efault

MaterialA

Yes

Checks for the defaultusing the production version

Default storage location

Yes

Yes

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 SCM310 9

5.10

SAP AG 1999


No

No

Error in WM stagingDefault storage bin (WMS)

Yes

Transfer requirement/order

Yes

Storage bin entered ?

No

Yes

Control cycle for materialand PSA maintained?

Mat. Master maintained for WMS warehouse (0088)?

Checks for default storage location in production 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.


5.11

SAP AG 2002

Material Withdrawal Variants

From ext. procurement

From consignment

From storage bin (WM)

From warehouse

Prod. order

Cost center

Asset

Sales

Project

Inspection sample

Scrap

ConsumptionConsumption IssuesIssues

Goods issue

Goods issues are generally carried out in the SAP R/3 component. 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).


5.12

SAP AG 2003

Manual Good Issues

Individual entry

Collective entry

Without reference

To an order

To a reservation

With reference Planned consumption

Unplanned consumption

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.


5.13

SAP AG 1999

Movement Type

Account Determination

Cost Update

Quantity Update

Print Indicator

Material DocumentMaterial Document ItemItem

Consumption Update Field Selection

Movement Type

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).


5.14

SAP AG 1999

Effect of a Goods Issue

Reserv-ation

Material document

Accountingdocument

Controlling document

MaterialA

Stock QuantityConsumption Stats...

Account determination

Stock accountConsumption account...

G/L accounts:

OrderCost center...

Consumption to the:

Goods issue slip Goods issue

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.


5.15

SAP AG 2003

Backflushing Materials

ExecutionExecution

12

9

6

3

11 1

7 58 4

210

ReleaseMaterial

withdrawalProcessing Confirmation Goods

receiptOrder

settlement

Synchronous with confirmation

Asynchronous withProgram 'CORUPROC‘

Reworking of terminatedwithdrawals with transaction'COGi'

Automatic

Proportional to the quantity

Control via material master, work center, or material assignment in routing

Termination when material stock = 0

Backflush PostingBackflush Posting

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 linesless 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.


5.16

SAP AG 2003

Negative Stocks or Reworks

50Current StockComp. 100-100

Negative Stocks Backlogs

-50Backflush 100 pieces 50100100

70GR 120 Pieces100100

Revise00

Backlog list

70

50

12

9

6

3

11 1

7 58 4

210

12

9

6

3

11 1

7 58 4

210

12

9

6

3

11 1

7 58 4

210

N/A

170

If, for organizational reasons, the goods issue is created before the corresponding goods receipt and the material already physically exists in the warehouse you can choose between three procedures.

Postprocessing unsuccessful material withdrawals. Negative stocks Stock determination

Negative stocks are possible in 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).


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SAP AG 2002

Material Staging: Unit Summary

This unit gave you information about somespecial features of the various material component types

There are various options (material master, BOM item, work center) for proposing a withdrawal storage location

Two pick lists with different scopes of functions are available for material staging in the warehouse


5.18Material Staging: Exercises


Unit: Material Staging

Topic: Material Staging(SCM310 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.


Material R-F1##


Order type PP01




1-1-1 Release the order.

1-1-2 Carry out an availability check for all materialsand in the table below, note any shortfall that may arise using the missing parts overview for the production order.

Path: → FUNCTIONS → AVAILABILITY CHECK

→ MATERIAL - ATP

Path: → GOTO → MISSING PARTS → MISSING PARTS OVERVIEW

Material Requirements quantity Stock Difference


R-B1##

R-B2##

R-B3##

R-B4##

1-1-3 Save the order. Order no.: __________________

1-2 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.

Post the goods issue by saving (picking) the result.

Path: R/3 → LO → PP → PC → 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.

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 R-F1##



Order type PP01




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 R-B1## and carry out a withdrawal of material with reference to the reservation.

Reservation number: ________________

Document number: ________________

Path: R/3 → LO → PP → PC → GOODS MOVEMENTS → GOODS ISSUE

Select the pushbutton TO RESERVATION

1-5-4 Carry out a withdrawal of material for assembly R-B3## with reference to the production order.


Path: Select the pushbutton TO ORDER

1-5-5 Carry out an over-withdrawal with a quantity of 1 for R-B1## with reference to the reservation.


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 a quantity of 1 for R-B1## without reference to a 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 planned material withdrawals remain open.

1-7 Ensure that the system has updated the production order (documented goods movements, withdrawal quantities, actual costs)

1-8 Display the material documents that have been generated.

Single document (transaction MB03)

Path: R/3 → LO → MM → INVENTORY MANAGEMENT → MATERIAL DOCUMENT → DISPLAY

Mass documents (transaction MB51)

Path: R/3 → LO → MM → INVENTORY MANAGEMENT → ENVIRONMENT → LIST DISPLAYS → MATERIAL DOCUMENTS


5.19Material Staging: Solutions


Unit: Material Staging

Topic: Material Staging(SCM310 Exercise 8)



6

SAP AG 1999

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

Order Control: Contents

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88





Course OverviewCourse Overview 11 Order ControlOrder Control


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Midpoint Scheduling

Example: a dispatched operation

Before dispatching

Dispatching operations

Forward and backwardscheduling

10 3020

20

302010

PS SS SF

SS SF

PF

DSPT

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

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.

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Order Split


6000767


Order

000006000767

000006001007

000006001105

Parent PrO

Child PrO

Child PrO

Status SPLT

Status CSPL

Product Cost Collector

M 1000 100-100 12.000E 1421 4230 1310 25.000V External processing 8.000X 300900 12.000G Additional raw material 8.500

Order

load

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 availableA 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 orderOnly operation confirmations can be carried out

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Splitting Capacity Requirements

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)

Application criteria

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Levels in a Split

Person APerson B. . .

Pooled capacitysetup

Plant1000

Cost center4230

Cost center4220

Machine group1111

. . .

. . .

Machine group1904

. . .

Person 1Person 2. . .

Capacity categoryPerson

Capacity categorymachine

Position

Qualification

. . .

. . .

Individual machine -1Individual machine - 2. . .

Person. .

.

Checked against HR tables !!

Machine group1112

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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Types of Split

Different capacities work simultaneously on thesame lot or order, but canalso undertake partial jobs.

5 h labor time

5 h labor time

10 h labor timefor 100 pcs.

Standard valueStandard value splitsplit

10050

Various capacities Various times

50

50 50

Quantity splitQuantity split

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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SAP AG 1999

PDC Systems: Objectives and Concerns

RealReal--time processtime process controlcontrol

Production with fewer shopProduction with fewer shop floorfloor paperspapers

Decentralized decision makingDecentralized decision making

BarBar code linkcode link

Improved transparencyImproved transparency inin productionproduction

AvailabilityAvailability ofof production statusesproduction statuses ((conditionsconditions))

Control ofControl of fullyfully oror partially automated systemspartially automated systems

RelativelyRelatively highhigh investmentinvestment

ChangesChanges inin process structureprocess structure

Independent implementation project advisedIndependent implementation project advised

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.

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Interfaces: Overview

CC = Communication channel

Subsystem

PP-PDC

PM PSPP-KANHR

Plantdatacoll-

ection

Plantmaint.dataentry

Projectdataentry

KanbanTimerecord-ing

(CC2) (CC3) (CC4) (CC5)

PDC interfaces

PP

CADintegra-tion

PP-CADinterface

PI

Processcontrol

PI-PCS interface

WM

Ware-housecontrol

WM-LSRinterface

PP

Materialdataentry

PP-REMinterface

MM

Mobiledataentry

MM-MOBinterface

QM

Inspect-ionproc.(LIMS)

QM-IDIinterface

(CC1)

R/3R/3

MMMMPPPP

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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SAP AG 1999

Download: Logical View

SubsystemSubsystem

PPR/3 online

Mat. masterHR masterReasons for var. Units ofmeasurement

Production orders

Delta download Initial download Master data download

Work centersWage types

etc.

HR

R/3R/3

MMMMPPPP

Program

You can download data in the following three ways:Master data downloadInitial downloadDelta 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.


6.11

SAP AG 1999

SubsystemSubsystem

Upload: Logical View

PP

UpdateOnline HR

CO

Pair formation

Act. time recording

Update

Time eventTime ticket Attendance - yes/no

Original values

AFRU

CONF21

R/3R/3

MMMMPPPP

RUECK

Analysis

Request PDC UPLOAD

Post PDC records

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.


6.12

SAP AG 1999

Operation time tickets

L20 - Time ticket partial finish

L40 - Time ticket finish

Work center events

Currently none

Personnel times (HR-PDC)

P10 - Clock-in

P15 - Break start

P20 - Clock-out

P25 - Break finish

P30 - Off-site work start

P40 - Off-site work finish

Interface Record Types

Operation time events

R10 - Setup start

R20 - Setup partial finish

R30 - Setup interruption

R40 - Setup finish

B10 - Processing start

B20 - Processing partial finish

B30 - Processing interruption

B40 - Processing finish

A10 - Teardown start

A20 - Teardown partial finish

A30 - Teardown interruption

A40 - Teardown finish

V20 - Var. activity partial finish

V40 - Var. activity finish

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.


6.13

SAP AG 2002

Order Control: Unit Summary

This unit gave you an overview of the meansand 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 SAP R/3 to PDC systems

Confirmations can be transferred from PDC systems to SAP R/3

An order progress report is available for checking the progress of production orders (see unit 13)

Course SCM360 provides more information about capacity planning


6.14Order Control: Exercises


Unit: Order Control

Topic: Order Control(SCM310 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.SAP R/3 and SAP APO provide you with many options for carrying out this work.

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)



Selection at operation level

Work center R-M##

Plant 1000

Familiarize yourself with the content and functions of this list.

Path: R/3 → LO → PP → PC → INFORMATION SYSTEM→ ORDERINFORMATION SYSTEM


1-2 Use the capacity planning table (capacity leveling) to schedule machine usage for the work center R-L##.

1-2-1 Select the objects

Plant 1000

Work center R-L##

Capacity category 001 to 002

Path: R/3 → LO → PP → PC → CONTROL → CAPACITY LEVELING → WORK CENTER VIEW → PLANNING TABLE (GRAPHICAL)

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 R-L##.

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

1-2-4 Set up the current planning strategy so that the following functions are carried out during planning:


Dispatching the orders Forward

For dispatching at the earliest opportunity

Check or change the strategy profile as follows:

Path: → SETTINGS → STRATEGY

1-2-5 Dispatch all orders automatically for the work center.

Path: → FUNCTIONS → DISPATCH

1-2-6 Which status do the dispatched 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 do these activities 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.

1-3-1 Create an order using the following data:

Material T-A



Order type PP08 !!!




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 pieces

Child order

Order type PP08

Basic finish date One week later than proposed


Path: GOTO → OVERVIEWS → OPERATIONS →

Select operation 0010

→ FUNCTIONS → SPLIT ORDER

Enter the split parameters

→ 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 ________________________________

The order split function is currently restricted to this form of cost object controlling!


6.15Order Control: Solutions


Unit: Order Control

Topic: Order Control(SCM310 Exercise 9)

1-2-6 Answer: DSPT (dispatched)

1-3-5 Answer: Parent order Number: ____________________

Child order Number: ____________________

1-3-6 Answer: Parent order Status: SPLT (split)

Expected yield variance = 5-

Child order Status: CSPL (Created by splitting)

1-3-7 Answer: Yes

1-3-8 Answer: Yes

1-3-9 Answer: Parent order Product-oriented for each cost collector

Child order Product-oriented for each cost collector


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SAP AG 1999

Confirmation types

Control Parameters for Confirmations

Procedures involved in the "confirmation of an order"

Confirmation data

Confirmation results

Confirmations: Contents

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SAP AG 1999


Confirmations: Course Objectives

Define the principles and processes of real-time production order confirmation

Describe the different types of orderconfirmation

Recognize the control parameters forconfirmations

Describe the effects of a confirmation

SAP AG 1999

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Order Confirmation: Process chain

The system is capable of performing avariety of functions when the confirmation

data is entered.

Confirmations

OrdersOrders

CapacityCapacityrequirementsrequirements

MaterialMaterialdocumentdocument HR dataHR data

ActualActual

Productionorder

..

..

..

Operation 0010

Operation 0020

Operation 0030

Operation 9999

Operation 0010

Operation 0020

Operation 0030

Operation 9999Confirmations are savedConfirmations are saved

......

Upload from PDC interface Manual Input

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).

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Confirmation Types and Functions



Production resources/toolsProduction resources/tools



2050

100

Confirmation for order (3.0)

Confirmation for operationFast (preliminary) entry (4.5)

Collective confirmationTime ticket/confirmation slipTime event confirmation (3.0)

Progress confirmation (4.0)

Milestone confirmation Cancellation

Check operation sequence Monitor activity default values Set status (user status) Process goods movements Backflush posting Withdraw posting for open

reservations Check delivery tolerances Transfer PDC data Reduce capacity requirements Determine actual costs Quantity calculations (4.6C)

Partial confirmation Final confirmation

End confirmation when minimumtolerance limit reached

Confirmation statusConfirmation status


Confirmation types

Confirmation functions

Confirmations are generally carried out in the SAP R/3 component. Confirmations can be carried out using various procedures (see next slide). Various functions are executed using a confirmation. Each confirmation is entered with a status. A confirmation can be made 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. You can only perform a cancellation for the individual, entire confirmation (no correction). 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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Confirmation Procedures

Time ticket/confirmation slips

confirmation

Setup start

Setup finish

Processing start

Processing finish

Time event confirmation

Confirmation for the

production order

Collective/fast entry

Progress confirmation

Milestone confirmation

Order-related confirmations Operation-related confirmations

There are various procedures at your disposal for confirmations. These different procedures are used for a variety of "real-life" requirements. Depending on conditions, only one or other of these procedures is employed when confirmations are

used in your company. Basically, a distinction can be made between operation-related and order-related confirmations. Order confirmation is the confirmation of the entire order at order header level. 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.

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Op.10

Op.20

Op.30

Requirements for Confirmations

11

Operation controlOperation control keykey

CTRL Confirmation

PP01PP01

Order type

Confirmationparameters

1 Milestone2 Normal3 No confirmation

Operation

Confirmation numberConfirmation number Operation control keyOperation control key

Production order

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.

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SAP AG 2002

Control Parameters for Confirmations

Final or partial confirmation

Final confirmation upon reaching tolerance limitsWithdrawal posting of open reservations (on final confirmation)

Confirmation function

Screen control

Default time units

Checks

Selection

Goods movements

Control

HR update

Error handling/logs

Display or default data

Order type

Control of first detail screen (1)

Hour, minute, optimized automatically

Operation sequence

Underdelivery

Overdelivery

Future dates

Confirmable operations (1)

Confirmed operations (1)

Open orders in a collective order

Display all movements or just backflush postings

Decoupling of the process

ActualGoods movements

Data to be confirmed, confirmed data, standard data (1)

Data transfer: PP -> HR

(1) inapplicable to single screen entry

Confirmationparameters

You control confirmations using settings in Customizing (parameters). You set the control parameters for order type and plant. There are different confirmation parameters for Time ticket confirmation using selection screen (can only be used with transaction CO11)

Time ticket confirmation using single screen entry (new form of the normal operation confirmation)Collective confirmation/fast entry

You can change some settings online. You must also enter the reasons for variance. The reasons for variance can trigger statuses that, in turn, control trigger points. Various programs are available for copying PDC confirmation data into the HR module.

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Determining the Yield

Yield of thelast confirmedoperation

Yield of thisoperation

= Yield to be confirmed

Which of these operations is last in the sequence ?

Do confirmed operations, confirmableoperations or operations which requireconfirmation already exist ?

The preceding operationrequiring confirmation

The preceding confirmableoperation

Yield ofthe order Yield of this

operation

Is it possible to perform the operation in sequence? (See Customizing)

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 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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Special type of confirmation automatic confirmationof preceding operations

"Unplanned milestone" each confirmable operation behaves in the same way as a milestone when it is confirmed

Special characteristics Total quantities are alwaysconfirmed

Combined use of progress confirmation and milestones is possible but with restrictions

Operations that have already been confirmed remain unchanged

New status PROG

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).


7.11

SAP AG 1999

Milestone or Progress Confirmation

Operation

0020

... ...

Milestone


Milestoneconfirmation

0030

0010

50

PROG

0040

(nn) - Update executed


Normal

1. 2. 3. Actual qty Status 1. 2. 3. Act. qty Status4.

(100) (100) MILE 70 (nn)(70) (80) (100)

50 PCNF70 PCNF20

50 50 PCNF

(100) 100 MILENormal

70 70 (nn)80 (100) 80 (nn) PROG

100 100 PROG100 100 MILE

Progressconfirmations

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.


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SAP AG 2003

Confirmation: Decoupling of Processes

Order typeConfirmationparameters "Process control"

Time procedures

Parameters

ImmediatelyImmediatelyAny

Number of parallel tasksSpecifying serverMaximum number of components permitted per MM posting document

Update taskOnlineBackground

Backflushing GIAutomatic GRCalculation of actual costs

Confirmation processes

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.


7.13

SAP AG 2003

Decoupling of Processes: Function Model

Create confirmationsOnline / Background jobs

Reprocess error records online

Process confirmations inthe background

AFFW/AFRC AFRU COEP/ MSEGAFFW/AFRP

Error records Preselection Confirmations Target table for process

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 receiptAFRP2 BackflushingAFRP3 Actual costsAFRP4 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 confirmationsCOGI Program CORUAFFW Reprocessing goods movementsCOFC Program CORUCOFC Reprocessing actual costs


7.14

SAP AG 2003

Process Flow For Confirmation for APO Order

Production order

C D

302010

A

C D

302010

A

Goods receiptConfirmation with automatic

goods receiptConfirmation with automatic

goods receiptReceiptsreduce

Increase stockReduce receipts Increase stock

Reduce receipts Increase stock

Remaining duration is scheduled to the confirmed actual end (usually today); capacity requirements for operation 10 are in future only partially visible, operation fixed

Partial confirmation for 50 pieces for operation 10 (100 pieces)

Production order with quantity 0

TimeToday TimeToday

Start RestartEnd

Transfer of operation

confirmation

R/3 APO

An SAP R/3 confirmation is transferred to SAP APO as an order change. The operation times and capacity requirements in SAP R/3 and SAP APO are adjusted with the

confirmation. SAP APO determines new dates and transfers them to SAP R/3. Order confirmations are transferred in the CIF interface as individual operation confirmations. Thus,

the same rules apply for order confirmations as for operation-related confirmations. If you confirm partial quantities of an operation, the operation is shifted to the confirmed actual end

date in SAP APO.In general, no actual end is given, and the operation is shifted to the today-line.A customer exit is available if you only want the operation to be shifted to the final confirmation. The duration of the entire operation remains the same, but the remaining duration does not. The partially confirmed operation has a start date, a restart date and an end date. The difference between the restart date and the end date of the operation is the remaining duration. Capacity requirements are not reduced with the confirmation (they are reduced only with the technical closing or the deletion flag), but the remaining time is reduced. The restart date is shifted to the today-line during confirmation. Only the remaining duration is in the future and thus creates capacity requirements in the future. Capacity requirements between the start date and the restart still exist, but are in the past.

Confirmed operations are fixed in SAP APO. Following the final confirmation for the operation, all the remaining capacity requirements for the

operation also disappear from SAP APO.


7.15

SAP AG 2002

Confirmations: Unit Summary

You have gained an overview of confirmationprocesses

You have several different confirmationprocedures at your disposal for productionorders

You can confirm entire production orders or individual operations, whichever suits your methods of organization or workload

Confirmations are controlled by parameters (see Customizing for the order type), which, in turn, can be partially modified


7.16Confirmations: Solutions


Unit: Confirmations

Topic: Confirmations(SCM310 Exercise 10)

1-2 Answer:

Operation

Confirmation Milestone Confirmation no.

Yes No Yes No0010 x x

0020 x x

0030 x x

0040 x x

0050 x x

0060 x x

0070 x x

1-3-2 Answer: SCM310_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? Answer: No

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

1-3-13 Answer: PRST and PRFN


8

SAP AG 1999

Executing goods receipts postings

Effects of goods receipts

Control parameters in the order

Goods Receipt: Contents

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8.2

SAP AG 1999

Define the posting methods for goodsreceipts

Describe the effects of a goods receipt

Recognize which parameters control goodsreceipts in an order

Explain the valuation process for goodsreceipts


Goods Receipt: Course Objectives

SAP AG 1999

(C) SAP AG SCM310 2

8.3

SAP AG 2003

1010














Goods ReceiptGoods Receipt


(C) SAP AG SCM310 3

8.4

SAP AG 2002

Goods Receipt

Initial entryof stock balances

Without production order

Without purchase order

Purchase order




Production resources/toolsProduction resources/tools

2050

100Costs Planned

TargetActual

Others

For purchase order For production order

Goods receipt

Goods receipt from production in a warehouse occurs exclusively in the component SAP R/3 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 material, the goods receipt is posted upon confirmation of the last

operation requiring confirmation.

(C) SAP AG SCM310 4

8.5

SAP AG 1999

Set "Delivery completed" Indicator




Prod. resources/toolsProd. resources/tools



2050

100

Set "Delivery completed" Indicator

Production orderGoods receipt

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.

(C) SAP AG SCM310 5

8.6

SAP AG 1999

Underdelivery and Overdelivery

70 80 90 100 110 120 130 140

Order quantity 100

Within the tolerances

no messages

Underdelivery tolerance10% Overdelivery tolerance 20%

WarningUnderdelivery

Error messageOverdelivery

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.

(C) SAP AG SCM310 6

8.7

SAP AG 1999

Goods Receipts and Quality Management

MaterialG

Ord er h eaderOrd er header

Operati o ns

Mater ial com po ne nts

Prod. res our ce s/t ool s

Cost s Plann edT argetAct ual

2050

100

111

222

333 Goods receipt

Setting the quality inspection indicator (possibilities)

In the material master

In the production order

During goods receipt

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.

(C) SAP AG SCM310 7

8.8

SAP AG 2003

Production Order and Handling Unit

Handling Unit (HU)

Print Documents

Materialwithdrawal

Processing ConfirmationGoodsreceipt

Settlement

Goods issue Goods receipt

such as truck, container, pallet, cardboard box, box or material

Unique ID per handling unit

One data object per handling unit

Management of material stocks and goods movements on the level of transport/packing units

As of Release 4.6C, you can use handling units (HUs) to support material staging and goods receipt within production with production orders.

Handling units have the following advantages:goods movements can be carried out more easily and are more transparentbetter support for logistics processes

The following functions are supported: Picking with HUs for components with or without WM integration Goods issue with HUs for components with or without WM integration Packing of the material which has been produced (assignment of packaging materials to the HU)

Materials which have been produced with a production order can be packed before goods receipt is posted and before they are placed in storage (transaction COWBPACK). The resulting handling units (transport and packaging units) are independent objects in SAP R/3.

Goods receipt with HUs for the material which has been produced with or without WM integrationGoods receipt is posted with a reference to the handling unit or the production order (transaction COWBHUWE).

Reversal of goods movements with HUs The following function is not supported: Backflush with HUs The SCM660 training course deals with these topics in detail.

(C) SAP AG SCM310 8

8.9

SAP AG 1999

Updating and Valuating Stocks

Valuation at standard price

Valuation with valuation variant

MaterialG

Order

Balance:??

SSS AAA

Stock valuation

Plant activityaccount

Ordercredit

Credit/debittransaction figures per company code; periods

Stock fieldsper plant, storage

location, special stock

Material masterSpecial stocks

G/L accountsin accounting

Quantity basis Value basis

Stock account

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.

(C) SAP AG SCM310 9

8.10

SAP AG 1999

Goods Receipt: Summary

You can now describe the process of postinga goods receipt

This posting has various effects

The posting of goods receipts is controlled byparameters in the order


8.11Goods Receipt: Exercises


Unit: Goods Receipt

Topic: Goods Receipt(SCM310 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: R/3 → LO → PP → PC → ORDER → CHANGE → GOTO HEADER

→ Select the GOODS RECEIPT tab page

1-2 Check the material stock of material R-F1##


Material stock: ______________

Path: R/3 → LO → PP → PC → INFORMATION SYSTEM→ STOCKOVERVIEW

1-3 Perform a goods 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: R/3 → LO → PP → PC → GOODS MOVEMENTS → GOODS RECEIPT

Select the pushbutton ADOPT + DETAILS

To find the movement type for goods receipt from production, choose the F4 (input help) beside Movement Type.

1-3-2 Which transaction type does the material document have? To find out, go to the document overview and then in the header of the document.

Answer: _______________________________________

Path: Select the pushbutton ADOPT

→ GOTO → OTHER FUNCTIONS → HEADER

1-3-3 Save the goods receipt posting.

Material document no.: __________________

1-4 Check the updated version of the delivered partial quantity in the order.

Which status does the order now have? Answer: ______

1-5 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 R-F1##.Use the stock overview.

1-8 Check the stock in the stock/requirements list for material R-F1##

Is the delivered order still in the list?

Answer: ______

1-9 Look at the material and accounting documents for the goods receipts performed.

Path: R/3 → LO → MM → INVENTORY MANAGEMENT→ MATERIAL DOCUMENT → DISPLAY

→ Document header

→ Item overview

1-10 Determine the number of the respective Controlling and accounting documents.

Controlling document ____________________

Accounting document ____________________

Path: → ENVIRONMENT → FI/CO DOCUMENTS


8.12Goods Receipt: Solutions


Unit: Goods Receipt

Topic: Goods Receipt(SCM310 Exercise 11)

1-1 Answer: Yes

1-3-2 Answer: WF (Goods receipt for order)

1-4 Answer: PDLV

1-6 Answer: DLV

1-8 Answer: No


9

SAP AG 1999

Settlement/Archiving/Deletion: Contents

Order settlement

Activities

Execution

Results

Archiving and Deleting

Preparation

Archiving

deleting

Retrieval

(C) SAP AG SCM310 1

9.2

SAP AG 1999


Settlement/Archiving/Deletion: Course Objectives

Define the purpose of order settlement

Explain when and how order settlementis carried out

Recognize the important control parametersfor this function

Describe the results of order settlement

Describe the necessary steps for archivingand deleting a production order

Deleted orders can be displayed again usinga retrieval function.

Recognize which control parameters to set

SAP AG 1999

(C) SAP AG SCM310 2

9.3

SAP AG 2003




1111











Settlement, ArchivingSettlement, Archivingand Deletionand Deletion


(C) SAP AG SCM310 3

9.4

SAP AG 2002

Crediting and Debiting Costs (Order-Related COC)

Settlement receiver

Distribution rule

Settlement parametersMaterial stock account (Qty. * Standard price/Price from valuation var.)Plant activity account (Qty * Price from valuation variant)

Production order credits

GR valuation control Settlement profile

Materialwithdrawal

Processing Confirmation Goodsreceipt

OrderOrdersettlementsettlement

Archiving / deleting

Actual costs forsettlementdate

Settlement account (according tosettlement schema)

Plant activity accountDifference account

Debit

Material costsProduction costsExternal activitiesProcess costsOverheads on material

Production order

M 1000 100-100 12.000E 1421 4230 1310 25.000V External processing 8.000X 300900 12.000G Additional raw material 8.500 12

9

6

3

11 1

7 58 4

210

The method of crediting and debiting the costs of a production order depends on the Cost Object Controlling (COC) variant selected in Controlling. It can be executed

with reference to the order orwith reference to the product

Order settlement is carried out in SAP R/3 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 using 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

(C) SAP AG SCM310 4

For more detailed information about cost object controlling, see course AC510 or AC515.

(C) SAP AG SCM310 5

9.5

SAP AG 1999

Settlement Profile

PA transfer structure

Source structure

Permissible settlement receiver- Cost center- Order- Project- Cost object- Asset ......

Parameters- Document type- Maximum number of distribution rules- Residence time of the documents

Indicators- 100% validation- Percental settlement- Equivalence numbers- Variance calculation

Default values- Settlement schema- PA transfer structure- Account assignment- Source structure

Assignment of debit costelement to the line in anapportionment structure forco-products

Assignment of debitcost element to the value fieldof a profitability segment

Assignment of debit costelement to the settlement cost element

Allocation structure

The settlement profile is composed of several elements:Allocation structureSource structurePA transfer structurePermissible settlement receiver and proposed account assignmentSpecial 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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9.6

SAP AG 1999

Allocation structure

650000

650100

Text651000

MaterialG

MaterialG

Debit cost elementsDebit cost elements SettlementSettlementcost categoriescost categories

Material (ext.)

400000400100400200

Material (int.)

400000400100

Activities

600000620000

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.

(C) SAP AG SCM310 7

9.7

SAP AG 2003

Cost Object Controlling - Product-Related

Actual costs of period =GR + WIP + Variance

product cost collector

TimePeriod 1 Period 2 Period 3

Material costsLabor costsMachine costs

Period end closing:Process costsSurchargesGoods in processDeviationsSettlement

ProductionordersProduction

ordersProductionorder

. . . . . . . . .



PCC

$$$$

Tgt Act. WIP Var.

product cost collector

COCO--PCPC

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 operationsThe values of variances (for example, scrap)

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9.8

SAP AG 1999

Crediting and Debiting Costs (Product-Related COC)

Settlement receiver

Distribution rule

Settlement parametersMaterial stock account (Qty. * Standard price/Price from valuation var.)Plant activity account (Qty * Price from valuation variant)

Credit product cost collector

GR valuation control Settlement Profile

Materialwithdrawal

ProcessingConfirmation Goods

receiptOrderOrder

settlementsettlementArchiving/ deleting

Actual costs forSettlementtime

Settlement account (according to allocation structure)

Plant activity accountDifference account

Debit

Material costsProduction costsExternal activitiesProcess costsOverheads on material

Product Cost Collector

M 1000 100-100 12.000E 1421 4230 1310 25.000V External processing 8.000X 300900 12.000G Additional raw material 8.500 12

9

6

3

11 1

7 58 4

210

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 productionsales order controlling, only in the profitability analysis

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9.9

SAP AG 2002

Order Statuses and Operations Allowed

TECO Technically completed CLSD Closed

DLV Delivered

DLFL Deletion flag DLT Deleted

Display status

Reversible

Actual costs = 0

No liabilities

Archive fileArchive file

TECO

DLV DLFL DLT

Delivery tolerance Delivery tolerance timetime

Residence time 1Residence time 1 Residence time 2Residence time 2

CLSD

X

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 movementsCLSD Set deletion flagDLFL Set deletion indicatorDLT Archiving and deletion

Residence times are defined in SAP R/3 T0030 with reference to the order.


9.10

SAP AG 1999

Order Settlement: Summary

In this unit the functions of order settlementwere discussed

In general order settlement is carried outperiodically.

Order settlement is controlled by a settlementprofile.

As a result of order settlement the order itselfno 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 usinga retrieval function.


9.11Order Settlement, Archiving and Deletion: Exercises


Unit: Order Settlement, Archiving and Deletion

Topic: Order settlement(SCM310 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 (settlement parameters and distribution rules) for the order.

Who is the settlement receiver, according to the posting rule?

Answer: Account assignment category ______________________

Settlement receiver ______________________

Path: R/3 → LO → PP → PC → ORDER → CHANGE →GOTO → HEADER → HEADER → SETTLEMENT RULE

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 and posting (no test run) for the current month (period).

Total overheads: ____________________

Path: R/3 → LO → PP → PC → PERIOD-END CLOSING → OVERHEAD CALCULATION → 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 Execute settlement for the current month (period) with posting (no test run).

Path: R/3 → LO → PP → PC → 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.: ____________________ (accounting document)

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: R/3 → ACCOUNTING → FINANCIAL ACCOUNTING → GENERAL LEDGER → DOCUMENT → DISPLAY →Select the pushbutton → LIST

Select using the document number



Topic: Archiving and Deleting(SCM310 Exercise 13)

• Deletion flag

• Archiving

• Deletion

• 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 SAP 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 SCM310_L## with the following program parameters:

Order number ________________

Exceeding of delivery date Empty

Actions Deletion flag


Deletion indicator

Options No test run

No detailed log

Path: R/3 → LO → PP → PC → 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!

Path: Select the pushbutton → START DATE

2-1-3 Maintain the parameters for printing the log.


Path: Choose the pushbutton SPOOL PARAMETERS

2-1-4 Start the job.

2-2 Check the status that is set in the order. What is it?

Answer: _______ and _______

2-3 Now archive the order.

2-3-1 Maintain a job variant SCM310_A## with the following program parameters:

Order number ________________

Create archiving file activate

Deletion program as test activate


Path: R/3 → LO → PP → PC → 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.






Path: Select the pushbutton SPOOL PARAMETERS


2-4 Delete the production order from the SAP R/3 database.

Path: R/3 → LO → PP → PC → TOOLS → ARCHIVING → ORDERS → Select pushbutton “DELETE”

2-4-1 Select the archive file that you created in step 2-3.


Path: Select the pushbutton ARCHIVE SELECTIONand select the files archived today.


After selection, the traffic light must be green!





Path: Select the pushbutton SPOOL PARAMETERS


2-5 In the archiving information system, check that your order numberis also actually contained in the archive file. Use the archiving step ADMINISTRATION to carry out this check.

Path: R/3 → LO → PP → PC → 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_ORDERArchive info structure SAP_PP_ORDER001

2-5-2 Start the display of the archived orders with the following limitations:

Plant: 1000


2-6 Use the normal order menu to try to display the order.Can the system display the order?

Answer: ______

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: R/3 → LO → PP → PC → TOOLS → ARCHIVING → ORDERS → Select pushbutton “RETRIEVAL”

In the selection screen, select the pushbutton ARCHIVE SELECTION


9.12Order Settlement, Archiving and Deletion: Solutions



Topic: Order settlement(SCM310 Exercise 12)

1-1 Answer: Account assignment category MAT (Material stock)

Settlement receiver R-F1## (Material)

1-2 Answer: FA_ABP

1-5-2 Answer: SA



Topic: Archiving and Deleting(SCM310 Exercise 13)

2-2 Answer: DLFL and DLT

2-6 Answer: No


9.13

SAP AG 2003



1212












Information SystemsInformation Systems



9.14

SAP AG 2003

Order Progress Report

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

Order Progress Report: Object Structure

List Edit Goto Settings System Help

Stock/requirements MRP Sales Profile

OrderSold-to party Becker Berlin

Type OR Plant Target qtyPlant stock

Receipt/requirementCustomer stock Project stock

Qty variance Unit of measureBase quantity

ExpectedStandard price

PC

PC

PC

PCPCPCPCM2PCPCPC

PCPC

Order Progress Report Key

Colors

MaterialDummy materialMaterial in sales order itemProcurement elementRequirements element

Symbols

Actual delay is too longExpected delay is too longDeficit quantity is too largeException exists for the elementMissing partElements assigned to an order

Blank for shaft

Blank for shaft

Support baseW'hse supportFly wheel GGSteel sheet ST37Spiral casingPressure coverShaftMat.

Mat.

Mat.

Mat.Mat.Mat.

Mat.Mat.

DepRqmtPReqPrdOrd

Mat.

PlOrd

Mat.

SalesOrder

Spiral casingMat.

StockStock

Mat.

SalesOrder

Pump GG I

Nut

Order Progress Report: ... Exploring - D45pp Enter other goods receipts...

An order progress report is available as of 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.


9.15

SAP AG 2002

Objects

Functions

Navigation to

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, individual customer)

Convert planned orders into production orders or purchase requisitions

Display and change all objectsRefreshProgress determination and warning systemfor each object (date/quantity variance)Print

Stock overview, stock/requirements lists, MRP list, pegged requirements, sales document flow, purchase order history, material document

R/3

R/3

R/3

R/3

R/3

R/3

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R/3

R/3

Order Progress Report - Characteristics

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)


9.16

SAP AG 2003

Sales order

Material P-100

Production order

Material 100-100

Planned order

Material 100-200

Purchase order

Purchase order

Expected delay in dates is too long

Meaning of the warning symbols

Current delay in dates is too long

Exceptions exist for this element

Elements are settled to the sales order

Missing quantities are too big

Plan

PS SS SF PE

Actual

Expected delay >0

Plan

PS SS SF PE

Actual

Expected delay = 0

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

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R/3

R/3

R/3

R/3

R/3

R/3

Order Progress Report - Warning System

Every time you "refresh", this report determines date and quantity variances of individual procurement elements (production order, purchase order, ..) automatically, and carries out progress determination based on final confirmations.

Variances are only processed, if they exceed the tolerance limits defined in the selection profile of the report. (Set up in Customizing: Production Control + Info System)

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)

If the system is to determine variances from confirmations, 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 that can be processed directly in the order progress report or in the background in variance determination using a program PPORPCRE.


As of Release 4.6C, hot package 33, this switch is ineffective, since an automatic execution has been implemented.


9.17

SAP AG 2002 R/3

R/3

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R/3

Multilevel Order Report

Multilevel 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

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.


9.18

SAP AG 2003

Alert Types

ATP no requirement coverage

Resource overload (SNP)

DP Macro Status Alerts

Date violations (SNP and PP/DS)

Resource overload (PP/DS)

Demandplanning

SupplyNetworkPlanning

PP/DS

ATP

Material shortage (PP/DS)

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

APO

The standard Alert Monitor contains a selection of 20 different alert types. The alert types must be prioritized and assigned to the various SAP APO applications.

For example, some alerts concern only SNP, whereas others may be assigned to both SNP and PP/DS. The alert monitor differentiates between alerts in a specific planning version and general alerts. For

example, capacity overload belongs to a specific planning version, while Demand Planning alerts are of a more general nature. Both alert types are displayed in the Alert Monitor.

Each alert type can be assigned to any number of applications.


9.19

SAP AG 2002

SAP OLTP Reporting Toolbox

SAP Tools

Openness

XX

Information systems

Report Painter/Writer

Special ledger

ABAPSAP Query

Business APIs

A B C

Profitability analysis

report treeEISreport portfolio

RFCTables, fields

Import/ Export

Key Figure 2Key Figure 1 . . . .

xxx xxTotal xxx xx

xxx xx

Charact .

KeyFig.

xxx xxKey 1, D escr. 1Key 2, D escr. 2

Key n, Descr. nOthers

SQL,ODBC

inSight forSAP-EIS

Word, Excel, and

so on...

R/3

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R/3

R/3

R/3

R/3

The SAP products offer various technical solutions for reporting and analysis These solutions have concentrated, up to now, on the reporting requirement in the operational

system (OLTP system) There are many such reporting systems in the company environment. With the Business Information Warehouse, SAP offers a complete solution for all reporting

requirements and decision support in an independent system (OLAP system).


9.20

SAP AG 2002

Generic Generic extractorsextractors

LIS

FI SL

CO PA

Transparenttable

Data from SAP R/3 LIS for SAP BW

InfoCubes

LISLISInfo structureInfo structure

S024 work centerS024 work center

R/3 Customizing:

Generate DataSource

Selection fields

More settings (for example, delta updates)

BW B

W B

W B

W B

W B

W B

W B

W B

W B

W B

W B

W B

W B

W B

W B

W B

W B

W B

W B

WBW

Datasource work center view 2LIS_04_P_ARBPL

The extractors for standard and customer-specific LIS structures can be generated using transaction LBWE in the Customizing cockpit of component SAP R/3.

The extractor defines which methods are used to extract data.The extraction can be made from a transparent table, through a database view, a function module, or through a SAP query.

The structure of the InfoCubes is defined, and the initial and delta update is controlled, through the extractor.


9.21

SAP AG 2002

Variable Object Overviews

Define fieldsDefine objects

Material or Material or task list grouptask list group

SequencesSequences OperationsOperations SuboperationsSuboperations

Standard seq.

Parallel seq.

Alternative seq.

Material components

Product. resources/tools

Inspect. characteristics

Trigger points

Create overview

Overview ID

Overview name

Row width

Row type (header,

heading, item)

Output characteristics

Select fields per row

Field sequence

Field attributes

R/3

R/3

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R/3

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.


9.22Information Systems: Exercises


Unit: Information Systems

Topic: Information Systems(SCM310 Exercise 14)

• Order Information System

• Order progress 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 Operationsprofile (No profile)Layout /SCM310_001Production orders Activateplanned orders Deactivate

Selection

Material R-F1##Production plant 1000Order type PP01Production scheduler 0##

Path: R/3 → LO → PP → PC → INFORMATION SYSTEM→ ORDER INFORMATION SYSTEM

1-1-1 Save these settings as selection variant

Variant name SCM310_##Description Demo group ##


Path: → GOTO → VARIANTS → SAVE AS VARIANT SAVE

1-1-2 Carry out selection

1-2 Change an order for material R-F1##.

1-2-1 Replace the work center of the first operation with the work center R-L##.

Path: Select the order → ENVIRONMENT → CHANGE ORDER→ OPERATIONS

1-2-2 Save the order.

1-3 Select the changed order in the list and refresh thechanged object.

Path: → LIST → REFRESH→ Refresh list

1-4 Check if the operation 0010 of the changed order is in the updated list at the work center R-L##.

2 Use the order progress report to check the situation of the sales order that you created in exercise number 5.

Call the report with the following parameters:

Element selection

Plant 1000Sales order number _____________ ____

Profile PP0000000001

Path: R/3 → LO → PP → PC → INFORMATION SYSTEM→ ORDER PROGRESS REPORT

2-1 If you have not already done so, open a second session and execute the following functions parallel to the order progress report.


2-2 In material requirements planning, insert a planned order for materialR-B3## with reference to your sales order.

Planned order profile KDMRP area 1000Order quantity 2 piecesfinish date AnyProduction plant 1000Sales order number _____________ ____

Path: R/3 → LO → PP → MRP → PLANNED ORDER → CREATE

2-3 Refresh the order progress report and check the appearanceof the planned order for material R-B3##.

2-4 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.

2-5 Release the production order for material R-B3## and refresh the list to check the released order.

2-6 Confirm operation 0010 of this production order.

Use the confirmation type: time ticket confirmation andnote the following:

Final Confirmation

Dates Start execution one month later

Finish execution one month later

Path: Expand the field group DATES in the confirmation screen and change the entry for the month

2-7 Refresh the report and check whether a warning was issued .


2-8 Carry out an availability check for the order, for material R-F1##.

Check whether a warning message was issued

2-9 Find out what the warning means.

Path: → LIST → KEY


9.23Information Systems: Solutions


Unit: Information Systems

Topic: Information Systems(SCM310 Exercise 14)



10

SAP AG 1999

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

(C) SAP AG SCM310 1

10.2

SAP AG 1999

Describe the automation options for morestreamlined production order management

Recognize the advantages and effects ofthese solutions

Explain how to control and apply theindividual options


Mass Processing and Automation: Course Objectives

SAP AG 1999

(C) SAP AG SCM310 2

10.3

SAP AG 2003






1313








Mass ProcessingMass Processingand Automationand Automation



(C) SAP AG SCM310 3

10.4

SAP AG 2003

Automation Options

Mass Processing

Create prod. order (assembly order)

Create rework order

schedule order

Availability Check

Release entire prod.order

Release operations

Print

WM requirement (transport reqmts)

Post goods issue (backflush)

Operation confirmation

Post goods receipt

Variable automation (such as workflow, insert operations)

Multi-level collective orders

Process multiple production orders

Event ControlOperation to be automated

Any

Create sales order

Confirmation (set status)

Release production order

Changes to production order

Prod. order creation / release

Create production orders




Confirmation

Milestone confirmation

Plant data collection

Confirmation


Create production orders

Any

Transaction COHVOMPP

Planning strategy 82

Trigger points

Production Scheduling Profile

Schedule param. for order type

Parameters for order type


Trigger points



Master, work center, or BOM component assignment

Operation control key

PDC interface

Operation control keyProduction control profile

Trigger points

Special procurement key 52

Order Information System

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)

(C) SAP AG SCM310 4

10.5

SAP AG 1999

Close

Set user status / delete

Print

Release

Costing

Picking

Material availability

Log display

Confirmation

Technical completion

Scheduling

Increase capacity requirements

WM material staging

PRT

Mass Processing Functions (HVOM)

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.

(C) SAP AG SCM310 5

10.6

SAP AG 1999

Production scheduling profile

Assignment optionsAssignment options

Mat. masterProduction scheduler

Additional control options

Production scheduling profileProduction scheduling profile

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

Automatic GR, adjustment of follow-up operationsControl options at confirmation

Automatic printing of documentReschedulingCreate document link (mat., BOM)

Control options at release

Automatic releaseCreate document link (mat., BOM)

Control options at creation

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 forCO01 Make-to-stock production CO08 Make-to-order production CO10 Engineer-to-orderCO07 Without material

(C) SAP AG SCM310 6

10.7

SAP AG 1999

Efficient Actual Data Entry

Backflush Posting Manually per material

Confirmations

Goods receipt posting

Backflush

MilestonesManually per operation

Manually per order Automatic

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.

(C) SAP AG SCM310 7

10.8

SAP AG 1999

Event-Triggered Automation

Set and / or remove status

System and / or user status

Manually and / or status-triggered

One time or always

Combinations of

options

Functions triggered by events at operationFunctions triggered by events at operation levellevel

Functions triggeredFunctions triggered AutomationAutomation functionsfunctions

Release subsequent operations

Release up to next "release point"

Define a "release point"

Release previous operations

Include a reference operation set

Create a production order by copying

Start a workflow task

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

(C) SAP AG SCM310 8

10.9

SAP AG 1999

Mass Processing/Automation Summary

Order management can be highly automated.

As of Release 4.6, there is a standardized concept forfast, variable and dialog-free mass processing.

Using the production scheduling profile, orders can be automatically released, scheduled and printed.

Backflush postings and milestone confirmations reducethe work involved when entering data to an absoluteminimum.

Other effects can be achieved by using trigger points.

(C) SAP AG SCM310 9

10.10Mass Processing and Automation: Exercises

Unit: Mass Processing and Automation

Topic: Mass Processing

(SCM310 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: R/3 → LO → PP → PC → CONTROL → MASS

PROCESSING

1-1-1 Select the Selection tab page and select using the following parameters:

List Order headersProfile (No profile)Layout /SCM310_001Material R-F1##Production plant 1000Order type PP01Production scheduler 0##System status CRTD


1-1-2 Select the MASS PROCESSING tab page and carry out the following settings:

Function Release

Execute function immediately

Execute changes to data

Function parameter Order Release

Path: 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, 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

Path: → MASS PROCESSING → LOG OF LAST MP

or

→ ORDER pushbutton

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.



Topic: Automation Options

(SCM310 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 R-F1##, enter the production scheduling profile 000002.

Path: R/3 → 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 ofproduction scheduling profile 000002 for plant 1000

Path: R/3 → transaction SPRO → PP → PC → MASTER DATA → DEFINE PRODUCTION SCHEDULING PROFILE

2-3 Create a production order using the following data:

Material R-F1##


Order type PP01





and save the order.

Order no.: ___________________

2-4 Check the status of the order.

2-5 How do you ensure that the goods issues are posted 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 is to be confirmed and despite this, all preceding operations are confirmed with proportional quantities?

Answer: _____________________________________________

_____________________________________________

2-8 How do you ensure that the goods receipt is posted 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 (work scheduling screen) for material R-F1##, delete the production scheduling profile 000002.


10.11Mass Processing and Automation: Solutions



Topic: Mass Processing(SCM310 Exercise 15)




Topic: Automation Options(SCM310 Exercise 16)

2-5 Answer: In the material master, work center, component assignmentto the operation or lastly, in the production order itself, backflushing must be activated.

2-7 Answer: By using milestones(switch in operation control key) orby progress confirmation

2-8 Answer: In the production scheduling profile or in the operation control key, automatic goods receipt must be activated


11

SAP AG 1999

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

(C) SAP AG SCM310 1

11.2

SAP AG 1999

Understand how several individual orders canbe linked over multiple levels to create acollective order

Ascertain where collective orders can beapplied, and understand their advantages andlimits

Describe the structures and functions ofcollective orders

Determine how collective orders can beintegrated into different applications


Collective Orders: Course Objectives

(C) SAP AG SCM310 2

11.3

SAP AG 2003





1414









Collective OrdersCollective Orders



(C) SAP AG SCM310 3

11.4

SAP AG 1999

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

(C) SAP AG SCM310 4

11.5

SAP AG 1999

Master Data for Collective Orders

MA

ST

ER

DA

TA

MA

ST

ER

DA

TA

Special procurement key "52"on MRP 2 screen

Bills of material and routingsat each assembly level

Any structure possiblePump

Pressure cap Spiral casing Shaft

Revolution counter Thermostat

(C) SAP AG SCM310 5

11.6

SAP AG 1999

Requirements Planning with Collective OrdersR

EQ

UIR

EM

EN

TS

PL

AN

NIN

GR

EQ

UIR

EM

EN

TS

PL

AN

NIN

G

Planned order 1

Pump

Planned order 2 Planned order 3

Pressure cap Spiral casing

Thermostat

Shaft

Planned orders created manuallyor by requirements planning

Conversion and availabilitychecks occur centrally via thefinished product / assembly

Changes to quantities and dates automatically change dependentorders during the next planningrun

Option of visible stockmovements between the levels inthe stock/requirements listRevolution counter

(C) SAP AG SCM310 6

11.7

SAP AG 1999

WarehouseWarehouse

Warehouse

PR

OD

UC

TIO

NP

RO

DU

CT

ION Pressure cap Spiral casing

ThermostatRevolution counter

Pump

ShaftShaft

Prod. order 1

Prod. order 2 Prod. order 3

Production with Collective Orders

Production orders generatedmanually or from planned orders

Conversion, release, availabilitychecks occur centrally via thefinished product/assembly

Changes to quantities, dates and so onautomatically lead to changesin dependent orders

Option of stock movementsbetween levels

Costing of orders per assembly

Overall costs are the result of all levels

(C) SAP AG SCM310 7

11.8

SAP AG 1999

Requirements (1)

Order 1

Component 1Component 2Assembly 1

Finished product

Order 2 Assembly 2

Component 3Component 4Assembly 3

Assembly 2

Special procurement key 52 52

Material master, 2 MRP screen

E - In-house production

Direct production

Bill of material, Item data

Explosion type

Can be deactivated

E - Special procurement

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).

(C) SAP AG SCM310 8

11.9

SAP AG 2003

Order Structure Bill of material structure

52

52

52

52

Finished Product Order 1

Component 1 Assembly 1 Component 2 Order 2

Order 3 Order 4

Order 5

Assembly 2 Assembly 3 Component 3

Component 4 Assembly 4 Component 5

Component 6

Requirements (2)

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.

(C) SAP AG SCM310 9

11.10

SAP AG 1999

Collective Order Views

Order 1Order 1

Order 1 Order 1

Order 1

Order 1 Order 1

Order 2 Order 3

Order 5

Order 6 Order 7

Order 1Order 1

Order 1Order 2

Overview of the entire collective orderOverview of the entire collective order

Entire Collective Order Subtree Individual orders

Order 3

Order 4 Order 5

Order 6 Order 7

Order 4

Order 1

Order 2 Order 3

Order 4 Order 5

Order 6 Order 7

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.


11.11

SAP AG 2003

Function Overview (1)

Maintenance can be carried out in... (read from DB)

Collective order Subtree

Individual order

Release

Scheduling

Availability Check

Determine costs

Lock order

Print

Graphic network overview ST

CO

ST

CO

CO

IO

IO

CO IO

IO

IO

ST

CO IO

IO

ST IO

STCO

ST

CO

Read in master data

Delete assembly

IO

IO

Create manually CO

Convert planned order

Coll. ord. overview

Function to be executed

CO, ST

Add assembly

WM staging

Generate inspection lot

CO ST

(2)

IO IO

IO

IO IO IO

CO, ST, IO

CO, ST, IO

IO

IO

(1)

CO ST IO (3)

(6)

Key: CO Function across entire collective orderST Function across subtreeIO Individual order functionFA Function can be controlled (exists), only has an effect per individual orderOI 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.


11.12

SAP AG 1999

Function Overview (2)

Function to be executed

Maintenance can be carried out in... (read from DB)

Collectiveorder

IndividualorderSubtree

Coll. ord. overview

Archiving

Set TECO

Set deletion indicator

Set deletion flag

Goods Receipt

Settlement

Determine surcharges

Material withdrawal

Confirmation

Determine variances

CO

from 30F

CO

CO

from 30E

ST

ST

ST

from 30E

IO

IO

IO

IO

IO

IO

IO

from 30E

FA

FA

FA

(5)

(4)


11.13

SAP AG 1999

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


11.14

SAP AG 1999

Outline dates

Outline dates

Basic order dates

Scheduled dates

Scheduled dates

E

(collective order)

(collective order)

(order)

(order)

Collective order

Operation 1 Operation 2 Operation 3

Leading order 1

Order 2

Order 3



E

E E

E

E E

E

E

E

S

S

S

S

SS

S S

S S

S

S

E

E

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).


11.15

SAP AG 1999

Interoperation Times Between Individual Orders


t

Order 1


t

Order 1

Operation 30 Operation 40 A

B

A = float before production, B = float after production

A

Relationship (2 days)

(no move time)

Move time (2 days)

Order 2

Order 2


There are two procedures for specifying interoperation times between assemblies. They are:Floats defined as a relationship, orFloats 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.


11.16

SAP AG 1999

Collectiveorder

IndividualorderSubtree

Coll. ord.overview

CO

Evaluation

Order quantity

Order dates

Assignment

CO

ST

ST

IO

IO

IO

CO, ST, IO

CO, ST, IO

IO

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

Collective Orders: Change Options


11.17

SAP AG 2003

Date Changes

Order 2

Start date 05.05.02 20.05.02

Assembly 1 Reqmts date20.04.02 15.05.02

Assembly 2 Reqmts date22.04.02 18.05.02

Start date 20.04.02 15.05.02 Order 3 Start date 22.04.02 18.05.02

Compon. 3 Reqmts date10.04.02 12.05.02




Date changes automatically cause dependent orders to be updated

You can view the effects that the changes have had on the dependentorders before saving.


11.18

SAP AG 1999

Quantity Changes

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.

Component 3 Reqmts qty 40 60


Order 2 Total qty 20 30 Order 3 Total qty 40 60



Order 1 Total qty 10 15

Assembly 1 Reqmts qty 20 30

Assembly 2 Reqmts qty 40 60


11.19

SAP AG 1999

Availability check

Order 2 Order 3Order 3

Order 1

Order 5Order 5Order 4Order 4

Availability checkfor component

Availability checkfor component

Order 3Order 3

Missing parts list

Component 1Component 7Component 8

Dis

pla

y o

nly

Order 3

Component 4Component 6

Order 4

Component 11Component 13

Order 5

Miss. parts overview

Component 1Component 7Component 8

Order 3

Availability checkfor order

Availability checkfor order

Change materialChange quantityChange materialChange quantity

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.


11.20

SAP AG 1999

Order Release

Order Release

When order 2 is released, orders 4 and 5 are released automatically.

Releasing an operation

You can only release operation 3 ifboth operations 2 and 1 and order 5have already been released.

Operation 1 can be released at any time.

Order 1

Order 3Operation 5

Operation 4

Operation 3

Operation 2

Operation 1

Order 4 Order 5

Ord

er 2

To release an order / operation, you must first access the entire collective order or subtree of thecollective order


11.21

SAP AG 1999

Shop Floor Papers

Shop floor papers with information about goods movements

Goods receipt (product)

Materials and assemblies yet tobe completed are managed by means of a goods receipt list

Order to order (assemblies)

The receiving order (order number, work center, operation number) is printed on theoperation control ticket and job ticket

Goods withdrawal (stock material)

Materials are printed on the pick list

Inventory

Operation 2

Operation 1



Inventory Inventory

Ord

er 2

Ord

er 2

Ord

er 1

Shop floor papers must be printed by order.


11.22

SAP AG 2003

Confirming Collective Orders

Confirmations cannot be carried out over several production levels when being performed at order header level.

You use milestone or progress confirmations to confirm the whole collective order.

A milestone set at operation 3 in order 1 would confirm the whole collective order.

Order 1

Operation 2

Operation 3

Operation 1

Order 2

Operation 1

Operation 2

Order 3

Operation 1

Operation 2


11.23

SAP AG 1999

Inventory Management with Collective Orders

Goods Receipt

Interim storage Interim storage

Material withdrawal

Goods Receipt

Materialwithdrawal

Receipt/issue postings are not needed between production levels If inventory postings take place they are automatic (see next slide)

Collective OrdersIndividual orders

Finished product Finished product

Assembly 3 Assembly 4Order 1 Order 1

Order 2 Order 3 Order 2 Order 3

Assembly 3 Assembly 4

Assembly 3 Assembly 4

Component Component Component Component

In the order types table (T003O) you can decide whether or not material accounts documents are to be created.


11.24

SAP AG 2003

Goods Movements (Goods Issue / Goods Receipt)

Goods Receipt

Operation 1

Order 1

Operation 2

Component 1

Assembly 1

Order 2

Order 3

Withdrawal quantity of 10 pcsis updated for assembly 1

when operation 1 is confirmed

Confirmation of order 3with yield of 10 pcs

for assembly 1

From order to warehouse (GR)

Confirmed yield is posted as goods receipt

Possibility of correcting goods movement errors

Similar to normal production orders

From order to order (GR/GI)

Confirmed yield is posted in the superior order as a withdrawal quantity

Optional: material accounts documents!

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.


11.25

SAP AG 2003

Settlement

100% 100%

100% 90% 10%

Cost center Material Sales order Project Network Asset Internal order

Cost center

Settlement profile

Order 1

Order 2 Order 3

Order 4 Order 5

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.


11.26

SAP AG 1999

Collectiveorder

Individualorder

Subtree Coll. ord.overview

IO

Evaluation

IO IO IOOperation overview

Comp. overview

PRT overview

Object overview

Graphics

Missing parts

Logs

IO

IO

IO

IO

IO

IO

CO

CO

ST

ST

IO

IO

IO

IO

IO

IO

IO

IO

CO, ST, IO

CO, ST, IO

SchedulingReleaseDeletion flagWM stagingRead master dataMaterial availabilityPRT availabilityDetermine costs

COCOCO

CO

STSTST

ST

IOIOIOIO

IOIOIO

CO, ST, IOCO, ST, IOCO, ST, IOIO

CO, ST, IOIOIO

CO ST IO

Display costs IO IO IO

CO ST

Collective Orders: Evaluation Options


11.27

SAP AG 2003

Integration of MPS, MRP and SFC

Productionorder 1

Productionorder 2

Productionorder 3

Sales order

Plnd Indep.reqmts

Planned Order 1

Goods Receipt

Convertplanned order 1

(or 2 or 3)

Multi-levelMRP run

Plannedorder 2

Plannedorder 3

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.


11.28

SAP AG 2002

Collective Orders: Unit Summary

Collective orders make it possible for you tolink individual orders over multiple productionlevels

Collective orders' multilevel structure enablesyou to reduce stock movement postings for sub-assemblies

Some order functions are valid for the entirecollective order, while others are onlyapplicable for individual orders

Collective orders are fully integrated in anumber of applications

This is the concluding unit of the SCM310training course


11.29Collective Orders: Solutions


Unit: Collective Orders

Topic: Collective Orders(SCM310 Exercise 17)

1-1 Answer: Material no.: R-B1##

R-B2##

R-B3##

R-B4##

1-4-2 Answer: Collective order (Read entire collective order)

Subtree (read hierarchy)

Individual order (Read order)

1-4-3 Answer: No

1-4-6 Answer: New symbol

Menu bars for order functions are now active and can be used.

1-5 Answer: Account assignment category MAT Settlement receiver R-B1##

MAT Settlement receiver R-B3##

Answer: Account assignment category MAT Settlement receiver R-F1##

1-6 Answer: All

1-10 Answer: Yes

1-11-1 Answer: NTER dates are not up-to-date

1-13 Answer: No

1-14 Answer: Yes


1-16-1 Answer: No

1-16-2 Answer: The operation is not released False

Previous milestone exists andhas not yet been confirmed True

Operation 0010 is not a milestone False


12

SAP AG 2003

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

Appendix: Contents

(C) SAP AG SCM310 1

12.2

SAP AG 2002

This appendix supplements course SCM310, providing you with further ideas and information about:

Appendix: Unit Objectives

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

(C) SAP AG SCM310 2

12.3

SAP AG 2003

Appendix: Overview Diagram

Technical DetailsTechnical Detailsand Data Structureand Data Structure 33

Serial NumberSerial NumberManagementManagement 55

Scrap and ReworkScrap and Rework 44

Customizing OverviewCustomizing Overviewand Sequenceand Sequence 11

Information onInformation onFurther CoursesFurther Courses 22

(C) SAP AG SCM310 3

12.4

SAP AG 2003

Configuration Sequence for Order Management 1

Scheduling control

Routing Selection

Create order type

Number assignment

M

M

M

M

Availability Check

M

O

M

BOM Selection

Document integration

Production scheduler and scheduling profileR

The configuration sequence listed above ensures that order types can be set up successfully. Several obligatory activities need to be taken into account.

Key: M = Mandatory activityO = Optional activityD = Activity completed by default settings.A = An activity to be completed by other applications.R = Recommended activity (rationalization effect)

(C) SAP AG SCM310 4

12.5

SAP AG 2003

Print control for order documents

Default storage location

Batch assignment / determination

Stock determination

Confirmation parameters

Valuation variant for goods receipt

Cost Object Controlling/settlement control

Configuration Sequence for Order Management 2

MaterialA

SettlementSettlement

O

O

Allowed material movement type

R

O

D

O

M

M

(C) SAP AG SCM310 5

12.6

SAP AG 2003

Information on follow-on courses

SCM360 Capacity Planning

PLM150 Change management

SCM350 KanbanSCM595 Batch ManagementPLM140, PLM143, PLM146 Variant Configuration

AC505 Product Cost PlanningAC510 Cost Object Controlling for ProductsAC515 Cost Object Controlling for Sales Order

PPPP

COCO

BWxxx Business Information Warehouse

SCM500 Processes in ProcurementSCM510 Inventory Management SCM630 Warehouse Management

QMQM PLM420 QM in der Fertigung

MMMM

BWBW

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. For information on all training courses that are offered, refer to the following Web site:

http://www.sap.com/education Choose you country, and then one of the options under Overview.

(C) SAP AG SCM310 6

12.7

SAP AG 2003

SCM310 Recommended Reading (1)

Books

G.Keller/T.TeufelSAP R/3 prozessorientiert anwenden1997/ISBN 3-8273-1073-3

T.Hantusch/B.Matzke/M.PretzSAP R/3 im Internet1997/ISBN 3-8273-1215-9

SAP PLM-TeammySAP Product Lifecycle ManagementISBN 3-934385-60-8

K.Weihrauch/G.KellerProduktionsplanung und –steuerung mit SAPISBN 3-934385-45-4

H.Bartsch/P.BickenbachSupply Chain Management mit APOISBN 3-89842-111-2

(C) SAP AG SCM310 7

12.8

SAP AG 2003

COCO_XX_(at the moment, approx. 50)ODC,OFC,OHC,OPC,POH

OrderAUART(T003O)Free choiceProduction PlanningC_AFKO_ATY, C_AFKO_AWAC_AFKO_AWK, C_AFKO_DEL,CO, RU, C2, C6, C8, C=, COTU,GOODSMOVEMENT

ORDEROwn change log

ORDE, ORDN, PSFCCOPP_ORDER

Production scheduling profile

Technical Details - Shop Floor Control

Development class(es)Function group(s)Logical database(s)

Number range object(s)Number range elementNumber range group tableNumber range group(s)Authorization classAuthorization object(s)

Message class(es)

Lock object(s)Change document object

Match code object(s)Archiving classArchiving object

Profile

(C) SAP AG SCM310 8

12.9

SAP AG 2003

DatabaseTableView

DocumentTable

DialogTable Dialog

IndexTable

Dialog(Data)table

AFFLAFFL

AFVCAFVC

AFVUAFVU

AFVVAFVV

AFRUAFRU

AFFHAFFH

RESBRESB

PLAFPLAF CRHDCRHD KAKOKAKO KBEDKBEDCOSPCOSPCOSSCOSSCOSLCOSL

COBRACOBRACOBRBCOBRB

CAUFV CAUFVDB CAUFVD

(AFPOB)

AFFLB

(AFRUB)

AFFHB

RESBB

AFVGB

(AFPOD)

AFFLD

(AFRUD)

AFFHD

RESBD

AFVGD

ITA

B

DT

AB

Data Structure

MLSTMLST

Ord er h eaderOrd er h eader


mat eri al com ponentsmaterial com ponents

Production r es/toolsProduction r es/t ools

Costs Plan nedTotalActual

Costs PlannedTotalActual

2050

100

AUFKAUFK

AFKOAFKO

AFPOAFPO

AUFMAUFM

The individual tables contain the following data:CAUFV View of AUFK, AFKO, AFPO AUFK Order headerAFKO Order headerAFPO Order itemAFFL Work sequenceAFVC Operation (general values)AFVV Operation (quantities/values/dates)AFVU Operation (user fields)RESB Material componentsAFFH Production resources/toolsMLST Trigger pointsAFRU ConfirmationsITAB Index tablesPLAF Planned orderCRHD Work centersKAKO CapacitiesKBED Capacity requirementsCOSP Primary costs

(C) SAP AG SCM310 9

COSS Secondary costsCOSL ActivitiesCOBRA Settlement objectCOBRB Settlement object


12.10

SAP AG 1999

Overview of planning options for scrap

Entering scrap

Triggering rework

Cost settlement for rework/scrap

Proof of rework/scrap

Appendix: Scrap and Rework


12.11

SAP AG 1999

Scrap and rework can occur whenprocessing materials.

Scrap and rework that occur as a result ofthe technical process should be pre-planned to ensure that the desiredyield and quality is available at the end ofthe production cycle.

Scrap or rework thatcannot be planned have to be disposed ofusing additional production processes andmaterial.

Scrap and Rework: Business scenario


12.12

SAP AG 1999

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

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 reworkModeling trigger points in the routing. These are intended to automatically incorporate a standard routing or to create a rework order.


12.13

SAP AG 1999

Planable Scrap - Example

5%

5%

7%

Casing forCasing for pumppump

1010

2020

3030

3%

Material master / BOM

Routing

11%Mat. master

Blank

Screws

Washer

Drill holes

Turn blank

Assemblecasing


12.14

SAP AG 1999

Trigger Points

System status

Confirmationof

Operation 2

Triggerpoint

User status

Status profile

Order type

Status Status

Operation 1

Operation 3

Trigger points are assigned to the operation in either the routing or production order. Possible reworking functions are:

Adding a reference operation setCreating a separate orderTriggering a workflowReleasing predefined operations

Triggered via status changes Planned using standard trigger points


12.15

SAP AG 1999

Confirmation

Confirmationof the

operation

User status 1-n for the operation, activate manually

Give reason forvariance

Table TRUGS

PlantReason for variance

User status 1

User status n

User statusis active in the

operation

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).


12.16

SAP AG 1999

Insert Reference Operation Set

Production orderProduction order

Turning

Checking

Sawing

Polish

Reference operation set

Turning

Checking

Triggerpoint

Checking

Turning Component 1

PRT

Determine the capacity requirements




Define operations for rework

Define components for rework

Calculate costs

Determine dates


12.17

SAP AG 1999

Creating an Order

Determine the capacity requirements




Reference operation set

Checking

Turning Component 1

PRT

Production orderProduction order

Turning

Checking

Sawing

Polish

Triggerpoint

Production order (rework)

Checking

Turning Component 1

PRT

Define operations for rework

Define components for rework

Calculate costs

Determine dates


12.18

SAP AG 1999

Rework costs

Production orderProduction order 11

Cost categories

Rework costs

Cost categories

Production orderProduction order 22

Raw material

External procurement

Internal activity allocation

Raw material

Internal activity allocation

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 inorder to display the rework costs (settlement schema)


12.19

SAP AG 1999

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


12.20

SAP AG 2002

General concept of serial number usage in SAP R/3

Create serial number profile and assign to material master records

Create master records for serial numbers

Use serial numbers in SAP R/3

Generate serial number listings and history reports

Appendix: Serial Numbers


12.21

SAP AG 1999

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 theproduction process

Serial numbers: Business scenario


12.22

SAP AG 1999

Integration

Serial number managementSerial number management

Production ordersProduction orders

SalesSales

Quality managementQuality management

Repetitivemanufacturing

Repetitivemanufacturing

Plant maintenancePlant maintenance

Plant maintenancePlant maintenance

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


12.23

SAP AG 1999

Serial Numbers and Batches

384 pc of material xyz

48 pc of material xyzBatch no. 0025

Material xyzSerial no. 0002358

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.


12.24

SAP AG 1999

Serial Number Management: Procedure

Mat. masterMat. master

Serial numbermaster 0001

Serial numbermaster 0001

Create serial number profileAssign profile to material masterCreate master records for serial

numbers

Serial Number Profile

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.


12.25

SAP AG 1999


Profile textExistence requirementEquipment categoryStock check rules

Serializing procedures


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


12.26

SAP AG 1999

Business Transactions with Serial Numbers

SDRE

SDLS

SDCR

SDCC

SDAU

QMSL

PPSF

PPRL

PPAU

MMSL

Serialnumberprofile

Use:

01: None02: Optional03: Obligatory04: Automatic

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


12.27

SAP AG 1999

Serial Number Usage with Movement Types

MMSLMMSL

Movement typegroup0001

Movement typegroup0001

Movement types:561561 E…562562 E...

Movement types:561561 E…562562 E...

Serialnumberprofile

Usage: 03 Obligatory

Usage: 01 Optional

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.


12.28

SAP AG 1999

Serial numbermaster

Serial numbermaster

Serial Number Master

Materialmaster

Materialmaster

Obtain status informationStock informationPartner dataConfiguration dataOptional equipment master with:

Plant maintenance dataLocation dataClassification data

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.


12.29

SAP AG 1999

Creating Serial Number Masters Directly

Serial numbermaster xxxx




Create individually

Create individually

Create using list processing

Create using list processing

Internal or external assignment

of serial number


of serial number


of serial number


of serial number

Serial numbermasters created directly

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.


12.30

SAP AG 1999

AssignAssign

AssignAssign

Create orderCreate order

Order ReleaseOrder Release

Goods receiptGoods receipt AssignAssign

Serial Number Masters in Production Orders

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

Detailedselection options

Detailedselection options

Serial Number List------------------------------------------------------------------------------------------------------------------------------------------------

Serial Number List------------------------------------------------------------------------------------------------------------------------------------------------



Documents- Orders- Materialdocuments

Documents- Orders- Materialdocuments

Serial numberhistory

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.


Rc SCM310 ProductionOrders

Documents

Transcript of Rc SCM310 ProductionOrders