PLM110-EN-470
Short Description
PLM110-EN-470...
Description
PLM110 Basic Data Part 1
PLM110 Basic Data Part 1
THE BEST-RUN E-BUSINESSES RUN SAP SAP AG 2003 SAP AG©2003
SAP R/3 Enterprise 2003/Q2 Material number: 5005 9586
Copyright
Copyright 2003 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. All rights reserved.
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Course Prerequisites
SAP01 - SAP R/3 Overview PLM100 - Life-Cycle Data Management Overview or SAPSCM - Solution Overview for mySAP SCM
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Target Group
Participants: Project team members and business requirements analysts who are responsible for material master records and bills of material.
Duration: 2 days
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Course Overview
Contents of Unit z Course goals z Course objectives z Course overview diagram z Main business scenario
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Course Overview: Course Goals
This course will prepare you to: z Maintain material master records z Manage bills of material (BOMs)
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Course Overview: Course Objectives
At the conclusion of this course, you will be able to z Create, change and delete material master
records z Manage material BOMs z Use reporting for material BOMs z Maintain variant BOMs and multiple BOMs z Use the engineering workbench
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Course Content
Preface Unit 1
Course Overview
Unit 5
Variants and Alternatives
Unit 2
Material Master Record
Unit 6
Engineering Workbench (optional)
Unit 3
BOM Management
Unit 7
Conclusion
Unit 4
BOM Reporting Appendix
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Course Overview Diagram
Course Overview
1
Variants and Alternatives
5
Material Master Record
2
Engineering Workbench
6
BOM Management
3
Conclusion
7
BOM Reporting
4
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Main Business Scenario
z Your company manufactures pumps, and you are
the project member responsible for managing basic data. z The engineering department designs the pumps.
We will maintain the material master records and bills of material that are required for this.
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Material Master Record: Basic Data View
Contents: Organizational levels for the material master record Organizational structures Material type and industry sectors Views Number assignment Units of measure Using documents Material status Deleting and archiving Classification
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Material Master Record: Unit Objectives
At the conclusion of this unit, you will be able to Distinguish how organizational levels, material type, industry sector, and material status affect the material master record. Maintain options for number assignment and units of measure. Maintain a material master record. Archive and delete a material master record. Use classification to search for a material number.
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Course Overview Diagram
Course Overview
1
Variants and Alternatives
5
Material Master Record
2
Engineering Workbench
6
BOM Management
3
Conclusion
7
BOM Reporting
4
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Material Master Record: Business Scenario
A design engineer displays a material master record. A finished product is created in the group, and plant views are added to it.
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Material Master Record: Definition
The material master contains information on the materials that a company constructs, procures, manufactures, stores, and sells. The information is stored in a database that is a central source of data on materials. The material master record integrates data from different areas of a company.
Material master record SAP AG 2003
For the company, the material master record represents the central source for data on materials. The material master is used by various R/3 logistics applications. The material can be a finished product (product, article), a semi-finished product (subassembly), or a raw material (purchased part).
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Plant: Definition A plant is an organizational unit within a company. A plant is a place where valuated goods and services are: Manufactured Stored Consumed Distributed
A plant can be used to define a: Manufacturing facility Central storage facility Corporate headquarters Sales office
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Organizational Structures and Plants Client Client Controlling area 1000
Company code 1000
Controlling area 1200
Company code 0001
Company code 0002
Valuation area 1000
Valuation area 1100
Valuation area 1200
Valuation area 0001
Plant 1000
Plant 1100
Plant 1200
Plant 0001
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Organizational units are tightly linked to each other to quickly process the relevant data for a business area. For example: Plant 1000 is assigned to a company code 1000. Company code 1000 is assigned to controlling area 1000. Therefore whenever a transaction involving cost occurs in plant 1000, the relevant records in controlling area 1000 are automatically updated. The valuation area is the organizational level at which material quantities and values are managed. It is essential for product costing that a valuation area exists for each plant. Within each valuation level, you can differentiate between values and quantities for valuation (inhouse production and externally materials) by using different valuation types. In Customizing for materials management, (define valuation type), balance sheet valuation is set up at company code level or valuation area level. Selection of valuation area level automatically causes the creation of a valuation area for each plant. In order to use product costing and order costing, inventory must be valuated at plant level.
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Organizational Levels in Logistics and Life-Cycle Data Management (LDM)
Client
Plant 1200
Stor. loc. 0003 (warehouse)
Plant 1300
Engineering level
Valuation level Production level Engineering level
Stor. loc. 0001 Stor. loc. 0002
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Organizational Levels for the Material Master Record
Material
General data
Client
Material number Description Units of measure Technical data
PlantPlant-specific data
Plant
Storage location
MRP data Work scheduling data Purchasing data
Stor. locationlocation-specific data
Data in the material master record has a hierarchical structure which covers the following organizational levels: Client, plant, and storage location The hierarchical structure of the data makes it easier to organize information on materials throughout the company and minimizes data redundancy. Engineering data is managed mainly on a client level.
Stock quantities
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Some material data is valid on all organizational levels and other data is only valid for specific levels. So that the material data can be managed centrally in the company without clogging up your data with redundant information, the material master is structured hierarchically, in such a way that a company's structure is reflected in it. Data on client level General material data that applies to the whole company is stored on client level. This includes material descriptions, base units of measure, and conversion factors for alternative units of measure. Data on plant level All data that applies to a plant and its assigned storage locations is stored on plant level. Examples of this kind of data are MRP and forecasting data. Data on storage location level All data that applies to a specific storage location is stored on storage location level. This is mainly storage location stock.
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Industry Sector and Material Type
Mechanical engineering
Chemical industry
Material master records are grouped according to industry sector and material type.
Raw materials Raw materials
Semifinished products
Semifinished products
Finished products
Finished products
Other
Other
The industry sector determines which industry-specific data appears in the material master record. The material type determines which departments can enter data and whether quantities and/or values are updated in inventory management.
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When you create a material master record, you must define the industry sector and material type for the material. The industry sector determines which data fields and screens are available for input during material master maintenance. The material type determines which R/3 business processes (such as sales, production, and purchasing) and functions (use of material in BOM or routing) are allowed for a material. The person who creates the first view of a material master record defines: The material number The industry sector The material type The unit of measure The description
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Industry Sector
The industry sector determines which branch of industry the material is assigned to. The industry sector determines:
Industry sector Description of Industry Sector A C M P
Aerospace & Defense Chemical Industry Mechanical Engineering Pharmaceuticals
Which screens appear and in which order Which industry-specific data appears
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Besides grouping together materials as different material types, you must also assign a material to a specific branch of industry. You do this by specifying the industry sector when you create a material master record. If necessary, you can predefine this field and hide it.
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Material Type A material type groups together materials that have attributes in common. The material type controls: Which departments (views) can maintain material master records Whether and how quantities and values are updated in the system Whether internal or external procurement is allowed
Material type
Which G/L accounts (for example, material stock account) are updated
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So that you can manage different materials according to the company's standard requirements, materials with the same characteristics are divided into groups and assigned to a material type. Examples of material types are: raw materials, semifinished products, and finished products. When you create a material master record, the material type determines: Which departments can maintain the material master record Whether the material number is assigned internally or externally Which number range interval the material number comes from Which screens appear and in which sequence Which department-specific data you can enter Whether quantity changes in the material master record are updated Whether value changes are updated to financial accounting stock accounts Additionally, the material type determines the procurement type of a material. For example, whether the material is produced in-house, procured externally, or both. Moreover, the material type determines which accounts are posted to when a material enters or leaves the warehouse.
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Material Master Record
Definition The material master record is a central data object in SAP R/3. It is used to model raw materials, auxiliary materials, semifinished products, products, and production resources and tools
Examples Business Processes Supported Material
Type
Sales
Purch.
Production
Pump
FERT
Yes
No
Yes
Shaft
HALB
No
No
Yes
Gasket
ROH
No
Yes
No
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Changing the Material Type
Since the material type influences internal processing, the system checks which changes are allowed. You can change the material type without restriction if no stocks, reservations, or purchasing documents exist. If stock, reservations, or purchasing documents exist, the material type can be changed if: The same G/L account is updated as by the old material type. Quantities and values are updated as they were by the old material type.
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For further conditions refer to the documentation.
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Views in the Material Master
t
S B BC A
A
XX
B
XX
Basic data
Purchasing
MRP
Sales
Stocks in plant/ storage location Accounting
Work scheduling
Material master record
Storage Warehouse management
Quality management Forecasting
Costing
Classification
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The material master record is used by all R/3 logistics applications. It controls whether a material is bought, manufactured and/or sold. Every business function can maintain one or more views of the material master. Because different user departments in a company work with the same material, and each of these departments wants to store different information on the material, you can subdivide material master data according to the department it "belongs" to. Each department has its own view of the material master record and is responsible for its data being correct. Data maintained in the following views is used by production planning functions: The basic data view contains general data such as the material number, the material description, base unit of measure, and technical data. The classification view contains user-defined class assignments for a material. The MRP view contains plant-specific data used in the planning of materials for production or procurement. The work scheduling view contains plant-specific data used in the scheduling of materials for production.
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Screens for Material Master Maintenance
c Ac
e
el lev s s
Client Material
B
MRP
Forecast
Sales
Accounting
wo rk
Basic data
Ma i
Purch.
in
XX
t
n
A
XX
g
lev el
t
a ion t i d Ad
ld
el ev l ata Texts
Document data
Units of measure
Administrative data
Consumption
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There is a standard sequence for the data screens on the main working level. You can interrupt this standard sequence at any point to go directly to any other screen. To see the screens on the additional data level, choose the Additional data pushbutton. Using the appropriate pushbuttons you can also branch from the main working level to secondary screens: Example: Accounting View 1 Pushbutton:
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Previous period/year or Std cost estimate
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Material Master Record: PP Data Basic Data View
Classification View
Material number Multilingual descriptions Base unit of measure Cross-plant material status Size, weight, and other dimensions Drawing data (design documents) Indicator: Material is configurable
Class type - 001 (Material) Class Characteristic values
MRP View
Work Scheduling View
Procurement type MRP type (MPS, MRP, other) Planning strategy Lot size and safety stock Indicator: Backflush MRP controller and MRP group Assembly scrap and component scrap In-house production time Indicator: Repetitive manufacturing
Unit of issue (base unit of measure) Production scheduler Indicator: Batch management reqmt Delivery tolerances In-house production time Inspection stock indicator Default storage location for GR/GI Plant-specific material status
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The basic data view consists of frequently used basic information which can be used by all business functions and processes. The units of measure, dimensions, and configurable material indicator are used in bills of material and routings. Classification data is part of the general material data. The characteristic values are used to find several materials that share a common attribute. MRP data is plant specific. The backflush indicator, assembly scrap, and component scrap values are also used in BOMs and routings. Work scheduling data is plant specific. The unit of issue and base units of measure are used in BOMs and routings. The lot size-dependent in-house production time in the work scheduling view can be updated from the material's routing data.
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Maintenance Functions
Default values
Material master record maintenance
Copy from material
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You can define defaults for views, organizational levels, and the industry sector. You can take the dialog boxes for selecting views and organizational levels out of the standard screen sequence. You can hide the industry sector. If you copy from another material, values from the material master are copied to the new material master record that you are creating, where you can overwrite them. Note: As of R/3 4.6, you can select the Create Views Selected checkbox, which automatically creates all views that exist in the reference material. Previously, each view (department) had to be viewed. This is no longer required.
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Material Master Record Defaults
To access material master data efficiently, you can: Predefine the industry sector Predefine the selection of views Predefine the selection of organization levels
To enable more efficient and accurate entry of MRP / forecast data, you can predefine MRP / forecast profiles Define MRP profile / forecast profile: Default values for MRP / forecast data fields Rules for MRP / forecast data field input
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The MRP profile allows users to set default values for MRP data fields and determine whether the values can be changed during material master maintenance. If a change is made to a default value in an MRP profile and the field cannot be changed by using material master maintenance, the system automatically changes the field value in all material masters linked to that specific MRP profile. The forecast profile allows users to set default values for forecast data fields and determine whether the values can be changed during material master maintenance. If a change is made to a default value in a forecast profile and the field cannot be changed by using material master maintenance, the system automatically changes the field value in all material masters linked to that specific forecast profile.
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Number Assignment (NA) for Materials
Material
Check externally assigned number Matl type
Group 1 Internal NA interval External NA interval
Group nn
...
Internal NA interval External NA interval
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Each material has a unique material number to identify it. You can assign a number externally or internally. If you assign a number externally, you enter the character string you require when you create a material master record. If you assign a number internally, you do not enter any material number when you create a material master record. The internal number is shown in the material number field, but is not saved to the database until you save the material. The type of number assignment that is allowed depends on the material type and is defined in Customizing. First, you have to maintain the number range groups. You then assign the material types to the groups. You can assign an interval to only one group. You can change the current number of an interval manually.
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Material Number Display and Layout
Material
Database Material number: 18 Characters Conversion Input/output length Leading zeros Template Storage type SAP AG 2003
The data you enter for material number conversion determines the way material numbers are displayed in dialog functions and printouts only. This means that the information is stored in the database unconverted. Caution: The display format for the material number is effective for all clients.
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Units of Measure
Base unit of measure: piece
4
16
Carton
Crate
(Unit of issue)
(Order unit)
72
Pallett (Sales unit)
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In addition to the base unit of measure that the system uses for stockkeeping and to execute all its calculations, other departments can use their own units of measure. All units of measure in R/3 that are additional to the base unit of measure are grouped together under the title "Alternative units of measure". The following alternative units of measure are supported: Base unit of measure: Stockkeeping unit. All other units of measure that you use are converted to the base unit of measure. If there is no standard formula for converting an alternative unit of measure to the base unit of measure, you must enter the conversion factor for the units of measure in the material master. Order unit: Unit of measure used for ordering the material. This is the default unit that is displayed in purchasing functions. Sales unit: Unit of measure used for selling the material. This is the default unit that is displayed in the sales order. You can change this unit in the sales order. Unit of issue: Unit of measure for issuing the material from stock. You use this unit for goods issue and stock movement transactions. You can enter use this unit for the BOM item quantity. The engineering department usually uses the base unit of measure.
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Grouping Units of Measure
Create unit of measure group
Create material master
Alternative units
Base unit of measure
Conversion factors to base unit of measure
Enter group name
Input transaction: Conversion factors to base unit of measure are known SAP AG 2003
You can group together several units of measure in a unit of measure group and assign them to a material. For each unit of measure in the group, you can enter the conversion factor to the base unit of measure. You maintain unit of measure groups in Customizing for the material master (Logistics - General). Note: The base unit of measure must not be entered in the unit of measure group.
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Using documents
Definition Information medium for information that is intended either for the user responsible or for data exchange between systems.
Examples NC program
Inspection instr.
Brochure
Drawing
Use Material master
Bill of material
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Material Status
Material status field Basic data
Application
Control
Application Plant
No Dialog
Purchasing BOM header BOM item Routing Independent requirements Forecast MRP Production order header Production order item PRT
Warning Error X
X X X X X X X X X
Plant maintenance
X
Inventory management
X
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The material status allows you to control where a material can be used in business applications. You define the material status in the material master record in accordance with the material, client, and plant. You can limit the use of a material in different ways: The material can be flagged for deletion. The material status can lock the material for certain business processes in materials management and production planning, You can display and check whether a material is subject to restrictions, and what these restrictions are, with the status information function. You can call this function when you create, display, or change a material master record. Proceed as follows: Choose Information on material from any screen. You can define the material status for all plants (basic data view), or separately for each plant (plant view). Note: The more restrictive status has priority (regardless of whether it is the cross-plant status or the plant-specific status).
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Extend Material Views
Extendable materials
Selection screen
Status
Material
Selection criteria
D MRP
T-F112
Maint. status
E Purchasing
T-F112
Created on Plant
K Basic data
T-F112
B Accounting
T-F112
Warehouse no. Material
T-F112
Material type Industry sector
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Allows you to extend the material master record by adding further views. The following questions can be answered: Which departments have to extend a material master record? Which material master records does a single department have to extend? Important maintenance statuses: Department:
Maintenance status:
Work scheduling A Accounting B Classification C MRP D Purchasing E Production resources/tools F Costing G Basic data K ...and so on (see maintenance status in transaction MM50: Extend Material Views) Note: If additional views are to be added to an existing material master record, you can also work with the create material function.
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Materials List
Numbers Numbers
Plants
Material type Material
User
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This function allows you to create lists of materials according to specific, combinable selection criteria: List by material numbers List of all materials that have been created in certain plants List of all materials of a certain material type List of all materials that have been created by a specific user
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Deleting a Material
Client 1. Flag for deletion Plant
Stor. location
2. Reorganization
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You can flag materials for deletion by setting the deletion flag in the material master record. The materials to be deleted can be determined by the system by using a proposal list.. The deletion flag can be scheduled in the future and must then be activated at the correct time. All records flagged for deletion are deleted by a reorganization run, provided that they are no longer used - as a BOM header, for example. Deletion consists of three steps: 1) The material master is flagged for deletion 2) The material master is selected for reorganization processing 3) Reorganization processing is executed Note: System checks are performed during reorganization to ensure that deletion and archiving of the material is allowed.
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Archiving a Material
Database 1. Archive
Sequential file
Tables
Database 2. Delete
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You can archive material master records. The data is stored in a sequential file (archive file). Archived data can be deleted from the database by using the deletion program/reorganization. Archived material master records can be displayed, but they cannot be retrieved. Archiving and reorganization are handled in detail in the administration courses.
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Classification
Routing Routing Group 10
Z1
Material master record
Grp ctr: 1310
20 30
Routing headers
PRT
Classification User-defined classification structure User-defined characteristics for object search Hierarchy, graphic
Work centers
Documents
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The functions of the classification are: To find an appropriate object To find similar objects To establish that no appropriate object exists To fulfill these objectives, you need to organize your data efficiently. The classification in SAP R/3 is a tool for organizing your data that goes far beyond matchcodes and systematically structured number assignment. The four parts of R/3 classification are: Characteristics maintenance Class maintenance Classification (assignments) Object search Course PLM130 contains more information on classification in SAP R/3.
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Classification Functions
Chars maintenance - Pump height - Pump capacity - Turning speed - Material - Use
Object maintenance
- Color - Pump medium - Type - Driven by
Material number Pump height Pump capacity Turning speed Material
Characteristics
Class maintenance Class: Pump - Pump height - Pump capacity - Turning speed - Material - Use
: T-F100 : 10 m : 20 m/s : 1000 /min : Cast iron
Values
Classification Assignment Object: Class:
T-F100 Pump
Characteristic values Pump height : Pump capacity: Turning speed : Material :
10 m 20 m/s 1000 Cast iron
Object search Find class
Find objects in class
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An object is a classifiable unit (such as material, supplier, work center, customer, and so on). A class is a name for a group of objects that have common or similar attributes. A characteristic describes attributes of an object (such as length, industry standard, and basic material). A characteristic value represents the specification of a particular attribute. (For example: 10 cm, DIN 931, or cast iron.) The procedure for class maintenance is as follows: 1. Define characteristics and allowed characteristic values 2. Maintain the class and assign the characteristics to it 3. Maintain the objects (for example, materials), assign them to one or more classes, and assign values to them 4. Find objects
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Finding a Material What is the number of the material?
List of classes
Display material master Material _____
Display material master Material P-105
Oils List of classes Pumps Tools
List of materials
Characteristics
P-103 P-105
Pump height: 10 m Turning speed: 1000 Material: Steel
10 10
Steel Steel
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SAP R/3 classification makes it easy for you to find objects (for example, materials). If you have set up classification, you can use it to find a material number and copy the number to your application.
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Characteristic Value Assignment
Constant
Example: 2.75 or OTTO or 123-KD-27
Constants
Example: 2.75; 3.6; 4 or Smith; Sims; Lopez
Intervals
Example: 10 - 27.3
Spec. interval
Example: 14 from 14 upward
Combination
30
Comparison type
Values are equal to the constant or lie within the interval Values are not equal to the constant or lie outside the interval Value includes string at any point
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You can use characteristic values in various ways when using classification to determine a material number. For instance you can: Link several entries in one line with an OR. Link entries in several lines with an AND. Use F4 help to display possible entries for selection criteria.
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Material Master Record: Unit Summary
You are now able to: Maintain different organizational levels for a material Control the processing of materials by using material type, industry sector, and material status Carry out number assignment internally or externally Recognize that material master data is divided into different user departments (views) Use the Extend material views function, which allows you to maintain further views (in addition to the create function) Use R/3 classification to classify materials. This enables you find materials more easily.
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Data Sheet for Exercises Explanation of the Symbols used in the Exercises and Solutions Exercises Solutions Course Objectives Business Scenario Hints and Tips Warning or Caution Note: There may not be sufficient time to work through all the exercises during the course. The exercises marked Optional should be seen as supplementary examples that can be used, as required and time permitting, during the course. Course participants can also use these exercises after the course, to consolidate what they have learned.
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Data in the Exercises Type of Data
Data in the Training System
T-F1##
T-F1##
T-F##
T-F1##
T-GR##
Created by participants
T-B##
T-B1##
100-100
100-100
100-110
100-110
100-120
100-120
100-130
100-130
100-200
100-200
100-300
100-300
100-600
100-600
100-700
100-700
T-B1##
T-B1##
T-B2##
T-B2##
T-B3##
T-B3##
T-T1##
T-T1##
T-T2##
T-T2##
T-T3##
T-T3##
T-T0##
T-T0##
T-T4##
T-T4##
T-F1## DRW 000 00
T-F1## DRW 000 00
T-FY##
T-FY##
T-FZ##
T-FZ##
T-BZ##
T-BZ##
T-F77##
T-F77
T-B71 to T- B75
T-B71 to T- B75
Role
SAP_CA_PLM_DESIGNER
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Material Master Record Exercises Unit:
Material Master Record
Topic:
Integration in mySAP PLM
At the conclusion of these exercises, you will be able to: • Display a material master record
A design engineer displays a material master record.
1-1
Display material master record T-F1## (## = group number). 1-1-1 Change the default settings for further processing as follows: Industry sector: Mechanical Engineering Hide the industry sector on the initial screen Views:
Basic Data 1 and 2 MRP 2 and 4
Organizational levels:
Copy from:
Plant: Storage location:
1000 0002
1000 0002
1-1-2 Write down the entries you see for: Base unit of measure
___________
Material group
___________
Laboratory/office
___________
What does this abbreviation mean?
___________
Procurement type
___________
1-1-3 From the material master record, display an original document belonging to the material. (Enter front-end type TR or PC if prompted). 1-1-4 When and by whom was the data created? (See icon I)
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By whom?
___________
When?
___________
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Record Exercises Unit:
Material Master Record
Topic:
Material Master Maintenance
At the conclusion of these exercises, you will be able to: •
Create a material master record using a reference material and classification.
• Extend and classify a material master record A finished product is created in the group, and plant views are added to it.
1-2
Create the following material master record by copying from a reference material: A finished product (FERT) with material number T-F## (## = group number) in plant 1000, storage location 0002, copied from material T-F1##, with the following views: Basic Data 1 and 2 MRP 2 and 4 1-2-1 Enter material number T-F## and use the classification system to find the material to Copy from as follows: Tab page:
Materials for class
Class
100 with keyword Pump*
Class type
001 (material class)
Characteristics and their values: Pump height: 10 m Pump capacity: 20 m³ Turning speed: 1,000 Copy material master record T-F1##. Note the maximum number of hits. This means that the material you are looking for may not be in the hit list. Check your user settings. Extras → User settings: Tab page Find object Field: Maximum hits (increase value to 200 or 500)
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1-2-2 Which views are selected? ______________________________________________________ ______________________________________________________ You want to ensure that you are creating a material for plant 1000, storage location 0001. To do this, choose Organizational levels. Change the description of the new material to Pump ## (## = your group number. View all the selected views before you save. Ignore any warning messages.
1-2-3 What happens if you do not view the views? In other words, if you do not confirm each view before you save? ___________________________________ 1-2-4 How can you add missing views to a material master? 1-2-4-1__________________________ 1-2-4-2__________________________ 1-2-5 How can you avoid having to confirm each view when you create a material? (New as of R/3 4.0) ___________________________________ 1-3
Create another material master record as follows: A semi-finished product (HALB) T-B##, copied from material T-B1## in plant 1000, with the following views: Basic Data 1 and 2 MRP 2 and 4 Change the description to Casing ##. Enter the material number of reference material T-B1##.
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OPTIONAL: 1-4
Delete the default settings for views and organizational levels that you created in the first exercise.
1-5
Create a third material master record for finished product T-GR## with the view Basic Data 1: Description: Demo – Group ## Base unit of measure: PC
1-6
Extend this material master record using the function Extend material view(s) by adding view: MRP Enter values of your choice (maintain the REQUIRED data fields). (On the selection screen, enter only the material number T-GR##.)
1-7
Flag material master record T-GR## for deletion.
1-8
Create a Classification view for the other material master record T-F1##. Class type: 001 Class: 100 Pumps Characteristics: Pump height: Pump capacity: Usage:
Material class 10 m 20 m³ House technology
1-9
Extend the semi-finished product T-B1## using the function Extend material view(s) by adding view Work Scheduling. In the Unit of issue field, enter: PAL (Pallet) In the dialog box you see, enter the conversion factor between pallet and piece. Example: 1 PAL contains 5 PC
1-10
Change the finished product T-F## (## = group number): View: Basic Data 1: Under General Data, in field X-plant matl status, enter: ZS (locked for BOM items)
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Material Master Record Solutions
1-1
Unit:
Material Master Record
Topic:
Integration in mySAP PLM
Display material master record: Logistics → Production → Master Data →Material Master→ Material → Display → Display Current or Logistics → Central Functions → Engineering→ Material → Material → Display → Display Current or Logistics → Materials Management → Material Master→ Material → Display → Display Current 1-1-1 Enter material number:
T-F1##
Defaults Industry sector: M Select Hide industry sector on initial screen Views: Basic Data 1 Basic Data 2 MRP 2 MRP 4 Select View selection only on request Copy from: Organizational levels: Plant: Storage location:
1000 0002
1000 0002
Select Org. levels/profiles only on request 1-1-2 Basic Data 1:
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Base unit of measure: Material group: Lab./office: Description:
PC 001 KB1 Construction Office KB1
MRP 2: Procurement type:
E (In-house production)
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1-1-3 Choose pushbutton Additional data then tab Document data Select and display a linked document and its originals: Icon: Display originals (If prompted, enter front-end type TR or PC.) 1-1-4 In addition to the material number and description: I Icon: (Information on material)
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Solutions Unit: Material Master Record Topic: Material Master Maintenance
1-2
Create material master: Logistics → Production → Master Data → Material Master → Material → Create (Special) → Finished Product or Create (General) → Immediately (Material type FERT) or Logistics → Central Functions → Engineering→ Material → Material → Create (Special) → Finished Product or Create (General) → Immediately (Material type FERT) or Logistics → Materials Management → Material Master→ Material → Create (Special) → Finished Product or Create (General) → Immediately (Material type FERT) 1-2-1 Use classification to find the reference material. Choose the search help in the Copy from "Material" field. Tab page: Materials for class Choose search help in field Class. Keyword: Enter pump*. Select class 100, class type 001. Characteristics: Pump height: 10m Turning speed: 1,000
Pump capacity:
20 m³
Pushbutton: Find in initial class Copy material master record T-F1## (## = your group number). Ignore any warning messages and view all of the chosen views, before you save. 1-2-3 What happens if you do not view the views? In other words, if you do not confirm each view before you save? The views (departments) are not created.
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1-2-4 How can you add missing views to a material master? 1-2-4-1Material → Create (Special) or Create (General) → Immediately (MM01) 1-2-4-2... Material Master → Other → Extend Material Views (MM50) 1-2-5 How can you avoid having to confirm each view when you create a material? (New as of R/3 4.0) Defaults: Views
Select: Create views selected
1-3
Procedure as for exercise 1-2. Exceptions: Material type HALB (semi-finished product), reference material TB1##.
1-4
Defaults Delete all default settings for views and organizational levels. Procedure similar to 1-1.
1-5
Procedure as for exercise 1-2. Exceptions: Material type FERT (finished product), without reference material.
1-6
In the material master menu Others → Extend Material View(s) Enter selection parameter material T-GR## on the selection screen and execute. Select the line with the status D and choose pushbutton Maintain materials. Enter plant 1000, maintain the view with any values (your choice), and save .
1-7
In the material master menu, choose Flag for Deletion → Immediately. On the selection screen, selection parameter material T-GR## and set the deletion indicator.
1-8
Procedure as for 1-6, maintenance status C, or: Create Material→ Immediately, with the material that already exists. Select the Classification view.
1-9
or From the material master menu, choose Create Material (General) → Immediately Select view: Work Scheduling Enter a Unit of issue such as PAL (Pallet) In the dialog box you see, enter the conversion factor between base unit of measure and the alternative unit of measure.
1-10
From the material master menu, choose Material → Change → Immediately. View: Basic Data 1: Under General Data, in field X-plant matl status, enter:ZS (locked for BOM items)
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BOM Management
Contents: Terminology Validity Item categories
SAP AG 2003
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PLM110
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BOM Management: Unit Objectives
At the conclusion of this unit, you will be able to Name the basic terms we use for bills of material Create bills of material on client level and plant level Distinguish between BOM category, BOM usage, and validity Name and use the different item categories in a bill of material Distinguish between BOM status and item status
SAP AG 2003
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Course Overview Diagram
Course Overview
1
Variants and Alternatives
5
Material Master Record
2
Engineering Workbench
6
BOM Management
3
Conclusion
7
BOM Reporting
4
SAP AG 2003
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BOM Management: Business Scenario
Your company has a central engineering department. You create group BOMs and assign them to different plants. You add various item categories to the BOMs. You use classification to find materials.
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Definition of a Bill of Material
Bill of material A bill of material is a complete, formally structured list of the components that make up a product or assembly. The list contains a description and object number for each component, together with the quantity and unit of measure.
SAP AG 2003
BOMs and routings contain important basic data or master data for integrated materials management and shop floor control. In the engineering department, new products are designed to be suitable for production, as well as for their intended function. The result of this product phase is drawings and a list of all the required parts, the bill of material (BOM). BOMs can be found in various forms wherever finished products or semifinished products are produced from several component parts or materials. Depending on the industry sector, they may be called: Recipe List of ingredients
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Terminology
Bill of material Single-level BOM Assembly Part 1 Part 2 Part 3
Item 1 Item 2 Item 3
Part n
Component 1 Component 2 Component 3 Component n
SAP AG 2003
Assembly: An assembly is a set of components for a product that belong together for production purposes. The assembly can itself be used as a component in another assembly. Single-level BOM: A single-level BOM is a set of all the components that represent one or more assemblies. Component, part, and item are synonymous terms.
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BOM Integration
Basic data Material
Sales Sales order
Controlling Product costing
Equipment
Materials mgmt
Documents
Purchasing
Bill of material Routings Classes PRTs Work center
Production MRP
Warehouse
Plant maintenance
Planned orders Production orders
Maintenance plan Maintenance order
SAP AG 2003
Data that is saved in BOMs forms a significant basis for various areas within production planning. The engineering department creates BOMs. You can create BOMs in R/3 using a CAD program and a CAD interface. Material requirements planning (MRP) explodes BOMs in order to determine economical order quantities at a particular point in time. In work scheduling, BOMs form the basis for the planning of operations and shop floor control. Production order management uses BOMs to plan the provision of parts. The BOM is also used: In the sales order as an aid to entering data In reservation and goods issue as an aid to entering data In product costing to calculate the material usage costs for a product The simultaneous use of BOM data in several areas of a company shows the great advantage of integrated modules that are linked in such a way that they facilitate a flow of data between various work areas and allow all the users to access the current values at any time.
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BOM Categories
Document
Material
Material BOM
Order BOM
Equipment BOM
Doc. structure
Func. loc. BOM
SAP AG 2003
BOM categories define the connection to an object. Material BOMs are used to represent the structure of products that are produced within the company. Order BOMs are used to produce a product for a specific sales order. A document structure can consist of several documents, for example, a program, technical drawings, paper documents, and photographs. You need document info records for these. Equipment BOMs are used in plant maintenance to describe the structure of a piece of equipment and to assign spare parts to the piece of equipment for maintenance purposes. Functional location BOMs are used in plant maintenance to link equipment to specific locations.
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Before You Create a BOM
Does a material master exist for the BOM header? What is the BOM going to be used for? Is this material type allowed in BOMs? In which plant is the BOM required? When does the BOM need to become effective? Are change documents necessary? Does the material belong to a BOM group? What status does the BOM have? Are there default values?
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The questions listed above must be answered before you create a bill of material.
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Default Settings for Bills of Material
The following default values are defined in Customizing: Base quantity for bills of material BOM status Settings for item category R (variable-size item)
The following default values can be defined by the user, or defined per user in Customizing: Item increment Item category Material provision indicator Various BOM reporting options
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You can use default values to make data entry more efficient. Each user can also define their own default values to optimize or simplify data entry. These settings can also be defined per user in Customizing.
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Bill of Material
Definition A bill of material is a comprehensive, formally structured list of the components that make up an object. The list contains a description and object number for each object, together with the quantity and unit of measure.
Examples Item
Item cat. Material
Quantity
Unit
10
L
Material 1
100
piece
20
L
Material 2
10
grams
30
L
Material 3
1
meters
SAP AG 2003
Note: The system proposes the base unit of measure from the material master record as a default unit. However, if the alternative unit of measure unit of issue is maintained in the Work Scheduling view, this can be used. However, this uses the conversion factor between base unit of measure and unit of issue, which must be entered when you maintain units of issue.
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BOM Usage Production
Engineering
Operations
Technical data
Costing
Material BOM
Plant maintenance
Sales
Price
Location data
Order quantity SAP AG 2003
The usage allows you to create separate BOMs for the various areas within the company, for example, engineering or production. The engineering BOM combines all the components of the product from the engineering point of view of and contains all the technical data. The production BOM is set up from the production point of view. For example, process data is required for assembly. The costing BOM is the basis for the automatic calculation of the material usage costs of a product. Of course, you can also work with just one BOM for all areas by using the item status to cover all possible differences. When creating BOMs with different usages for one material, the system saves each BOM usage under its own internal number. The usage is read by the authorization checks for BOM maintenance. Note: The BOM usage controls which item statuses are available, but detailed control features are set up in the individual item (on the item detail screen).
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Area of Validity (1) Plant
Internal no. 4801
Group BOM
fe Re
r en
ce
Internal no. 4801
Refere
1000
nce
1100
Referenc e
1500 Re fe
Internal no. 4801
ren ce
1600
SAP AG 2003
To define the precise conditions under which a bill of material must be used by different areas in a company, you define an area of validity and a validity period. The area of validity defines which plants can use a bill of material. You can extend the area of validity by assigning the same bill of material (with the same internal BOM number) to a material in different plants. If you do this, you should be aware that there is still only one BOM, so any changes you may make will affect all plants (plant assignments). There must be a plant view for the BOM header and all the item materials in each plant that the BOM is assigned to.
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Area of Validity (2) Plant
Internal no. 4801
Group BOM
fe Re
r en
ce
Internal no.no. 4801 Internal 4801
Refere
1000
nce
1100 Internal no. 4801
Referenc e
1500 Co py
Internal no. 5678
fro m
1600
SAP AG 2003
Material BOMs can be valid on different organizational levels: A material BOM can manage data that is directly relevant to production. In this case, the area of validity is the plant. The plant is a place of work where all the necessary work scheduling activities are organized, for example: Planning material requirements Creating routings In this case, you create a plant-specific BOM. You can also create a BOM without reference to any plant - a group BOM. This is useful, for example, if a design engineer maintains a BOM during the engineering phase. The group BOM can be made effective for individual plants by using the plant assignment function.
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Area of Validity (3)
Internal no. 4321
Plant 1000
Internal no. 4521
1100 Internal no. 1924
1500 Internal no. 1231
1600
SAP AG 2003
Plant-specific BOMs are independent of each other. In other words, a separate BOM structure exists for each plant in the system. This means that if you make changes to a BOM in plant 1000, BOMs in plants 1100, 1500, and 1600 will not be affected.
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Validity Period
11 10
12
1 2
9
3
8
4 7 6 5
Valid-from date
Valid-to date 11 10
12
1 2
9
3
8
4 7 6 5
2
SAP AG 2003
The validity period is the time during which the BOM is valid. This period is defined by the following entries in the BOM header and in the BOM item: Valid-from date When creating a BOM this date specifies the point in time as of which the BOM header or BOM item is effective. If you create or change a BOM by entering a change number, the system copies the valid-from date from the change master record. Valid-to date This date marks the end of the validity period for the BOM item. The system calculates this dynamically. Note: The system assigns a default valid-to date of December 31, 9999. If you change a bill of material with a change number that has a valid-from date, the validity period of the previous state of the object ends at 0.00 hours on that date. You can define a valid-from date for an entire BOM and for individual items.
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BOM Structure: Pump Low-level code
Pump T-F00
0
Spiral casing
Fly wheel
Shaft
T-B00
100100-200
100100-300
Slug
Slug
Slug
Slug
1
2
SAP AG 2003
When you create a BOM, a low-level code is automatically assigned to each material. This is used in MRP and costing. You can display the administrative data in the material master record to find out the low-level code for a material. Low-level coding is used in material requirements planning (MRP) to determine the sequence in which materials are planned. Low-level coding takes account of the fact that a material may be used in multiple products and on multiple production levels of one product. The low-level code is the lowest explosion level on which a material occurs in all product structures. Low-level coding collects the total requirements for a material on the lowest explosion level where it is used.
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BOM Structure
Header
Item
Check material type
Check material type
1) Subitem
Status Texts Lot size ... Status Scrap Texts Recursion ... Quantities Installation point ...
2) Subitem . . .
SAP AG 2003
The large amount of data required in a bill of material is managed in structured form: You maintain data that applies to the entire BOM in the BOM header. You maintain data that applies to an individual component in an item. Items can be divided into subitems if partial quantities have different installation points. Subitems have no control functions.
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Subitem
Item 0030 Bolt 8x
Subitem 0010 3 pieces Assemble at front...
Subitem 0020 5 pieces Assemble at back... back
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Subitems represent different installation points for partial quantities of an item. For every subitem, you can also maintain a short text next to the subitem quantity. The sum of the subitem quantities replaces the item quantity. A subitem has no control functions in the BOM. This means, for example: - Assignments to operations in routings are defined only at the item level. - Scrap is calculated only at the item level.
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BOM Status and BOM Item Status BOM status field
Usage Item status field
Material BOM
BOM header
Item
Application
Application
Allowed in:
Relevant to:
- MRP - Costing - Operation assignment - Production orders - Collective withdrawal - Sales orders
- Engineering - Production - Plant maintenance - Spare parts - Sales - Costing
Exception message History requirement SAP AG 2003
The BOM status controls BOM processing in different application areas. When you configure your system in Customizing for bills of material, in activity Define BOM status, you define the statuses for different indicators that allow or disallow BOM processing. Examples: BOM A: A BOM with status 1 can be exploded in MRP and released for a planned order. BOM B: A BOM with status 2 cannot be exploded in MRP or released for a planned order. When you configure your system in Customizing for bills of material, in activity Define BOM Usages, you define which item statuses are allowed or disallowed for each BOM usage. You can define item status fields as required, optional, or disallowed for a specific application area in your company.
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Item Categories
Stock item NonNon-stock item VariableVariable-size item Text item Document item Class item PM structure element Intra material
SAP AG 2003
When you create a new BOM item, you must specify an item category for each item. The item category defines the features and functions of an item. The item category identifies whether special data must be processed, and it controls further system activities. The item category addresses the following questions, for example: Must a material be entered? Does the item support quantity-based inventory management? Are both plus and minus signs supported? Are subitems supported? Which screens are selected and how does the screen layout of the item detail screens look? Note that you cannot change the item category after you have entered the item. You can only correct an entry for the item category by deleting the item and then creating a new one.
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Non-Stock Item: Item Category N
BOM T-F00 Item
Component
10 20 30 40 50
T-B00 100 - 200 100 - 300 (without) 100 - 400
Quantity 1 piece 1 piece 1 piece 1 piece 1 piece
Item cat. L L L N N
Items 40 and 50: Purchasing data - Price - Price unit - Cost element
- Material group - Purchasing group - Delivery time
Fields relevant to MRP and costing
SAP AG 2003
You can create non-stock items both with and without a material master record. If you create a nonstock item without entering a material number, you must enter a descriptive text and purchasing data. Using the price data (purchasing data) entered, the system calculates the release strategy. The material group is necessary for creating a purchase requisition. The component is procured directly for the production order. Purchase requisitions are created automatically.
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Variable-Size Item: Item Category R
Cutting a bar to size
Different dimensions, up to 3 sizes Variable-size item data determines the component quantity
SAP AG 2003
Enter this item category to represent different sized pieces of a material under one material number. On the item detail screen for variable-size item data, the system calculates the variable-size item quantity from the sizes specified and the formula specified, if any. Advantages: Material requirements planning can be executed without any additional work steps, by using the BOM explosion. You do not have to create a separate material master record for each size you cut. All calculations use the variable-size item quantity.
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Variable-Size Item with Formula for a Cylinder
r = 0.8m
Circumference
π?
r ?
r = 0.8m
h = 1.2 m
2 Area
π ?r 2
2π
r? h
Cutting measure
SAP AG 2003
Entering a formula for calculating the quantity of a variable-size item allows you to execute complex calculations. You must maintain these formulas in Customizing. If there is no formula key, the system multiplies the sizes: Size 1 * Size 2 * Size 3.
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Document Item: Item Category D
Document info record Material
Material Material
Documents
BOM SAP AG 2003
Use this item category if you want to document the product or a component. Prerequisite: A document info record exists for the document, maintained in R/3 document management. The document info record contains basic information for integration into the business process, for example, information about the processing state and the storage location. Depending on the document type, you can manage various types of document data (such as technical drawings, photos, or texts). You can use these documents to describe an object comprehensively. You can display the document on the screen. You can find out more about SAP R/3 document management in course PLM120.
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Class Item: Item Category K
Class: PAINT Material Red Blue Green Yellow ...
Class: Type 200/300
Material Material
PAINT
Classified materials
BOM SAP AG 2003
A class item has characteristics and is used in configurable BOMs. You can use classes that have materials or documents classified in them (with class types 200, 201, and 300) as class items. When you configure a BOM, the class node can be replaced by a specific material or document.
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Recursion
P1 C1
C2
?
A3 P1
C3
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A BOM is recursive if the product contains a component that has the same object number as the product. Recursion may be an error, but it can also be intentional. If the system recognizes the recursion online, you see this message: Error: BOM is recursive In exceptional cases, recursion can only be recognized by the update program. The person who creates the recursive BOM receives a message. If you want to create a recursive BOM, set the Recursion allowed indicator in the BOM item.
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Item Control Indicators
Screen
Item indicator
Control function
B
Recursive
Recursion allowed
B
Discon.
Discontinuation
B
Co-product
Planned as co-product
B
AltItemGroup
Item used as alternative
B
Explosion type
Overrides material master control
B
Phantom item
Phantom assembly
B
Fixed quantity
Requirement same for any lot size
S
Item status (relevancy)
To production, costing, and so on
S
Material provision, Spare part
Material provision and spare parts
S
Bulk material
Overhead material
SAP AG 2003
The various item categories can be combined with various indicators. This covers many special procedures. Screens: B = Basic data S = Status/lng text You can set most control indicators in the material master. Most are not copied to the BOM. You can make settings for MRP data on the basic data screen for the BOM item that override the indicators in the material master record: Switch off phantom assemblies Individual requirements indicator Direct production (special procurement key SOBSL 52) Long-term planning
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Deleting a Bill of Material
You can delete bills of material by using: The deletion function Deletion flags
You can: Delete the entire BOM Delete individual items
BOMs can be deleted: Without history With history using engineering change management
Authorization groups control who can delete a bill of material
SAP AG 2003
Using the deletion function removes the BOM immediately or on the valid-from date of the change master record. If you set the deletion indicator in the BOM header, the BOM is deleted during the next reorganization run. Deletion at the header level removes the entire BOM, whereas deletion at the item level removes only the item specified. If you delete a BOM without history (without a change master record) the deletion is carried out immediately. Once the deletion has been executed, you can create a new BOM with the same material, plant, and usage. If you delete a BOM with history (with a change master record) the system deletes the bill of material on the valid-from date of the change master record. Before deleting a BOM, the system checks for: Items with object dependencies to check whether the change master supports maintenance of dependencies for configurable BOMs. Items with operation assignments. If assignments exist, the system displays the relevant message. See the SAP Library for more information.
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Why Use Engineering Change Management?
Monitoring und documentation of changes Planning and execution at a specific point in time Saving of several change states of the same object Integration in the supply chain Collation of changes that belong together For different objects For the same or different points in time With special comprehensive documentation
SAP AG 2003
Engineering change management in R/3 is a central logistics function that can be used to change various master data and document the changes. By using a valid-from date for the change master record (or for the ECR/ECO), the changes become valid on a predefined date. This aids long-term planning. You can use engineering change management to store R/3 objects (for example, BOMs and routings) more than once. This means that the objects can be stored in all relevant change states. The changes take effect automatically at the predefined time right across the supply chain, for example, in the sales order, material requirements planning, and shop floor control. You can use engineering change management to group together changes to different R/3 objects that are affected by one change. You can change all the objects at the same time, or you can define different change dates for individual objects. You can create general documentation for the change and also special documentation for each specific object change. You can use engineering change management to fulfill your legal obligations to document changes.
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Engineering Change Management
With change documents
With history
old
old
new
new
+
Change documents
+
Change documents
SAP AG 2003
You can make object changes (for example, BOM changes and routing changes) in SAP R/3 either with or without history. However, you should be aware that change documents are created by the system, even for changes without history. Changes without history These are changes that do not have to be documented because they take place during the development stage of the product, for example. The state of the object before the change is not saved. You can only find out about the status of the object before the change indirectly, by using change documents. Changes with history These are changes that must be documented because they take place during production, for example. Both the state before the change and the state after the change are saved. In addition, the system creates change documents. For some objects, these change documents differ from those created for changes without history. Engineering change management in R/3 enables you to document changes completely, to cover product liability requirements, for example.
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Effectivity Types: Serial Number
BOM for the pump with serial number 1002
Color
Pump type
Yellow Red
Change 0
Piston Rotary
Change 0
Change 1
Blue
Change 2
Wing
Change 3
Change 2
Serial no.
1000
1001
1002
1003
1004
1007
1008
1009
1010
Color
Yellow Red
Red
Red
Yellow Yellow Yellow Red
Blue
Blue
Yellow
Pump type Piston Piston Wing
Wing
Wing
1005
Wing
1006
Piston Piston Rotary Rotary Piston
SAP AG 2003
As of R/3 4.0 you can define validity by serial number. You can define the validity of an assembly as depending on the serial number of a specific finished product. You can define this effectivity type for the serial number of a specific finished product or for a range of serial numbers. If you want to define validity according to serial numbers, you must use engineering change management.
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Effectivity Types: Time Interval BOM for pump from January 1 until June 30 Change no. Effectivity: Time interval 01/01 – 06/30
1
30
SAP AG 2003
As of R/3 4.0 you can define validity by time interval. You can define the validity of an assembly for a period of time with an upper and lower limit. If you want to define validity according to time intervals, you must use engineering change management.
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Effectivity Types: Company-Specific Types
Bill of material for customer Change no. Effectivity: Customer B
Change no. Effectivity: Customer A
Change no. Effectivity: Customer C
SAP AG 2003
As of R/3 4.0 you can define your own company-specific effectivity types. You define parameters, such as customer or airline, which you link to a data element. You can use the assigned parameter type to enter single values or open intervals. You can combine the different effectivity types. This means that you can define the effectivity of a bill of material as "customer A and serial numbers 1-10" or "customer B, serial number 11", for example. If you want to use company-specific effectivity types, you must use engineering change management.
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3-34
BOM Management: Unit Summary
You are now able to: Create a bill of material for a material, plant and usage, and define the circumstances under which it is valid. Use different item categories to control further system activities. Use the BOM status to control BOM processing in different application areas.
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PLM110
3-35
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PLM110
3-36
BOM Management Exercises Unit:
BOM Management
Topic:
Basics of Bills of Material
At the conclusion of these exercises, you will be able to: • Create a group BOM and assign it to other plants • Create, change, and display BOM basic data The engineering department creates a group BOM. This BOM is to be made effective in other plants by using plant assignments. Because the structure of the BOM in plant 1000 is not identical to that of the group BOM, a plant-specific BOM is maintained in this plant.
1-1
Set the default settings for your user so that the item increment is 10. These should be the default settings. When you create a: Material item Item category L Document item Item category D
1-2
Create a group BOM for material T-F## (## = group number). Note the following when you create a group BOM: Plant: (group BOM has no entry for plant) BOM Usage: 1 (Production) Alternative BOM: No entry Today's date Valid from: 1-2-1 Which system message do you get, and why? (only if material status ZS is assigned) 1-2-2 Enter the following items for BOM T-F##: Item Item cat. Component Quantity Sort string 10 20 30
L L L
100-100 100-200 100-300
1 2 1
A5 A1 A3
Save the BOM and display the material item overview in the Change Material BOM transaction. Go to the BOM header and make a note of the internal BOM number: _______________ Enter a 4-line BOM long text. 1-2-3 You are not sure if the fly wheel component of your pump is the right material. Go to the material master record so that you can check the © SAP AG
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material group. Do not exit the current transaction and do not create another session. What is the name of the material group? 1-3
_________
Assign the group BOM to plants 1000 and 1100. 1-3-1 Why can you not assign it to plant 1100? ______________________________________________________ 1-3-2 Go to the BOM header for plant 1000. What is the internal BOM number?
_______________
Why?
_______________
1-3-3 Explode the plant assignment (plant 1000) and create a plant-specific BOM for T-F## in plant 1000. Use the group BOM as a template. In item 10, replace assembly 100-100 with material T-B##. Change the component quantity of item 20 from 2 to 1. Which components are assemblies themselves? ______________________________________________________ Maintain item 20 as a spare part with indicator A. (See icon Item or key F7) Sort bill of material T-F## (plant 1000) according to the sort string. 1-4
Create assembly T-B## in plant 1000 as follows: Item 10 20 30
Item cat. L L L
Component 100-110 100-120 100-130
Quantity 1 1 1
1-4-1 What is the status of the bill of material?
_______________
Does this status allow the BOM to be used in costing? _______________ 1-4-2 In the appropriate field, enter Construction Office KB1 as being responsible for the BOM (header: further data). Save your BOM.
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3-38
Exercises Unit:
BOM Management
Topic:
BOM Maintenance
At the conclusion of these exercises, you will be able to: • Process further BOM items according to item category
The plant-specific BOM is extended by adding different items according to requirements.
1-5
Extend your plant-specific BOM T-F## in plant 1000 from the previous exercise by adding the following data: 1-5-1 Item 40
Item cat. L
Component 100-600
Quantity 2
The 2 support bases are mounted on the pump. Two support bases: One support base is to be mounted at the front of the pump and one at the back of the pump. Create subitems for this. 1-5-2 Item 50
Item cat. N
Item text: Purchasing org.: Price: Purch. group: Cost element: Material group: 1-5-3 Item 60 Size 1 Size 2
Item cat. R
Component
Quantity 1
A non-stock item 1000 10 EUR 000 415000 Metal processing Component 100-700
Quantity 1 piece
200 mm 300 mm
Note the calculated variable-size item quantity. Change variable-size 2 to 400 mm. Get the system to recalculate the variable-size item quantity.
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1-5-4 Item 70
Item cat. L
Component 100-130
Quantity 10
Maintain this item as a bulk material. 1-5-5 Item 80
Item cat. Document D T-F1##
Typ DPt DRW 000
Vs 00
Quantity 1
Save your BOM. 1-5-6 Display your BOM T-F## with 15 as the required quantity. Who created the BOM? _________________ On what date? 1-6
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________________
When using Universal usage, which fields are set as required fields?
PLM110
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BOM Management Solutions
1-1
Unit:
BOM Management
Topic:
Basics of Bills of Material
Set defaults for user: Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create or Logistics → Central functions → Engineering → Bill of Material → … → Create and Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change or Logistics → Central functions → Engineering → Bill of Material → … → Change Then: Settings → Current settings → User-specific settings: Icon: Execute : User: User ID that you log on to system with. Item increment:
0010
Material item category:
L
Document item category: D 1-2
Create material BOM Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create (menu paths: see solution 1) Material: Plant: Usage: Valid from:
T-F## (Default) 1 Today's date
(Default) (Default)
1-2-1 Warning message "Group BOM", and because of the assigned material/production planning and control status, you may also see a warning message "Material status does not allow BOM". Material T-F## has status ZS (locked for BOM items).
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1-2-2 Enter the following components in the general item overview: Item 10 20 30
Item cat. L L L
Component
Quantity Sort string
100-100 100-200 100-300
1 2 1
A5 A1 A3
Save your BOM. Material BOM → Change Item overview → Tab page Material Header pushbutton → Tab page Quants/long text Enter any long text (your choice). 1-2-3 Item pushbutton Select component 100-100 and choose: Environment → Display Material → Basic Data Or double-click on the material number. Material master view: Basic data 1
→ Material group 001 (Metal processing) 1-3
Assign the group BOM to plants 1000 and 1100. Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Plant Assignment → Create Assign to plant 1000 and save. 1-3-1 Assign to plant 1100 → "Material T-F## is not maintained in plant 1100" 1-3-2 The internal BOM number in plant 1000 is the same as the number from 12. A reference has been created. The BOM structure is saved under one number in the system. Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Display: Header pushbutton
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1-3-3 Change the plant assignment. Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Plant Assignment → Change Display all assignments (pushbutton All allocs to BOM). Select and delete the assignment to plant 1000. (Pushbutton Delete allocation). Save. Create a plant-specific BOM as follows: Material: Plant: Usage: Valid from:
T-F## 1000 (Default) 1 (Default) Today's date (Default)
On the create screen, use the Copy from function. Copy from Material: Plant: Usage: Valid from:
T-F## (Leave blank!) 1 (Default) Today's date (Default)
Select the items you want to copy, and choose the Copy pushbutton. Change items 10 and 20 as described. •
Item overview → Tab page Material
•
Materials 100-200 and 100-300 are assemblies (
•
Select item 20 Pushbutton: Item Or double-click on item number 20 Tab page Status/Lng text → Spare part indicator: A (Spare part customer A)
•
Go back to the item overview: Icon: Arrow (green, on the left) Edit → Sort → Sort by sort string
Asm).
Save your BOM.
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1-4
Create BOM Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create Material: Plant: Usage: Valid from: Item 10 20 30
T-B## 1000 1 Today's date
Item cat. L L L
(Default) (Default) (Default)
Component 100-110 100-120 100-130
Quantity 1 1 1
1-4-1 BOM status 1 (bottom right of header) Released for costing (see predefined BOM statuses by choosing F4) 1-4-2 Header pushbutton → Tab page Further data Laboratory/office: KB1 (use possible entries) Save.
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Solutions
1-5
Unit:
BOM Management
Topic:
BOM Maintenance
Change material BOM T-F##. Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change Pushbutton: 1-5-1
New entries
Item
Item cat.
Component
Quantity
40
L
100-600
2
Select item 40 and choose pushbutton: Sub-items SubI Installation point 0001 Front of pump 0002 Back of pump Back with F3 1-5-2
Item
Item cat.
50
N
Component
60 Size 1: Size 2:
Sub-item text
Quantity 1
Item text: Purchasing organization: Price: Purchasing group: Cost element: Material group: 1-5-3 Item
Sub-item qty 1 1
Item cat. R
A non-stock item 1000 10 EUR (Chef) 000 415000 001 (Metal processing)
Component
Quantity
100-700 200 300
1
mm mm
Variable size item quantity: 0.060 m2 Size 2: 400 mm Variable size item quantity: Delete (!) Variable size item quantity: 0.080 m2
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1-5-4 Item
Item cat.
70
Component
L
Quantity
100-130
10
Select item and choose pushbutton Item or double-click on item number 70, tab page: Status/lng text Bulk material (bottom right) CostingRelevncy Back with F3 1-5-5 Edit → New entries → Tab page Document or Item category D in the input field ICt Item 80
Item cat.
Component
D
T-F1## DRW 000 00
Quantity 1
1-5-6 Display material BOM Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Display Material:
T-F##
Required quantity:
15
(bottom line)
Header: Tab page Admin. data 1-6
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When using 'Universal' there are no required fields set.
PLM110
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BOM Reporting
Contents: BOM explosion Where-used lists BOM comparison Mass changes Product structure
SAP AG 2003
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PLM110
4-1
BOM Reporting: Unit Objectives
At the conclusion of this unit, you will be able to Work with BOM explosions, where-used lists, and BOM comparisons Work with the product structure browser Use mass change functions to change several objects
SAP AG 2003
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PLM110
4-2
Course Overview Diagram
Course Overview
1
Variants and Alternatives
5
Material Master Record
2
Engineering Workbench
6
BOM Management
3
Conclusion
7
BOM Reporting
4
SAP AG 2003
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PLM110
4-3
BOM Reporting: Business Scenario
The structure of a BOM has to be checked. A material (item) has to be replaced. All the objects in a structure have to be displayed, processed, or created.
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PLM110
4-4
BOM Explosion
P1
2
3
P2 4
5 A1 4
C1
3
2
C2
C3
Product
P1
BOM level by level
Multilevel BOM
Summarized BOM
Material C1 C2 A1 C2 C3
Material .1 C1 .1 C2 .1 A1 ..2 C2 ..2 C3
Material A1 C1 C2 C3
Quantity 2 3 4 16 8
Quantity 2 3 4 16 8
Quantity 4 2 19* 8
SAP AG 2003
The BOM explosion answers this question: What does a product consist of? This question arises in various situations, such as when: You need to determine requirements for a product The engineering department needs to look at the overall structure of a product You need an overview of all the necessary parts and materials You need to calculate costs or effects of cost changes The BOM application defines the following criteria for the search procedure: Priority of BOM usage Priority of a specific alternative for a particular multiple BOM Production versions in the material master Checks for particular status indicators In your user master record you can enter a default value for the BOM application. This value is SET/GET parameter CSA.
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Where-Used Lists
Where is ... ?
SAP AG 2003
You can create where-used lists for: Work centers Capacities Production resources/tools Reference operation sets Materials Documents You can use the object overview to select the list you require.
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Single-Level and Multi-Level Material Where-Used Lists P1
2
P2 4
3
5 A1 4
C1
3
2
C2
Component:
C3 C2
Level
Material
Quantity
1 2 2
A1 P1 P2 P1
4
1
16 20 3
SAP AG 2003
The where-used list provides an answer to this question: Where is a material used and in what quantity? This question arises especially where there are a lot of multiple-use parts and materials. Examples of situations where this information is required: To calculate the requirements for a particular material To find the products that are affected by a change to an individual part To find the assemblies that will be produced late because, for example, delivery of a raw material is delayed To calculate the cost effects on a product if raw materials costs change
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BOM Comparison
P1 4
P2
16 8 3 2
=
A1
A1
C2
=
C2
C3
=
C3
C2
=
5
20 10 C2
3
C1 C3
3
SAP AG 2003
The BOM comparison is useful if: Several BOMs exist for a material The BOMs have different usages and/or different change states The comparison can be single-level or multi-level. You can select which fields you want to compare.
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Mass Change in BOMs
by component Z
Component XY replaced
in selected
BOMs
10
...
10
...
10
...
10
...
20
...
20
...
20
...
20
...
30
...
30
...
30
...
30
...
SAP AG 2003
You can use the mass change function to make changes to items in several BOMs with only one function call. The following item changes are supported for material items, document items, and class items: Changing the component quantity Changing the item data Adding items Replacing items –In all selected BOMs –Assigning a new item quantity, if required –Using engineering change management, if required –With restrictive selection criteria, such as plant and/or usage Deleting an item –In all selected BOMs –Using engineering change management, if required –With restrictive selection criteria, such as plant and/or usage
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Product Structure Product Structure: Validity date ... MAT
P-100 Revision levels REV P-100 Documents DOC P-100 DOC P-100 DOC P-100K BOMs Production Engineering ASS ASS
1000 1 A
PP-AE1 Design change
DRW 000 00 DRW 000 01 DRW 000 00
100-100 100-200 MAT 100-200
ASS ASS
Pump PRECISION 100
100-300 100-400 MAT 100-410 MAT 100-420 MAT 100-430 MAT 100-431 100-500 ASS MAT 100-600 100-700 MAT DRW P-100 DOC P-100K DOC DRW
Assembly drawing for pump Assembly drawing for pump CH Control drawing for pump
1000 Spiral casing 1000 Fly wheel 1000 Slug for fly wheel 1000 Shaft 1000 Pressure cover 1000 Slug for pressure cover 1000 Packing seal 1000 Safety ring 1000 Retainer ring 1000 Bearing case 1000 Support 1000 Sheet metal ST37 000 00 Assembly drawing for pump 000 00 Control drawing for pump
SAP AG 2003
The product structure enables you to display and process all functionally related objects (for example, material, BOM, document, and routing). The product data is displayed in a tree structure. You can limit the structure to display only the detail data that is required for the current processing situation. You can explode the product structure across different systems. Data can be evaluated and processed either locally or in multiple systems (ALE destinations). You can: Go directly to display mode or processing mode for individual objects Display or process similar objects Create an additional tree structure for any object Select several objects for object management records in engineering change management Go to the engineering workbench
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BOM Reporting: Unit Summary
You are now able to: Analyze BOM structures by using BOM explosions, where-used lists, and BOM comparisons Make changes quickly in several BOMs at once, by using the mass change function Display and process all objects belonging to a product, by using the product structure function
SAP AG 2003
© SAP AG
PLM110
4-11
© SAP AG
PLM110
4-12
BOM Reporting Exercises Unit:
BOM Reporting
Topics: • BOM explosion and BOM comparison At the conclusion of these exercises, you will be able to: • Use BOM explosion functions to analyze your plant-specific BOM
The engineering department checks the BOMs that have been created.
1-1
For reporting, use BOM application Production – general. 1-1-1 Which items in multilevel BOM T-F## (plant 1000) have spare part indicator A? _________________________________ 1-1-2 Which items in multilevel BOM T-F## are spare parts? _________________________________ 1-1-3 Which items are non-stock items? _________________________________ 1-1-4 Which item is handled as bulk material? _________________________________ 1-1-5 How many hexagon head screws M10 (100-130) are required for 10 pumps (T-F##)? _________________________________ 1-1-6 In which materials and in what quantities is the hexagon head screw 100130 used? ______________________________________________________
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1-2
Compare your BOM T-F## in plant 1000 with the group BOM for T-F## on one level and differentiated, with usage 1. 1-2-1 Which items are similar? ______________________________ 1-2-2 Select only the object description as a field to compare. Repeat the comparison. Which items are similar now? ______________________________ Reset the fields to compare.
1-3
Compare your BOM T-F## (plant 1000) with BOM P-100 (plant 1000) – a multilevel, summarized comparison with application PP01. Compare stock items only.
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PLM110
4-14
Exercises Unit:
BOM Reporting
Topic:
Product Structure
At the conclusion of these exercises, you will be able to: •
Analyze and correct your product structure
The design engineer wants an overview of all objects in the multilevel BOM for the pump, in order to process them if required.
1-4
Look at the product structure for material T-F##. Display the BOM and open a document info record.
1-5
Change items 10 and 30 for BOM T-F##: Make item 10 a spare part for customer A. The explosion type for item 30 needs to be set to Switch off phantom assembly. This means that first you check whether the material has special procurement key 50.
1-6
Go to classification and display the characteristics of your pump.
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Pump height:
____________
Pump capacity:
____________
Usage:
____________
PLM110
4-15
© SAP AG
PLM110
4-16
BOM Reporting Solutions Unit:
BOM Reporting
Topics: • BOM explosion • BOM comparison 1-1
BOM explosion Logistics → Production → Master Data → Bills of Material: or Logistics → Central Functions → Engineering→ Bill of Material: → Evaluations→ BOM Explosion → Material BOM → BOM (Multi-Level) Material: Plant: Application:
T-F## 1000 PP01
1-1-1 Icon: View Spare part ID: Icon: Execute Fly wheel: 1-1-2 Back with F3 Icon: View Spare part sel. X Caution: Icon: Execute Fly wheel:
(Default) (Default) (Production – general)
A
Spare part customer A
100-200
(All spare parts) Delete Spare part ID A 100-200
1-1-3 Back with F3 Icon: View Item category N (Non-stock item) Caution: Delete Spare part sel. X Icon: Execute One non-stock item 1-1-4 Back with F3 Icon View Select Bulk material Caution: Delete Item category N Icon: Execute Hexagon head screw M10: 100-130.
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1-1-5 Summarized BOM Logistics → Production → Master Data → Bills of Material: or Logistics → Central Functions → Engineering→ Bill of Material: → Evaluations→ BOM Explosion → Material BOM → Summarized BOM Icon: Execute Read number 1-1-6 Where-used list Logistics → Production → Master Data → Bills of Material: or Logistics → Central Functions → Engineering→ Bill of Material → Evaluations → Usage → Material Material: 100-130 Type of where-used list:Direct Icon: Next Screen Resulting qty: 1 ________________________________ 1-2
BOM comparison Logistics → Production → Master Data → Bill of Material: or Logistics → Central Functions → Engineering→ Bill of Material: Evaluations → BOM Comparison 1-2-1 Primary and secondary BOM:
Material BOM
Button Single-level comparison Enter the group BOM (T-F## without a plant) and the plant-specific BOM (T-F## with plant). Valid from: Today's date Pushbutton: Diff. comparison Item 20 is similar.
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1-2-2 Back with F3 Goto → Fields to compare: Select only the object description as a comparison criterion, copy, and repeat the comparison. Item 20 is now the same in both BOMs because the quantities are no longer being compared. Back with F3 Goto → Fields to compare: Pushbutton: Reset 1-3
BOM Comparison→ Multi-level comparison Icon: View (Further settings) Item category: L (Continue) Pushbutton: Application: Pushbutton:
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Multi-level comparison PP01 (Production – general) Summarized comparison
PLM110
4-19
© SAP AG
PLM110
4-20
Solutions
1-4
Unit:
BOM Reporting
Topic:
Product Structure
Call the product structure browser Logistics → Central Functions → Engineering Change Management → Environment → Product Structure: or Logistics → Central Functions → Engineering → Environment → Product Structure: Enter material T-F## on the tab page Material and choose Enter. Expand the tree structures for bills of material and documents by clicking on the hierarchy node. By double-clicking on the symbol for a bill of material or document, you display its master record. By selecting the individual objects with the right mouse button, you display a context menu. From the context menu, you can display or change the objects or go to the Engineering Workbench.
1-5
Open the tree structure of BOM T-F## to item level. Select the header of the BOM and click on the right mouse button. Choose Change. Select the item you want to change and click on the Detail icon, or double-click on the item increment (items 10 and 30). On the Status/lng text tab page, maintain the spare part indicator. On the Basic data tab page, maintain the explosion type. The special procurement key is maintained in the material master record in the MRP 2 view.
1-6
Expand the hierarchy node Classification and select the Class. Use the right mouse button to select the assigned values or double-click on the material symbol and display the classification. Pump height: Pump capacity: Usage:
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10 m 20 m³ House technology
PLM110
4-21
© SAP AG
PLM110
4-22
Variants and Alternatives
Contents: Variant BOM Multiple BOM (alternative BOM) Variant configuration
SAP AG 2003
© SAP AG
PLM110
5-1
Variants and Alternatives: Unit Objectives
At the conclusion of this unit, you will be able to Work with variant BOMs Work with multiple BOMs Distinguish between variant BOMs and variant configuration
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© SAP AG
PLM110
5-2
Course Overview Diagram
Course Overview
1
Variants and Alternatives
5
Material Master Record
2
Engineering Workbench
6
BOM Management
3
Conclusion
7
BOM Reporting
4
SAP AG 2003
© SAP AG
PLM110
5-3
Variants and Alternatives: Business Scenario
For additional BOMs, you want to use variant BOMs or multiple BOMs For the planning of complex products that can exist in several variants, you want to use variant configuration
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© SAP AG
PLM110
5-4
Variant BOM: Several Products
Oil
Pump Pump Pump
Variant parts
Water Waste water
Casing GC Casing A Casing (steel top)
Shaft Shaft Fly wheel
20
Shaft assembly
30
10 Bearing Bearing Bearing
Nonvariable part
Shaft
Slug
SAP AG 2003
If several similar products are manufactured whose component parts differ in minor ways only, you can use a variant BOM to represent these different products. Variants can also differ in component quantity alone. Only a simple material BOM can be extended to become a variant BOM. You cannot convert a multiple BOM into a variant BOM.
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PLM110
5-5
Variant BOM
Variant BOM "V" Several similar products
One internal BOM
Up to 99 variants Different material number for each variant
BOM header for each variant
SAP AG 2003
You can create a variant only if: A BOM does not already exist for the material. The base unit of measure of all variant materials is the same. This is because the base unit of measure of the bill of material must be the same as the base unit of measure of the material master record.
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5-6
Variant BOM "V"
Plant: 1000
Usage: 1
Variant BOM Material: 1 T-F00
BOM group VA##
Variant 1
Material: 2 T-F## Variant 3
Material: 3 T-F88
Up to 99 variants
Variant 2
SAP AG 2003
The BOM group field can also be used as an external BOM number. Several products created as variants of a variant BOM are saved under one internal BOM number. You can give a name to all of the variants of a variant BOM by entering a BOM group in the BOM header. Each variant has its own material number. The plant and the BOM usage are part of the unique key of a bill of material. Each variant has a BOM header. You can create a variant only if: A BOM does not already exist for the material. The base unit of measure of all variant materials is the same. This is because the base unit of measure of the bill of material must be the same as the base unit of measure of the material master record.
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PLM110
5-7
Variant Configuration
Pump for • Oil • Water
Pump type • Piston • Rotary • Wing
Mode • Manual • Electric
Connection • Square flange • Round flange (2 hole) • Round flange (4 hole) • Other
Color • Blue • Black • Red
Pump height • 2 - 20 m • 2 - 50 m
Rotation direction • Clockwise • Counter-clockwise • Any
Range • Open • Closed
SAP AG 2003
When dealing with multivariant products, the combinations of individual product features give rise to a vast range of variants. Complex products mean complex configuration tasks in both sales and production. However, a company that sells or produces products with variants must perform these configuration tasks quickly and accurately. This is not easy, as product development cycles and life cycles of products become shorter than ever before. Standard product is a general term used to define a product that is to be manufactured in multiple variants. It covers all the possible features of the variant product, and therefore does not refer to one specific article. The features of configurable products are defined in R/3 as characteristics.
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PLM110
5-8
Configuration of a Pump
Super BOM
Super task list
Configured BOM
Object dependencies
Configured routing
SAP AG 2003
There are often interdependencies between the individual features of multivariant products. It is frequently the case that not all combinations that are theoretically possible are allowed. There are two reasons for this: Some combinations are not possible for technical reasons. Other combinations may not be allowed for marketing and sales reasons. For example, if you want to order a motor cycle, you may only be able to have certain colors of paint and seats if you are ordering an expensive model. Instead of creating a separate BOM for each product variant, you can group the components together into a super BOM. This super BOM consists of some parts that appear in all variants of the product, and others that can be selected and included in the product depending on the variant. You use object dependencies to define which components are selected under which conditions. In the sales order, an individual product structure is created dynamically. Variant configuration is taught in the following courses: PLM130 Classification PLM140 Variant Configuration 1 – Modeling PLM143 Variant Configuration 2 – Integration PLM146 Variant Configuration 3 – Scenarios
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PLM110
5-9
Multiple BOM: One Product
T-F77 Blue paint
Alternative 1
LOT SIZE
1 - 100
Alternative 2
LOT SIZE
101 - 200
Alternative 3
LOT SIZE
201 - 1000
PIGMENT 1 T-B73
Water T-B75
Solvent T-B74
PIGMENT 2 T-B72 PIGMENT 3 T-B71
30
20
Non-variable part 10 Variant part SAP AG 2003
One product may be made of different combinations of components, depending on the quantity (lot size) to be manufactured or depending on the date. This type of product is often represented by alternative BOMs (alternatives). These alternatives BOMs differ only slightly from one another, usually in terms of the component quantity. A variant BOM cannot be converted to a multiple BOM.
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5-10
Multiple BOM "M"
Plant: 1000
Usage: 1
Multiple BOM T-F77 Alternative 1
T-F77 Alternative 2
BOM group PaintPaint-##
T-F77 Alternative 3
Approx 1000 alternatives
SAP AG 2003
The BOM group field can also be used as an external BOM number. All the alternatives for a multiple BOM are saved under one internal BOM number. You can assign one name to all the alternatives in a multiple BOM by entering a BOM group in the BOM header. The plant and the usage are part of the unique key that identifies a BOM. Each alternative has a BOM header. The alternative is selected according to the selection method indicator in the material master record: Lot size Date Production version
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5-11
Comparison of Different Types of Bill of Material
Simple
Variant
Multiple
Product
one
n similar
one
Internal BOM number
one
one
one
Technical type
' '
'V'
'M'
Variants/ Alternatives
'01'
Variant for each product
Alternative '01', '02', '03'
SAP AG 2003
© SAP AG
PLM110
5-12
Variants and Alternatives: Unit Summary
You are now able to: Use other technical types for BOMs (variant BOMs and multiple BOMS) Recognize the difference between variant BOMs and variant configuration
SAP AG 2003
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PLM110
5-13
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PLM110
5-14
Variants and Alternatives Exercises Unit:
Variants and Alternatives
Topic:
Variant BOM
At the conclusion of these exercises, you will be able to: • Process variant BOMs and recognize the difference between variant BOMs and variant configuration The engineering department requires BOMs for simple but similar materials.
1-1
You now want to create two additional variants of the pump T-F## in plant 1000 with usage 1. These are pumps T-FY## and T-FZ##. Please use the following data when you create variants of T-F## (pushbutton Create variant of): BOM text: Standard pump BOM group: VA## 1-1-1 In the variant for pump T-FY##, replace item 10: T-B## with item 10 assembly T-B1##. 1-1-2 In the variant for pump T-FZ##, replace item 10: T-B## with item 10 assembly T-BZ##.
1-2
1-3
© SAP AG
Display all variants of T-F##. (BOM group VA##) Check your entries. Pay particular attention to the following: BOM group
_______________
Internal BOM number
_______________
Technical type
_______________
Enter BOM item 100-801 in BOM group maintenance (any quantity you choose), which is only valid for variants T-FY## and T-FZ##. Check the result.
PLM110
5-15
© SAP AG
PLM110
5-16
Exercises Unit:
Variants and Alternatives
Topic:
Multiple BOM
At the conclusion of these exercises, you will be able to: • Maintain a multiple BOM
Recipes for blue paint are grouped together in a multiple BOM.
OPTIONAL: 1-4
The recipe for blue paint (material number T-F77## (## = group number) has different components or quantities for different lot sizes. 1-4-1 Create a finished product T-F77## in plant 1000 by copying from reference material T-F77. 1-4-2 Create a BOM for the recipe and two alternatives with the following data: Material T-F77##, BOM group: Paint-##, BOM text Multiple BOM Group ## Item 10 20 30
Item cat. L L L
Component T-B71 T-B74 T-B75
Quantity 0.5 1 1
Un kg kg kg
1-4-3 Create an alternative (by copying alternative 1). In this alternative, replace item 10, component T-B71 with: Item 10
Item cat. Component L T-B72
Quantity Un 0.3 kg
Change the quantity of component T-B74 in item 20 to 1.41. 1-4-4 Create another alternative (copy alternative 1) and replace item 10, component T-B71 with: Item 10
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Item cat. L
Component T-B73
PLM110
Quantity Un 0.3 kg
5-17
1-4-5 Add the following data to the BOM headers of the alternatives: Alternative
Alt text
1 2 3
From lot size to
Paint Color 1 Paint Color 2 Paint Color 3
1 101 201
100 200 500
1-4-6 Display all alternatives of T-F77##. (BOM group Paint-##) Check your entries. Pay particular attention to the following: BOM group
____________
Internal BOM number
____________
Technical type
____________
1-4-7 Maintain alternative selection by date for the different alternatives of the multiple BOM. Example:
© SAP AG
Material T-F77##
Plant 1000
BOM usage Valid from 1 01/01/xxxx
AltBOM 1
T-F77##
1000
1
01/07/xxxx
2
T-F77##
1000
1
01/12/xxxx
3
PLM110
5-18
Variants and Alternatives Solutions
1-1
Unit:
Variants and Alternatives
Topic:
Variant BOM
Create additional variants for pump T-F##. Logistics → Production → Master Data → Bills of Material → Bill of Material: or Logistics → Central Functions → Engineering→ Bill of Material → Bill of Material: Material BOM → Create Material: Plant: Usage: Valid from:
T-FY## 1000 (Default) 1 (Default) Today's date (Default)
Material BOM → Create variant of (F9) or Create variant of pushbutton Material: T-F## Icon: Select all Icon: Copy Icon: Header BOM text: Standard pump BOM group: VA## Confirm by choosing Enter. 1-1-1 Item Overview Icon: Item Item Item cat. 10 L
Component T-B1##
Quantity 1
Save BOM Material: Plant: Usage: Valid from:
T-FZ## 1000 1 Today's date
(Default) (Default) (Default)
Material BOM → Create variant of (F9) or Create variant of pushbutton Material: Icon: Icon:
T-F## Select all Copy
Confirm by choosing Enter.
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PLM110
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1-1-2 Item overview Item 30
Item cat. L
Component T-BZ##
Quantity 1
Save BOM 1-2
Display your BOM group. Logistics → Production → Master Data → Bills of Material → Bill of Material: or Logistics → Central Functions → Engineering→ Bill of Material → Bill of Material → Material BOM→ BOM Group → Display: BOM group: Plant: Valid from:
VA## 1000 Today's date
(Default) (Default)
Pushbutton: Variants Select all variants Goto: Header BOM, BOM usage 1, and technical type V exist only once. Note: From the header, choose the Item Overview pushbutton. Switch between the individual variants using the Next variant and Previous variant pushbuttons. From the summarized BOM, choose pushbutton Variant items for the selected items. 1-3
Change your BOM group. Material BOM → BOM Group → Change: Pushbutton: New entries Enter material 100-801 and a quantity, and set the indicator Item in alternative/variant for variants T-FY## and T-FZ##.
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PLM110
5-20
Solutions
1-4
Unit:
Variants and Alternatives
Topic:
Multiple BOM
Create alternative BOMs for the recipe for blue paint (T-F77## in plant 1000). 1-4-1 Create material T-F77## (##=Group number) with the reference material TF77 (compare with unit Material Master, topic Material master maintenance). Logistics → Production → Master Data → Material Master → Material → Create (Special) → Finished Product 1-4-2 Create a recipe Logistics → Production → Master Data → Bills of Material → Bill of Material: or Logistics → Central Functions → Engineering→ Bill of Material → Bill of Material: Material BOM → Create Material: Plant: Usage: Valid from:
T-F77## 1000 (Default) 1 (Default) Today's date (Default)
Item overview Item
Item cat.
10 20 30
L L L
Component T-B71 T-B74 T-B75
Quantity 0,5 1 1
Icon: BOM group:
Header Paint-##
Tab page: BOM text:
Quants/long txt Multiple BOM Group ##
Save BOM
© SAP AG
PLM110
5-21
1-4-3 Create alternative 2 Material: Plant: Usage: Valid from:
T-F77## 1000 (Default) 1 (Default) Today's date (Default)
→ Copy from (F7) Confirm warning message Dialog box Icon: Icon:
Alternative 1 Select all Copy
Item overview Item 10 20
Item cat. L L
Component T-B72 T-B74
Quantity 0.3 kg 1.41
Save BOM 1-4-4 Create alternative 3 Material: Plant: Usage: Valid from:
T-F77## 1000 (Default) 1 (Default) Today's date (Default)
→ Copy from (F7) Confirm warning message Dialog box
Alternative 1
Icon: Icon:
Select all Copy
Item overview Item 10
Item cat. L
Component T-B73
Quantity 0.3 kg
Save BOM
© SAP AG
PLM110
5-22
1-4-5 Complete header data Change material BOM Material: Plant: Usage: Valid from:
T-F77## 1000 1 Today's date
(Default) (Default) (Default)
Select alternative 1 Tab page: Quants/long txt (F6) Alt text.
Paint Color 1
Lot size from 1 to 100 Repeat these steps for alternatives 2 and 3. 1-4-6 View all alternatives Material BOM → BOM Group → Display: BOM group: Plant: Usage: Valid from: Pushbutton:
Paint-## 1000 1 Today's date
(Default) (Default) (Default)
Alternative overview
Select all alternatives Icon Header Switch between the individual alternatives by using the pushbuttons. alternative / Previous alternative.
Next
BOM, BOM usage 1, and technical type M should be the same in all alternatives. Alternative texts and lot sizes should be different for each alternative (see defaults). 1-4-7 Maintain alternative selection by date for multiple BOM Logistics → Production → Master Data → Bills of Material → Bill of Material: or Logistics → Central Functions → Engineering→ Bill of Material → Bill of Material Material BOM→ BOM Group → Create or Change: Settings: Current settings Double-click on icon: Execute Maintain alternative selection by date for multiple BOM. Maintain data as described in exercise and Save.
© SAP AG
PLM110
5-23
© SAP AG
PLM110
5-24
Engineering Workbench (EWB) - (Optional)
Contents: Engineering workbench: introduction Changing and copying workbench objects Simultaneous processing in the engineering workbench
SAP AG 2003
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PLM110
6-1
Engineering Workbench: Unit Objectives
At the conclusion of this unit, you will be able to Describe the benefits of the engineering workbench
SAP AG 2003
© SAP AG
PLM110
6-2
Course Overview Diagram
Course Overview
1
Variants and Alternatives
5
Material Master Record
2
Engineering Workbench
6
BOM Management
3
Conclusion
7
BOM Reporting
4
SAP AG 2003
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PLM110
6-3
Engineering Workbench: Business Scenario
You want an optimum maintenance environment for the changes that are always being made. Changes need to be made simultaneously. You want new master data and its links to be created hierarchically.
SAP AG 2003
© SAP AG
PLM110
6-4
Why Use the Engineering Workbench?
To support complex planning processes For precise selection of objects from bills of material and routings For the integrated processing of operations and items To carry out parallel processing For precise setting of locks To show the development of change states
SAP AG 2003
© SAP AG
PLM110
6-5
Simultaneous Processing of Objects
2
1
Worklist 1
Worklist 2
SAP AG 2003
Any items from any BOMs can be processed at the same time by different people. The same applies to operations in routings. If you want to process an item that is already being processed by someone else, the engineering workbench information shows you who to contact, so that you can consult with the other user. This user can then release the item (or the operation) for you without interrupting their work on other objects.
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PLM110
6-6
Structure of the Engineering Workbench
Material Material
Routing Routing header header
Materialrouting assignment
BOM BOM header header
MaterialBOM assignment
Sequence Sequence Operation Operation
Component-operation assignment
Item Item
Suboperation Suboperation Subitem Subitem
PRT PRT Trigger Trigger point point Inspection Inspection characteristic characteristic SAP AG 2003
In order to display or process individual objects using the engineering workbench, you have to select the corresponding objects. Examples of objects are: BOM header
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PLM110
6-7
Screen Layout Toolbar Cockpit
Process using
Validity window
9/21/2002
AE-12345
9/15/2002
12/31/2003
Context F-100 M 00000629
Overview screen
General items
For example, items Loc S.
ItemID
Pump
1000
Pump change number
1
Status
MRP
Item O.. ICt Component
VSI
Purch.
Component description
Class
Administration
Quantity
Un
Semifinished Product Raw Material
SAP AG 2003
The screen layout is divided into the elements: Toolbar, Cockpit, and Overview Screen. The Toolbar provides the user with currently available functions at the touch of a button. The Cockpit is always available in the engineering workbench and controls the engineering workbench. It consists of three areas: Process using, for entering the date or change number for processing the objects in the worklist. The entry of a date or a change number is necessary when an object has to be created, changed, or deleted. Selection range, to display a particular time segment of the worklist. Context, to display the hierarchical relationships between objects on the overview screen. On this slide there is an input line each for material, BOM, and item. The Overview Screen lists objects that are contained in the worklist and that match the entries in the selection range and in the context. It provides information about the object and change state of a particular object type.
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PLM110
6-8
Select Working Area
Process using
Selection range
Operation
BOM header
Item
Subitem
EWB: Select Working Area Working area settings • Current working area
S_ALLES
• Default working area
S_ALLES
SAP AG 2003
Working areas are created in Customizing for the engineering workbench. Using the Select working area button, you can specify a default working area or select another working area. From the dialog box Select Working Area you can also go to the detail screen of the working area. Information about the predefined focus and the object types contained in the working area is displayed on this detail screen.
© SAP AG
PLM110
6-9
Selection Criteria
Process using
Rtg header
Selection range
Operation
BOM header
Item
Subitem
Fields from structure: Item W Created by W Changed by W Change number W Bulk material
SAP AG 2003
You use the selection range to restrict the time period for the data. Only data that is valid entirely or partially in the validity period is copied to the worklist. The system automatically offers the tab page for the object on which the focus is placed. When entering selection criteria you can switch to other tab pages. By choosing additional selection criteria on the tab page, you can enter additional selection criteria in fields that are not shown as selection criteria on the tab pages on the screen. In addition, you can also use this procedure when you want to select according to several individual values, value ranges, or generically.
© SAP AG
PLM110
6-10
Different Focuses - Bill of Material
Focus
BOM header
Item
Component
Component
All BOM headers All items for the bills of material
All BOM headers Only items for the material
Selection
Results
SAP AG 2003
These examples illustrate the expected results of different focuses. The prerequisite for these results is that the working area always contains the same object types. The working area (with focus) and the selection criteria can be viewed by choosing Extras from the menu: Working area Selection criteria
© SAP AG
PLM110
6-11
Different Working Areas - Bill of Material
Working area
Complete
Bill of material only
Component
Component
All BOM headers All items for the bills of material All objects for the routing
Only all BOM headers All items for the bills of material
Selection
Results
SAP AG 2003
These examples illustrate the expected results of different working areas. The prerequisite for these results is that the focus is always based on the same focus object. The working area (with focus) and the selection criteria can be viewed in the menu entry Extras: Working area Selection criteria In the example, the focus is set to the BOM header.
© SAP AG
PLM110
6-12
Validity
Validity window
=
Selection range
Validity window
=
Restricted
Validity window = Date
SAP AG 2003
The validity window filters the objects displayed on the overview screen. On this slide, the example is of a working area with three BOM items. One item has been partially changed. If you select the selection period in the validity window, all items that are valid during the selection period are displayed. If you restrict the validity window, the items that lie completely outside of the validity window are not displayed. If you choose a key date in the validity window, only those items that are valid on the key date are displayed.
© SAP AG
PLM110
6-13
Engineering Workbench: Unit Summary
You are now able to: Name the differences between transactions for processing bills of material and routings, and the engineering workbench, and the benefits
SAP AG 2003
© SAP AG
PLM110
6-14
Course Overview Diagram
Course Overview
1
Variants and Alternatives
5
Material Master Record
2
Engineering Workbench
6
BOM Management
3
Conclusion
7
BOM Reporting
4
SAP AG 2003
© SAP AG
PLM110
7-1
Course Objectives
You are now able to z Create, change, and delete material master records z Create, change, and delete material BOMs z Analyze BOMs z Process variant BOMs and multiple BOMs z Name the benefits of the engineering workbench
SAP AG 2003
© SAP AG
PLM110
7-2
Recommended Follow-Up Courses z SCM200 Overview of Supply Chain Planning z SCM310 Production Orders z SCM320 Repetitive Manufacturing z PLM111 Basic Data Part 2 z PLM112 Customizing for Basic Data z PLM130 Classification z PLM140 Variant Configuration 1 – Modeling z PLM143 Variant Configuration 2 – Integration z PLM143 Variant Configuration 3 – Integration SAP AG 2003
© SAP AG
PLM110
7-3
Recommended Follow-up Activities
z Go through the exercises using IDES data or your own data. z Read online documentation z Read IMG documentation z Read release notes
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© SAP AG
PLM110
7-4
Appendix
Contents: Material master record Technical details - bill of material Menu paths Distributed data storage: ALE
SAP AG 2003
© SAP AG
PLM110
8-1
Technical Details for the Material Master
Development class(es) Function group(s) Module pool Logical database(s)
MG, MGA, and so on M.... SAPLMGMM, SAPLMGD1 None
Number range object(s) Number ranges
MATERIALNR 01 internal 02 external None Group 1 MMNR Material master record M_AENR_BGR Material master authorization group
Number range group table Number range group(s) Number range transaction Authorization class Authorization object(s) Lock object(s) Change document object
EMMAR* (several) EMVKE* None
Search help Message class(es) Archiving class(es) Archiving object
MAT1, MAT2, MCH1 MM, M3, WE, MG
Profile(s)
MRP profile, forecast profile
SAP AG 2003
© SAP AG
PLM110
8-2
Table Structure of the Material Master
MARA
MAKT
MARC
MARM
MVKE
MLAN
MEAN
MBEW
MLGN MLGT
MARD
MVER
MAPR
SAP AG 2003
The individual tables contain the following data: MARA General Data MAKT MARM MVKE MLAN MEAN MBEW MARC MLGN MLGT MARD MVER MAPR
© SAP AG
Descriptions/short texts Conversion factors Sales data per sales organization Sales data per country EAN (European Article Number) data Valuation data Material data per plant Material data per WM warehouse Material data per WM storage type Material data per storage location Consumption data Forecast data (pointer)
PLM110
8-3
Technical Details for BOM Management
Development class(es) Function group(s) Logical database(s)
CS CS.. CDC, CEC, CKC, CMC, CSC, CTC
Number range object(s) Number range transaction Authorization class Authorization object(s)
STUED, STUEE, STUEM, STUEK, STUES, STUET CV91 IB90 CS90 CS92 CS91 IB91
Lock object(s)
ECEXSTLE, ECEQSTE, ECDOSTE, ECMASTE, ECTPSTE, ECSTSTE, ECKDSTE
Collective search help Search help
STZ1 STZ1D, STZ1E, STZ1M, STZ1T
Archiving class Archiving object
CS_BOM BOM
Profile
User-specific defaults
Production planning C_STUE_BER C_STUE_WRK C_STUE_NOH
SAP AG 2003
BOM numbers are recorded internally - for the system's use only. You do not need to define any settings.
© SAP AG
PLM110
8-4
Table Structure for BOM Management
DOST
EQST
MAST
KDST
STKO
STST
TPST
STZU
STAS STPO STPU
SAP AG 2003
The individual tables contain the following data: MAST
Assignment of BOM to material
EQST
Assignment of BOM to equipment
DOST
Assignment of document structure to document
KDST
Assignment of BOM to functional location
KDST
Assignment of BOM to sales order
STST
Standard BOM assignment
STKO
BOM header data
STZU
Permanent BOM data
STAS
BOM item selection
STPO
BOM item data
STPU
BOM subitem data
© SAP AG
PLM110
8-5
SAP R/3 Enhancements
User exits BAPIs
SAP AG 2003
© SAP AG
PLM110
8-6
Material Master User Exits: Number Assignment (1)
Internal Number Assignment Number is assigned when you create a material, not when you save it.
Customer Enhancement MGA00001 (Exit: EXIT_SAPLMGMU_001, module MATERIAL_UPDATE_ALL) Adds checks for customer-specific fields. Extends checks for existing fields. Enables (restricted) changes to material data Example: enter basic material, material group, and consecutive number --> In material description
SAP AG 2003
© SAP AG
PLM110
8-7
Material Master User Exits: Number Assignment (2)
Customer Enhancement MGA00002 (Exit: EXIT_SAPLMG02_001 for internal number assignment, module MATERIAL_NUMBER_GET) Influences internal material number assignment:
The internally assigned number is adjusted by a change from the customer program. Example: the program takes an internal material number from the number range, puts the material type in front of the number, then saves the new number. (Exit: EXIT_SAPLMG02_002 for external number assignment, module MATERIAL_NUMBER_GET) Influences external material number assignment:
The externally assigned number is adjusted by a change from the customer program. Example: the program adds a check digit to external material number. SAP AG 2003
© SAP AG
PLM110
8-8
Material Master User Exits: Number Assignment (3)
Customer Enhancement MGA00003 (Exit: EXIT_SAPLOMCV_001 and EXIT_SAPLOMCV_002, EXIT_SAPLOMCV_901 and EXIT_SAPLOMCV _902, module: MATERIAL_UPDATE_ALL) Influences material number display format:
Example: Converts the material number from #### to MAT-#### CAUTION: Problem using the search help, for example, using the search term M* Result 1: Result 2:
All materials starting with MATAll materials starting with MAT- M
SAP AG 2003
© SAP AG
PLM110
8-9
BAPIs for the Material Master
BAPI_MATERIAL_GET_ALL BAPI_MATERIAL_SAVEREPLICA
SAP AG 2003
© SAP AG
PLM110
8-10
Menu Paths (1) Material master Logistics --> Materials Management --> Material Master Logistics --> Production --> Master Data --> Material Master Logistics --> Central Functions --> Engineering --> Material Create, change, display material Material Extend material view(s) Material (Master) --> Other Archive material Material (Master) --> Other --> Archiving
SAP AG 2003
© SAP AG
PLM110
8-11
Menu Paths (2) Bill of material Logistics --> Production --> Master Data --> Bills of Material Logistics --> Central Functions --> Engineering Create, change, display material BOM Bill of Material --> Material BOM Plant assignment Bill of Material --> Material BOM --> Plant Assignment BOM explosion, where-used list, BOM comparison Bill of Material --> Evaluations Mass changes Bill of Material --> Extras
SAP AG 2003
© SAP AG
PLM110
8-12
Menu Paths (3) Engineering Workbench (SAP Easy Access)
Logistics --> Production --> Master Data: Engineering Workbench Logistics -> Central Functions --> Engineering: Engineering Workbench
SAP AG 2003
© SAP AG
PLM110
8-13
Data Transfer Programs
Master data in the legacy system
Function module (background processing only)
Direct input process
R/3 database
Formatting of the master data in R/3 format in legacy system
Screen (dialog or background processing)
Batch input process
SAP AG 2003
SAP provides the file structure for each master data file. The user must create an SAP master data file using the file structure provided and then write a conversion program to extract data from the legacy system and transfer it into the SAP master data file in SAP R/3 format. Once the data is in R/3 format, the user can update the R/3 database using direct input or batch input. Regardless of the input process used, R/3 performs its normal data validation routines.
© SAP AG
PLM110
8-14
Enterprisewide View of Product Data
ALE Engineering
Production Production BOM Material master record PRTs Documents
ALE Engineering BOM Material master record Documents
R/3
ALE R/3
Product Productstructure structure Product
BOM data Documents Material where-used list
SAP AG 2003
Objectives: To use R/3 with special Customizing as a PDM system To use ALE for any necessary data transfer between the R/3 PDM and R/3 ERP Benefits: Independent upgrades Distributed load on the system Heterogeneous infrastructure possible New in R/3 Enterprise 4.7: Distribution of material masters is possible with single-level value assignment. Benefits: Configured material is visible in all systems and/or clients.
© SAP AG
PLM110
8-15
List Profile
1.
Create list profile
2.
Display standard profile (Structure explosion => display blocks)
LO970SMXM
SAPCSSMXMP01 Block 1 Block n
3.
Create display blocks for new profile
4.
Process new display blocks
5.
SAPCSSMXMP01 Block 1 Block n
Copy Reference
LO970SMXM LO970 BL1 Block n
Check new profile
SAP AG 2003
In the standard system, a list profile is predefined for every reporting function. This profile is used as a default value for display profiles. You can create a new profile by using a standard profile as a template. The name of your own list profile must not begin with "SAP". You cannot change standard profiles. The number of display blocks in your profile must be the same as the number of blocks in the corresponding standard profile. The number of fields you can select for each display block is determined by the maximum display block. Naming conventions for standard profiles: Example: BOM explosion level by level SAPCSLBLMP01 SAP CS = LBL MLV WSD SMX M = D = P01 = P02 =
© SAP AG
= Standard BOM = Level by level => BOM explosion level-by-level = Multilevel => Multilevel BOM explosion = Where used => Where-used list = Summarized explosion => Summarized BOM Material Document First profile Corresponds to SAP R/2 format
PLM110
8-16
Standard Profiles
BOM level by level:
SAPCSLBLMP01
Multilevel BOM
SAPCSMLVMP01
Summarized BOM:
SAPCSSMXMP01
Material where-used list: SAPCSWSDMP01
SAP AG 2003
© SAP AG
PLM110
8-17
Product Designer and iPPE
Product designer Integrated product and process engineering (iPPE)
SAP AG 2003
© SAP AG
PLM110
8-18
Product Designer Documents
Product specifications
Product costs
Production data
Product Designer Sales configuration data
Part number
CAD / PDM
CAD
SAP AG 2003
© SAP AG
PLM110
8-19
Integrated Product and Process Engineering (iPPE) Feature and requirements structure
Contains documents on requirements and features Assignment to functional or concept/design structures
Functional structure
Concept/design structure
First structure of the product Usually contains no material master records
Contains concept alternatives Final concept alternatives are released for the product structure
Product structure
Contains the final concept alternatives Contains production information
SAP AG 2003
© SAP AG
PLM110
8-20
Menu Paths Material Master Maintenance: Create
Logistics → Production → Master Data → Material Master → Material → Create (Special) Logistics → Production → Master Data → Material Master → Material → Create (General) → Immediately Logistics → Central Functions → Engineering...
Change
Logistics →Production →Master Data → Material Master → Material → Change → Immediately Logistics → Central Functions → Engineering...
Display
Logistics → Production → Master Data →Material Master→ Material → Display → Display Current Logistics → Central Functions → Engineering...
BOM Maintenance: Create
Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create Logistics → Central Functions → Engineering...
Change
Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change Logistics → Central Functions → Engineering...
Display
Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Display Logistics → Central Functions → Engineering...
© SAP AG
PLM110
8-21
© SAP AG
PLM110
8-22
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