PLM110_EN_Col51_FV_Inst_A4.pdf

PLM110 Basic Data 1 mySAP Product Lifecycle Management

Date Training Center Instructors Education Website

Instructor Handbook

Course Version: 2005 Q1 Course Duration: 2 Day(s) Material Number: 50072254 Owner: Uwe Blumöhr (D022513)

An SAP Compass course - use it to learn, reference it for work

Copyright Copyright © 2004 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors.

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About This Handbook This handbook is intended to complement the instructor-led presentation of this course, and serve as a source of reference. It is not suitable for self-study.

Typographic Conventions American English is the standard used in this handbook. The following typographic conventions are also used. Type Style

Description

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Icons in Body Text The following icons are used in this handbook.

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About This Handbook

Icon

PLM110

Meaning For more information, tips, or background Note or further explanation of previous point Exception or caution Procedures

Indicates that the item is displayed in the instructor’s presentation.

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Contents Course Overview ......................................................... vii Course Goals ...........................................................vii Course Objectives .................................................... viii

Unit 1: Material Master Record: Basic Data View .................. 1 Integration in mySAP PLM.............................................3 Material Master Maintenance ....................................... 19

Unit 2: BOM Management.............................................. 57 Basics of Bills of Material ............................................ 59 BOM Maintenance .................................................... 83

Unit 3: BOM Reporting ................................................ 119 BOM explosion, where-used list, BOM comparison .............120 Mass Changes and the Product Structure Browser .............133

Unit 4: Variants and Alternatives .................................... 143 Variant BOM ..........................................................144 BOMs in Variant Configuration ....................................153 Multiple BOMs and Alternatives....................................158

Unit 5: Engineering Workbench (EWB) - (Optional) ............ 175 EWB - Introduction...................................................176 BOM creation and change in the EWB............................183

Appendix 1: Technical Details and Tables: Material Master ............................................................................... 191 Appendix 2: Technical Details and Tables: BOMs Appendix 3: User exits and BAPIs Appendix 4: Menu paths

............................... 195

........................................... 197

Appendix 5: Data Transfer and ALE

............................. 199

Appendix 6: Product Designer and iPPE

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........... 193

© 2004 SAP AG. All rights reserved.

....................... 203

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Course Overview Target Audience This course is intended for the following audiences: • •

Project team members Analysts reponsible for material master records and BOMs

Course Prerequisites Required Knowledge • •

SAP01 PLM100 or SAPSCM

Recommended Knowledge •

None

Course Duration Details Unit 1: Material Master Record: Basic Data View Integration in mySAP PLM Exercise 1: Integration in mySAP PLM Material Master Maintenance Exercise 2: Material Master Maintenance

100 Minutes 15 Minutes 110 Minutes 30 Minutes

Unit 2: BOM Management Basics of Bills of Material Exercise 3: Basics of Bills of Material BOM Maintenance Exercise 4: BOM Maintenance

120 Minutes 30 Minutes 120 Minutes 30 Minutes

Unit 3: BOM Reporting BOM explosion, where-used list, BOM comparison Exercise 5: BOM explosion, where-used list, BOM comparison Mass Changes and the Product Structure Browser Exercise 6: Mass Changes and the Product Structure Browser Unit 4: Variants and Alternatives Variant BOM

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30 Minutes 15 Minutes 30 Minutes 10 Minutes 30 Minutes

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Course Overview

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Exercise 7: Variant BOMs BOMs in Variant Configuration Multiple BOMs and Alternatives Exercise 8: Multiple BOMs and Alternatives (optional) Unit 5: Engineering Workbench (EWB) - (Optional) EWB - Introduction BOM creation and change in the EWB

15 Minutes 10 Minutes 25 Minutes 15 Minutes 30 Minutes 30 Minutes

Course Goals This course will prepare you to: • •

Maintain material master records Manage bills of material (BOMs)

Course Objectives After completing this course, you will be able to: • • • • •

Create, change, and delete material master records Manage material BOMs Use reporting for material BOMs Maintain variant BOMs and multiple BOMs Use the engineering workbench

SAP Software Component Information The information in this course pertains to the following SAP Software Components and releases: For your demo examples, use materials T-F00, T-F99, and T-F77. When presenting the solutions, use T-F98. Participants work with the materials and BOMs T-F1##, T-F##, T-FY##, T-FZ##, T-B1##, and T-B##. User IDs and Passwords for Course Participants Users “PLM-##” already exist and have the initial password “init” . Preparation in the System Check the users and the user authorizations. Check the call of documents from, for example, material master record T-F1##.

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Course Overview

Example ABAPs None CATTs None required Technical Hints This course must not be held in the same system as PLM111.

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Unit 1 Material Master Record: Basic Data View

1

The material master record forms the basis for all of the following units.

Unit Overview This unit provides the necessary information on how to maintain material master records. •

• •

Participants acquire knowledge of how organizational levels, material type, industry sector, and material status affect control of the material master in the system. Participants learn SAP-specific structuring of material master records according to application and practise maintaining material master records. They learn to optimize material master data maintenance using default values and by working with a reference material.

Participants use classification to find a material.

Unit Objectives After completing this unit, you will be able to: • • • • •

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Discern 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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Unit 1: Material Master Record: Basic Data View

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Unit Contents Lesson: Integration in mySAP PLM .............................................3 Exercise 1: Integration in mySAP PLM ................................... 13 Lesson: Material Master Maintenance ........................................ 19 Exercise 2: Material Master Maintenance................................ 41

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PLM110

Lesson: 2

Lesson: Integration in mySAP PLM

Integration in mySAP PLM Lesson Duration: 100 Minutes

Lesson Overview • • • • •

Material master record organizational levels Organizational structures Material type and industry sectors Material master views Number assignment

Lesson Objectives After completing this lesson, you will be able to: • • •

•

•

•

•

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Discern how organizational levels, material type, industry sector, and material status affect the material master record. Maintain options for number assignment and units of measure. Organizational Structures and Plants Explain the connections between the organizational structures and their importance for the material master record. General Clarify the definition of the material master record. Point out central source of data and avoidance of data redundancy. Logistics, LDM Organizational Levels Material master record organizational levels Briefly repeat the definitions of client, plant, and storage location and their effects on material master data (client-specific and plant-specific data). Material type and industry sector Explain what the material type and industry sector control. Views Explain the purpose of views and the different maintenance statuses. Using an example, explain the PP-relevant data of a material master record.

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Demonstration for previous slides: 15 minutes 1. 2.

3. 4. 5.

Show the menu paths for processing a material master record (refer to the appendix in the user handbook). Display material T-F100 in plant 1000 and explain the most important LDM-relevant fields for the views Basic Data 1 and 2, MRP 2 and 4, Work Scheduling, and Storage, as well as how they relate to the organizational levels. Show the additional data and especially the administrative data. Display a document from the material master record. Maintain the default values: Industry sector: M 2 + 4”, Work scheduling, and Storage Organizational levels: plant 1000, storage location 0001, Copy from plant 1000.

Exercise for the section: 15 minutes

Business Example A design engineer displays a material master record. A finished product is created in the group, and plant views are added to it. 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.

For the company, the material master record represents the central source for data on materials. The material master is used by various SAP 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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Lesson: Integration in mySAP PLM

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

Figure 1: Organizational Structures and Plants

Organizational units are tightly linked to each other to quickly process the relevant data for a business area. For example:

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Plant

1000 is assigned to

company code

1000

Company code

1000 is assigned to

controlling area

1000

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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 (in-house production and external procurement) by using different valuation types. In Customizing for materials management, (define valuation type), balance sheet valuation is set up at company code 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.

Figure 2: Organizational Levels in Logistics and Lifecycle Data Management (LDM)

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Figure 3: Organizational Levels for the Material Master Record

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, so that it reflects a company’s structure. 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 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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Figure 4: Industry Sector and Material Type

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 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

for the material.

Figure 5: Industry Sector

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Lesson: Integration in mySAP PLM

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.

Figure 6: Material Type

In order to be able to 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 have to enter Whether quantity changes in the material master record are updated Whether value changes to financial accounting stock accounts are updated

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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Figure 7: Material Master Record

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 used. The same quantities and values are updated.

For further conditions, refer to the documentation.

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Lesson: Integration in mySAP PLM

Figure 8: Material Master Views

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 includes general data such as the material number, the material description, base unit of measure, and technical data. The Classification view contains user-defined specifications 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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Exercise 1: Integration in mySAP PLM Exercise Duration: 15 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Display a material master record

Business Example A design engineer displays a material master record.

Task: 1.

Display material master record T-F1## (## = group number).

2.

Change the default settings for further processing as follows: Industry Sector:

Mechanical Engineering Hide the industry sector on the initial screen

Views:

All basic data All MRP All accounting Work scheduling Flag “Selected Views”

Organizational levels:

3.

Copy from Plant: 1000

1000

Storage location: 0002

0002

Write down the entries you see for: Base unit of measure ___________ Material group ___________ Laboratory/office ___________ What does this abbreviation mean? ___________ MRP type? _________________ Continued on next page

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Procurement type ___________ Production scheduler ___________ Valuation class ___________ 4.

When and by whom was the data created? (See icon I) By whom? ___________ When? ___________

5.

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From the material master record and display an original document belonging to the material. (Enter front-end type PC if prompted).

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Lesson: Integration in mySAP PLM

Solution 1: Integration in mySAP PLM Task: 1.

Display material master record T-F1## (## = group number). a)

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

2.

Change the default settings for further processing as follows: Industry Sector:

Mechanical Engineering Hide the industry sector on the initial screen

Views:

All basic data All MRP All accounting Work scheduling Flag “Selected Views”

Continued on next page

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Organizational levels:

a)

Copy from Plant: 1000

1000

Storage location: 0002

0002

Enter material number: T-F1## Industry Sector defaults: “M” Select “Hide industry sector on initial screen” Views:

All “basic data ” All “MRP” All “accounting” Select “Work scheduling” Select “Create views selected” Copy from:

Organizational levels:

3.

Plant:

“1000”

“1000”

Storage location:

“0002”

“0002”

Write down the entries you see for: Base unit of measure ___________ Material group ___________ Laboratory/office ___________ What does this abbreviation mean? ___________ MRP type? _________________ Procurement type ___________ Production scheduler ___________

Continued on next page

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Lesson: Integration in mySAP PLM

Valuation class ___________ a)

Basic Data 1: Base unit of measure: PC Material group: 001 Lab: KB1 Description: “Construction office KB1” MRP 1: MRP type= material requirements planning MRP 2: Procurement type: I= in-house production Work scheduling: Production scheduler:0## Accounting 1: Valuation class: 7920

4.

When and by whom was the data created? (See icon I) By whom? ___________ When? ___________ a)

In addition to the material number and description: I Icon (Information on material)

5.

From the material master record and display an original document belonging to the material. (Enter front-end type PC if prompted). a)

Choose push button Additional Data → Document Data Select and a linked document and display its originals Icon: Display originals (If prompted, select front-end type PC.

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Lesson Summary You should now be able to: • Discern how organizational levels, material type, industry sector, and material status affect the material master record. • Maintain options for number assignment and units of measure.

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Lesson: 17

Lesson: Material Master Maintenance

Material Master Maintenance Lesson Duration: 110 Minutes

Lesson Overview • • • • •

Units of Measure Using documents Material status Deleting and archiving Classification

Lesson Objectives After completing this lesson, you will be able to: • • •

Maintain a material master record. Archive and delete a material master record. Use classification to search for a material number.

•

Screens for Maintaining a Material Master Show which levels are available for material master record maintenance. Material Master Record: PP Data Use the data from the demonstration below to maintain the views. Maintenance Functions Briefly explain again the possible default values and how a reference material can be used. Default values for material maintenance Focus is on MRP profile. Use the data in the relevant optional exercise. Number assignment for materials Material number display Explain the options for internal and external number assignment. Mention number groups, intervals, and current number level. Explain that the display can be adapted. Units of measure Grouping units of measure Explain the four alternative units of measure. Emphasize the options for grouping units of measure to make data maintenance easier.

•

•

•

•

•

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Demonstration for the following slides 10 minutes 1.

2. 3. 4. 5.

Create a finished product T-F99 with views Basic data 1+2, MRP 2+4, Work scheduling and Storage in plant 1000 with reference material T-F100. Point out the external number assignment. In the material master record, define the unit of measure crate = 10 pieces. Explain the definition and grouping of units of measure by using the example LAMP in Customizing. Add the unit CRT (crate) to LAMP. In Customizing, show the definition of number assignment and the formatting options for the output format. Create a material master record for a finished product using internal number assignment, without copying from a reference material. Point out the number, and use the unit of measure group LAMP.

Business Example A design engineer displays a material master record. A finished product is created in the group, and plant views are added to it.

Figure 9: Screens for Material Master Maintenance

There is a standard sequence for the screens on the main working level in Customizing. 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, press the corresponding pushbutton. Same applies as above with respect to the standard sequence.

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PLM110

Lesson: Material Master Maintenance

You can also branch off into secondary screens in the main working area using appropriate buttons. Example:Accounting 1:

Pushbutton: Previous period/year Pushbutton: Standard cost estimate

Figure 10: Material Master Record: PP Data

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 BOMs and routings. Classification data is part of the general material data. Characteristic values are used to find several materials that share a common attribute. MRP data is plant-specific. The MM/PP status, backflush indicator, assembly scrap, and component scrap values are used in BOMs and routings. Work scheduling data is plant specific. The issue/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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Figure 11: Maintenance Functions

You can define defaults for certain views, organizational levels, and industry sectors. 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. Hint: As of SAP R/3 4.6X, you can select the Create Views Selected checkbox to automatically create all views that exist in the reference material (departments). Previously, each view (department) had to be viewed individually. This is no longer necessary. 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 several MRP / forecast profiles Defining MRP / forecast profile: – –

Default values for MRP / forecast data fields Rules for MRP / forecast data field input

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 using material master maintenance, the system automatically changes the field value in all material masters linked to that specific MRP profile.

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PLM110

Lesson: Material Master Maintenance

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 using material master maintenance, the system automatically changes the field value in all material masters linked to that specific forecast profile.

Figure 12: Number Assignment (NA) for Materials

Each material has a unique material identification number. You can assign a number externally or internally. If you assign a number externally, you enter the required character string 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. Until you save the material master record, the system sets the “internal” material number in the appropriate field. When you save, the system automatically assigns the next available number. 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 also change the current number of an interval manually.

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Figure 13: Material Number Display and Layout

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.

Figure 14: Units of Measure

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.

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Lesson: Material Master Maintenance

All units of measure in the SAP system 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 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 material master maintenance. Order unit: Unit of measure used for ordering the material. This is the default unit for purchasing functions. Sales unit: Unit of measure used for selling the material. This is the default unit displayed in the sales order. You can also 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 use this unit for the BOM item quantity.

The design engineering department uses the base unit of measure as a rule.

Figure 15: Grouping Units of Measure

You can group together several units of measure in a unit of measure group and assign these to a material. For each unit of measure in the group, you can enter the conversion factor to the base unit of measure.

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You maintain unit of measure groups in Customizing for the material master (Logistics - General). Hint: The base unit of measure must not be entered in the unit of measure group.

Figure 16: Using Documents

Using documentsShow assignment to document (T-F1##, DRW, 000, 00) and use assignment to dispay document and originals.

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Lesson: Material Master Maintenance

Figure 17: Material Status

Material status Explain the effects of the material master status on other application areas. Explain the interdependencies between the statuses at client level and/or plant level. Demonstration for material status 5 minutes 1. 2. 3.

Maintain a material status ME that produces a warning message when maintaining the BOM header and an error when maintaining the BOM item. Assign the status to material T-F99 at client level and create a BOM. Explain the warning message. Use material T-F99 as an item in an existing BOM and explain the error message.

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: • •

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You can flag the material for deletion You can use the material status to lock the material for certain business processes in materials management and production planning,

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You can check whether a material is subject to restrictions and what these are using the status information function. You can call this function when you creating, displaying, or changing a material master record. Proceed as follows: •

Choose Extras → Status information in any screen.

You can define the material status for all plants (basic data view), or separately for each plant (plant view). Hint: The more restrictive status has priority (regardless of whether it is the cross-plant status or the plant-specific status).

Figure 18: Extend Material View(s)

•

•

28

Extend material Explain how other views can be maintained: 1. Create material or 2. Extend material: Explain the initial screen for the material number and/or maintenance status. Materials list Explain how materials can be listed according to set selection criteria. Note: The output lists cannot be customized or adapted in Customizing.

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PLM110

Lesson: Material Master Maintenance

Demonstration for material status 5 minutes 1.

2.

3.

Extend material T-F99 by adding the Classification view. -> Material Master -> Other -> Extend Material View(s) Maintenance status: C Material: T-F99 Search for the material using the matchcode for classes: Class type 001 -> Keyword Pump -> Class 100 Characteristics: Pump height 10m, Pump capacity 20 m³, Turning speed 1,000 Usage House technology Show the material master record for T-F99: From the point of view of MRP department Maintenance status: D Material type: FERT. 3. Show the materials list. -> Material Master -> Other -> Materials List

Allows you to extend the material master record by adding further views. The following questions should 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:

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Department:

Maintenance status:

Work scheduling

A

Accounting

B

Classification

C

MRP

D

Purchasing

E

Production resources/tools

F

Costing

G

Basic data

K

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Unit 1: Material Master Record: Basic Data View

PLM110

and so on: (see maintenance status in transaction MM50: Extend Material View(s)) Hint: If additional views are added to the existing master record, you can also work with the function Create material.

Figure 19: Materials List

This function allows you to create lists of materials according to certain 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

The following is intended as a final overview of transactions in material master record maintenance to - Create new material master records, - Add views to existing material master records - Change existing material master views. Create material master records - Transactions Material Master Record: Create New Views - Transactions Change Material Master Record (Views) - Transactions

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Lesson: Material Master Maintenance

Use these 3 slides as a summary of what you have explained so far. EWB will be covered later, as will engineering change management. Show the remaining transactions. Create material master record - Transactions • • • •

MM01 - Create (general) immediately MM11 - Create (general) planned for the future MM#1 - Create with special material type immediately (# = R, B, F, I, H, U, N, V, L, S, K, P, W and G) CEWB - Engineering Workbench Hint: Information on the Engineering Workbench is contained in the chapter on BOMs. The Engineering Workbench enables material master records to be created for new BOM items. The material is usually created immediately. It is generally the case that BOM maintenance cannot work with material master records which are only planned.

Material Master Record: Create New Views - Transactions • • • • • •

MM01 - Create (general) immediately MM11 - Create (general) planned for the future MM#1 - Create with special material type immediately (# = R, B, F, I, H, U, N, V, L, S, K, P, W and G) CEWB - Engineering Workbench MM17 - Create new data records (views) immediately in mass maintenance MM50 - Create new views for extendable materials Hint: The above comments on the Engineering Workbench apply here too. Also ensure that, when using MM#1 transactions, material type of existing material master record is appropriate for the transaction. This is not important for transactions MM01 and MM11, as the system reads the material type from the material master and in doing so overwrites any data entries.

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Change material master record (Views) - Transactions • • • •

MM02 - Change existing views immediately MM12 - Change existing views planned for the future CC04 - Immediate changes using the product structure browser MM17 - Immediate changes in mass maintenance

Figure 20: Material Master Mass Maintenance

Show Material Master Mass Maintenanceusing simple examples such as T-F201 to T-F299 using any uncritical fields from the MARC.

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PLM110

Lesson: Material Master Maintenance

Mass maintenance enables many objects to be changed at the same time. Only users with the relevant experience should therefore use this tool. 1. 2. 3. 4.

5.

6.

Call up the transaction for mass maintenance. If you have already defined one version, you can enter this here. Select the tables for which you would like to see the data. Select the fields you want to change on the relevant tab page, and click Execute. Enter the desired selection criteria. You can select other fields by clicking Select Fields. The system now selects the data records. Depending on how may data records you have selected, the system may now ask whether you would like continue working in the dialog or whether you would like to perform the changes in the background. If you choose the second option, you will be informed of the changes you have carried out later using a workflow. If you continue working in the dialog, the system will display the data records you have selected. Enter the new value in the corresponding column, select the column header (for example, short text) and the data records you wish to change and select Change Field Values. You have the following options: - Only change fields that have a definite current value, - Display previous value - Test changes. Save the data. The system will perform a consistency check for the data you have altered. Changes that lead to data discrepancies are not executed and a note is made in the protocol.

Figure 21: Deleting a Material

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Unit 1: Material Master Record: Basic Data View

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Deleting a material Explain the steps required to delete a material record: 1. Set deletion flag + 2. Reorganize. Explain that deletion flag can be “with proposal list” or “planned”. Planning must be activated. A material master record can only be deleted if it meets certain criteria (see documentation archiving of materials -> Deletion criteria). Archiving a material A material can be archived before being deleted. Explain the steps required for archiving: 1.Generate sequential archiving file 2. Set deletion flag 3. Start deletion program Reorganization runs can also be incorporated for each job. Note: Archived data can be displayed, but not retrieved. Demonstration for deleting material 5 minutes 1.

2.

Show how deletion flag is set -> Material Record -> Material -> Flag for deletion Immediately: a) Enter an internal material number or b) Choose Extras -> Proposal list Show where archiving can be started. Mention the special administration course. -> Material Record -> Other -> Archiving

You can flag materials for deletion by setting the deletion flag in the material master record (see 1). Materials to be deleted are determined by the system by using a proposal list.. The deletion flag can be scheduled for the future and must then be activated at the relevant point in time. All records flagged for deletion are deleted during a reorganization run providing they are no longer being used - as a BOM header, for example.

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PLM110

Lesson: Material Master Maintenance

Deletion is carried out in three steps: 1. 2. 3.

Material master is flagged for deletion Material master is selected for a reorganization run Reorganization run is executed Hint: During the reorganization run, the system checks whether material may be deleted and whether material may be archived.

Figure 22: Archiving a Material

You can also archive material master records. The data is stored in a sequential file (archive file). Archived data can be deleted from the database using the deletion program / reorganization. Archived material master records can be displayed, but they cannot be retrieved. Archiving and reorganization are handled in greater detail in the administration courses.

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Figure 23: Classification

Classification System Classification System Functions Finding a Material Explain the purpose of classification and which LDM objects can be classified. Briefly explain characteristics maintenance and assigned values for objects. Explain how you can find a material by using classification. Point out the differences between a conventional search and a search with the classification system. Demonstration for Classification 5 minutes Search for a reference material by using classification.Create material -> Matchcode K -> Class type 001, Class 100 -> Valuate characteristics. 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 SAP classification system is a tool for organizing your data that goes far beyond matchcodes and systematically-structured number assignment.

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Lesson: Material Master Maintenance

The four parts of R/3 classification are: • • • •

Characteristic maintenance Class maintenance Classification (assignments) Object search

Course PLM130 contains more information on the SAP classification system.

Figure 24: Classification Functions

An object is a classifiable unit (such as a material, vendor, or work center). A class is a description of a group of objects that have specifications that are common or similar. A characteristic describes specifications of an object, such as length, width, weight, color... A characteristic value represents the specification of a particular attribute. (For example: 10 cm, DIN 931, cast iron.) The procedure for class maintenance is as follows: Step 1: Define characteristics and allowed characteristic values Step 2: Maintain the class, including assignment of characteristics Step 3: Maintain the objects (for example, materials), including assigning them to one or more classes and assigning values to them Step 4: Search for objects.

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Figure 25: Finding a Material

The classification system makes it easy for you to find objects (for example, materials). Once you have set up classification, you can use it to find a material number and copy the number to your application.

Figure 26: Characteristic Value Assignment

You can use characteristic values in various ways when using classification to determine a material number.

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Lesson: Material Master Maintenance

For instance you can: • • •

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Link several entries in one line using OR. Link entries in several lines using AND. Use F4 help to display possible entries for selection criteria.

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Unit 1: Material Master Record: Basic Data View

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PLM110

35

Lesson: Material Master Maintenance

Exercise 2: Material Master Maintenance Exercise Duration: 30 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create a material master record using a reference material and classification. • Extend and classify a material master record

Business Example A finished product is created in the group, and plant views are added to it.

Task: 1.

Create the following material master record by copying from a reference material: A finished product with material number T-F## (## = group number) in plant 1000, storage location 0002, copied from material T-F1## with the following views: Basic data MRP Work scheduling Accounting

2.

Search for a reference material by using classification in the following way: Tab page:

Materials for class

Class

Select 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

Continued on next page

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Unit 1: Material Master Record: Basic Data View

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Copy material master record T-F1##. Hint: Note the number of hits: It is possible the material you are looking for may not be in the hit list. Check your user settings. Extras → Settings:Tab page Find object Field: Maximum hits (increase value to 200 or 500) 3.

Which views are selected? Which items are marked? Which organizational levels are applicable? ______________________________________________________ ______________________________________________________ Change the description of the new material to Pump## (## = your group number.

4.

How can you be sure that all selected views are created?

5.

How can you add missing views to a material master?

6.

Create another material master record with reference material as follows: A semi-finished product T-B## copied from material T-B1## in plant 1000 with the following views: Basic data MRP Work scheduling Accounting Change the description to Casing ##. Enter the material number of reference material T-B1## . Continued on next page

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PLM110

Lesson: Material Master Maintenance

7.

OPTIONAL: Delete the default settings for views and organizational levels that you created in the first exercise.

8.

Further option Create a third material master record for finished product T-GR## with the view Basic Data 1:

9.

Description:

Demo group ##

Base quantity:

PC

Further option Now extend this material master and the transaction Extend Material View(s) with the view: MRP plant 1000. On the selection screen, enter only the material number T-GR##.. Entry values are undetermined in the MRP views (maintain the REQUIRED data fields).

10. Further option Flag material master record T-GR## for deletion. 11. Further option Create a “Classification” view for the other material master record T-F1##. Class type:

001

Material class

Class:

100

Pumps

Pump height:

5m

Pump capacity:

15 m3

Usage:

House technology

Characteristics:

12. Further option Extend the semi-finished product T-B1## using the transaction Change Material Immediately in the Work Scheduling view. In the Unit of issue field, enter the value: PAL (Palet) In the dialog box which appears, enter the conversion factor between pallet and piece - for example: 1 1 PAL contains 5 PC Continued on next page

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13. Further option Change the finished product T-F## (## = group number): View: Basic Data 1 Under General Data, in the field X-plant matl status, enter the value: 02 (locked for BOM items/changing plan) 14. Further option Create an MRP profile for rapid and secure maintenance of MRP data from the material record. Create an MRP profile R## with the description Raw Material Group ## for use in creating material masters with the material type RAW. Use the parmaters in the following table for this exercise: Data of MRP profile R## Field Name

Maintenance Strategy

Default Value

MRP characteristic

Fixed value

MRP controller

Default

ABC Indicator

Fixed value

In-house production time

Default

5 days

Scheduling margin key

Default

002

MRP lot size

Fixed value

Purchasing group

Default

000

Planning time fence

Default

10 days

Component scrap in %

Default

1 %

Backflush

Fixed value

VB = manual order point MRP 0## A = important material

EX = exact

2 = work center decides

15. Further option Use the MRP profile R## to create another material master record for a purchasing part as a raw material . Create views for basic data, sales, MRP and accounting for the raw material R110-## in the plant 1000. In doing so, test your MRP profile and compare the relevant MRP data with the table below. Try to change the data for the material master using the MRP profile. Use the following table Continued on next page

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PLM110

Lesson: Material Master Maintenance

Material:

R110-##

Industry sector:

M = mechanical engineering

Basic data Description:

Nylon gasket

Base unit of measure:

PC

Material group:

001041 = Connecting elements

Additional data Units of measure:

1 box = 144 PCS

Purchasing Purchasing group:

001

MRP MRP characteristic:

VB

Reorder point:

100

Planning time fence:

15

MRP controller:

0##

MRP lot size:

EX

Procurement type:

F

Planned delivery time:

10 days

Goods receipt process time

2 days

Scheduling margin key:

002

Availability check

02

Accounting

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Valuation class

3000

Pricing

moving average cost

Moving cost

5

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Solution 2: Material Master Maintenance Task: 1.

Create the following material master record by copying from a reference material: A finished product with material number T-F## (## = group number) in plant 1000, storage location 0002, copied from material T-F1## with the following views: Basic data MRP Work scheduling Accounting a)

Create material master: Logistics → Production → Master data → Material master → Material → Create (special) → Finished product or Create (General) Immediately (Material type Finished product) or Logistics → Central Functions → Engineering → Material → Material →Create (Special) → Finished Product or Create (General) → Immediately (Material type: Finished product) or Logistics → Materials Management → Material Master → Material → Create (Special) → Finished Product or Create (General) → Immediately (Material type: Finished product). Enter the material number T-F## without using a change number and use a reference material. See next point for information regarding reference material.

2.

Search for a reference material by using classification in the following way:

Continued on next page

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PLM110

Lesson: Material Master Maintenance

Tab page:

Materials for class

Class

Select 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##. Hint: Note the number of hits: It is possible the material you are looking for may not be in the hit list. Check your user settings. Extras → Settings:Tab page Find object Field: Maximum hits (increase value to 200 or 500) a)

Use classification to find the reference material. Select the search help in the Copy from “Material” field. Tab page: Materials for class Select the search help in the “Class” field. Tab page: “Find by key word” Keyword: Choose Pump*, class 100, class type 001. Characteristics: Pump height:

10m

Pump capacity:

20 m³

Turning speed:

1.000

Pushbutton: Find in initial class Display material master record T-F1## (## = group number) by selecting the row and using the first pushbutton. Ignore any warning messages and take a look at all the views you have chosen, before you save.

Continued on next page

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Unit 1: Material Master Record: Basic Data View

3.

PLM110

Which views are selected? Which items are marked? Which organizational levels are applicable? ______________________________________________________ ______________________________________________________ Change the description of the new material to Pump## (## = your group number. a)

Views are marked according to your “user-specific settings”. The “Create Views Selected” flag is also present. Organizational levels including reference material are also set according to “user-specific settings”. Change the short text as required.

4.

How can you be sure that all selected views are created? Answer: Take a look at all the selected views or: Defaults –> Views Views Select here: Create Views Selected

5.

How can you add missing views to a material master? Answer: Material Create (Special) or Create (General) Immediately (MM01, MM#1) or ... Material Master → Other: Extend Material View(s) (MM50) Transactions MM17 and CEWB can be used for this.

6.

Create another material master record with reference material as follows: A semi-finished product T-B## copied from material T-B1## in plant 1000 with the following views: Basic data MRP Work scheduling Accounting Change the description to Casing ##. Enter the material number of reference material T-B1## . a)

Proceed as in above exercise to create a finished product. (Exceptions: Material type SEMI (semi-finished product), reference material T-B1##.

7.

OPTIONAL: Continued on next page

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Lesson: Material Master Maintenance

Delete the default settings for views and organizational levels that you created in the first exercise. a)

Defaults Delete all settings for views and organizational levels. Proceed as above (and set these defaults)

8.

Further option Create a third material master record for finished product T-GR## with the view Basic Data 1: Description:

Demo group ##

Base quantity:

PC

a)

Proceed as in exercise to create semi-finished product. (Exceptions: Material type Finished product and without reference material.

9.

Further option Now extend this material master and the transaction Extend Material View(s) with the view: MRP plant 1000. On the selection screen, enter only the material number T-GR##.. Entry values are undetermined in the MRP views (maintain the REQUIRED data fields). a)

In the Material Master menu Other → Extend Material View(s) Choose the selection parameters in the selection mask Enter T-GR## and execute. Select the line with the status “D” and click the pushbutton Maintain material. Enter plant 1000, maintain the view with any values you wish and save .

10. Further option Flag material master record T-GR## for deletion. a)

In Material Master menu → Flag for Deletion → Immediately On the selection screen, select parameter material T-GR## and set the deletion flag.

11. Further option Create a “Classification” view for the other material master record T-F1##. Continued on next page

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Unit 1: Material Master Record: Basic Data View

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Class type:

001

Material class

Class:

100

Pumps

Pump height:

5m

Pump capacity:

15 m3

Usage:

House technology

Characteristics:

a)

Proceed as in 9, maintenance status “C” or Create Material → Immediately with the existing material. Select the classification view. Hint: Class type can only be changed by → Extras → Change Class Type.

12. Further option Extend the semi-finished product T-B1## using the transaction Change Material Immediately in the Work Scheduling view. In the Unit of issue field, enter the value: PAL (Palet) In the dialog box which appears, enter the conversion factor between pallet and piece - for example: 1 1 PAL contains 5 PC a)

In the Material Master menu Material Change → 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 alternative unit of measure.

13. Further option Change the finished product T-F## (## = group number): View: Basic Data 1 Under General Data, in the field X-plant matl status, enter the

Continued on next page

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PLM110

Lesson: Material Master Maintenance

value: 02 (locked for BOM items/changing plan) a)

In the Material Master menu Material Change → Others View: Basic data 1 Under General Data, in the field X-plant matl status, enter the value: 02 (locked for BOM items/changing plan)

14. Further option Create an MRP profile for rapid and secure maintenance of MRP data from the material record. Create an MRP profile R## with the description Raw Material Group ## for use in creating material masters with the material type RAW. Use the parmaters in the following table for this exercise: Data of MRP profile R## Field Name

Maintenance Strategy

MRP characteristic

Fixed value

MRP controller

Default

ABC Indicator

Fixed value

In-house production time

Default

5 days

Scheduling margin key

Default

002

MRP lot size

Fixed value

Purchasing group

Default

000

Planning time fence

Default

10 days

Component scrap in %

Default

1 %

Backflush

Fixed value

a)

Default Value VB = manual order point MRP 0## A = important material

EX = exact

2 = work center decides

Logistics -> Production -> Master Data -> Material Master -> Profile -> MRP Profile -> Create First select the fields using the Selection Screen button, then select the default values using Screens 1 and 2.

15. Further option Use the MRP profile R## to create another material master record for a purchasing part as a raw material . Continued on next page

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Unit 1: Material Master Record: Basic Data View

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Create views for basic data, sales, MRP and accounting for the raw material R110-## in the plant 1000. In doing so, test your MRP profile and compare the relevant MRP data with the table below. Try to change the data for the material master using the MRP profile. Use the following table Material:

R110-##

Industry sector:

M = mechanical engineering

Basic data Description:

Nylon gasket

Base unit of measure:

PC

Material group:

001041 = Connecting elements

Additional data Units of measure:

1 box = 144 PCS

Purchasing Purchasing group:

001

MRP MRP characteristic:

VB

Reorder point:

100

Planning time fence:

15

MRP controller:

0##

MRP lot size:

EX

Procurement type:

F

Planned delivery time:

10 days

Goods receipt process time

2 days

Scheduling margin key:

002

Availability check

02

Accounting

Continued on next page

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Lesson: Material Master Maintenance

Valuation class

3000

Pricing

moving average cost

Moving cost

5

a)

Menu path: see above. Hint: Please not that you must enter your MRP Profile R## in the Organizational Levels window in order to use this in creating the material master R110-##.

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Lesson Summary You should now be able to: • Maintain a material master record. • Archive and delete a material master record. • Use classification to search for a material number.

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Unit Summary

Unit Summary You should now be able to: • Discern 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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Unit Summary

56

PLM110

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Unit 2 BOM Management

51

We now build on the knowledge that has been acquired of material master records to create bills of materials. After explaining basic terms for and maintenance of bills of material, Customizing is demonstrated briefly.

Unit Overview This unit explains maintenance of simple BOMs. Participants acquire knowledge of the the following BOM aspects:· • • • • • •

How bills of material are integrated in R/3 Technical types BOM usage and how it affects item status The BOM application Validity (area of validity, validity period, and company-specific effectivity) Participants create bills of material and test the effects of the various item categories and their control functions (statuses).

They learn the effects of the BOM status.

Unit Objectives After completing 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

Unit Contents Lesson: Basics of Bills of Material ............................................. 59 Exercise 3: Basics of Bills of Material..................................... 73

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Unit 2: BOM Management

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Lesson: BOM Maintenance..................................................... 83 Exercise 4: BOM Maintenance ...........................................103

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Lesson: 52

Lesson: Basics of Bills of Material

Basics of Bills of Material Lesson Duration: 120 Minutes

Lesson Overview Basics of Bills of Material

Lesson Objectives After completing this lesson, 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

Bill of Material: Part of PDM Explain the integration of bills of material in the PDM environment. Definition of a Bill of Material Terminology Explain the difference between assembly and single-level BOM. BOM integration BOM integration in the individual application components can be explained with regard to function and PP / PDM integration. It is a good idea to explain the next slide (BOM categories) at the same time, since there is a direct connection. BOM Categories Before You Create a BOM Default Settings for Bills of Material Show which default values can be set in Customizing. Demonstrate the user-specific proposed values, such as: item increment, item category, material provision indicator and so on.. Bill of Material Usage Show BOM usage and settings in Customizing and refer to connection with item status. Technical Type Use the slides to explain the basics of BOM managment and refer to the unit Variants and Alternatives. Area of Validity (1-3) Explain the different areas of validity and that it is possible to create a client / group BOM and assign these to the plants. The use / applications of

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Unit 2: BOM Management

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a plant BOM and its reference to plants should be explained with an example. Use another example to explain how to create a BOM with reference material (plant or group BOM). Validity Period Explain that there are different validity types. Change statuses can be documented accordingly. Refer to course PLM150, Engineering Change and Configuration Management. Note: Point out that the other validities can only be applied in connection with Engineering Change Management.

Business Example Your company has a central engineering design department. You create group BOMs and assign these to different plants. You add various item categories to the BOMs. You use classification for the material search.

Figure 27: Definition of a Bill of Material

BOMs and routings contain important basic data or master data for integrated materials management and shop floor control. In the engineering design 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 semi-finished products are produced from several component parts or materials:

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Lesson: Basics of Bills of Material

Depending on the industry sector, they may be called: • •

Recipe List of ingredients

Figure 28: Terminology

Assembly: An assembly is a set of components for a product that belong together for production purposes. The assembly may 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 all synonyms.

Figure 29: BOM Integration

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Data that is saved in BOMs forms a significant basis for various areas within production planning. Engineering design 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.

Figure 30: BOM Categories

BOM categories define the connection to an object. Material BOMs are used in PP to represent the structure of products that are manufactured. 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.

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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. 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?

The questions listed above must be answered before you create a bill of material. 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

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 for a user in Customizing.

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Figure 31: Bill of material

Hint: 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. This uses the conversion factor between base unit of measure and unit of issue however, which must be entered when you maintain units of issue.

Figure 32: Where-used list

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The where-used list allows you to create separate BOMs for the various areas within the company, for example, engineering or production. • • •

The engineering BOM combines all components of the product from the engineering point of view and contains all technical data. The production BOM is set up from the manufacturing points 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 where-used lists for one material, the system saves each BOM with a separate internal number for each where-used list. The where-used list is read by the authorization checks for BOM maintenance. Hint: The BOM where-used list provides an overview of item statuses, while detailed control is set for the individual item using the item detail screen.

Figure 33: Validity: Area (1)

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.

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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, note that still only one BOM exists, so any changes you may make will affect all plants. There must be a plant view for the BOM header and all the item materials in each plant that the BOM is assigned to.

Figure 34: Validity: Area (2)

Material BOMs can be effective 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 of material requirements and Creation of routings

In this case, you create a plant-specific BOM. You can also create a group BOM. This is a BOM without reference to any one plant. This is a good idea, for example, when the engineer/designer is maintaining a BOM in the engineering/design phase. The group BOM can be made effective for individual plants using the plant assignment function.

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Lesson: Basics of Bills of Material

Figure 35: Validity: Area (3)

Plant-specific BOMs are independent of each other and exist separately in the system (BOM number). This means that if you make changes to a BOM in plant 1000, BOMs in plants 1100, 1500, and 1600 will not be affected.

Figure 36: Validity: Period

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:

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Valid-from date When creating a BOM, this date specifies the point in time from 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. Hint: 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. Structure: Pump Show the structure of the IDES pump structure. Explain the low-level code and when it is assigned. BOM structure Explain the SAP BOM structure. 1. Header data 2. Item data BOM status, Item status Explain how you can use the BOM status to control BOM processing. Explain the connection between BOM usage and item status. It is important to point out that when only one BOM is used for all business areas, then the item status represents the fine-tuned control. Demonstration for the topic 25 minutes Perform the exercise for this topic with header material T-F00. Explain the various screens in the course of the demo. Head Total Quantities/Long Text Additional data Administrative data Item Overview Material

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Lesson: Basics of Bills of Material

General Data Status/Long Text Administrative data Show the area of validity and validity period. Create a plant assignment for plant 1000. See corresponding exercise. Create a material BOM for T-B00 in Plant 1000. See corresponding exercise.

Figure 37: BOM Structure: Pump

When you create a BOM, a low-level code is automatically assigned to each material which is used in MRP and costing. You can display the administrative data in the material master record. Low-level codes are used in material requirements planning (MRP) to determine the sequence in which materials are planned and by product costing to determine how costs are rolled up. 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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Figure 38: BOM Structure

The large amount of data required in a bill of material is managed in structured form: • • •

You enter and maintain data that applies to the entire BOM in the BOM header. You enter and 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.

Figure 39: Subitem

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.

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Lesson: Basics of Bills of Material

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 only at item level Waste is calculated only at item level

Figure 40: BOM Status and BOM Item Status

The BOM status controls BOM processing in different application areas. When you configure your system in Customizing under Bill of Material -> 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 under Bill of Material each company defines which item statuses are allowed or disallowed for each BOM where-used list. You can define item status fields as required, optional, or disallowed for a specific application area in your company.

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Lesson: Basics of Bills of Material

Exercise 3: Basics of Bills of Material Exercise Duration: 30 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create a group BOM and assign it to other plants • Create, change, and display BOM basic data

Business Example The engineering design 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.

Task 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

use

Item category L,

Document Item

use

Item Category D

are suggested.

Task 2: 1.

Create a group BOM for material T-F## (## = group number). Note the following when you create a group BOM:

2.

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Plant:

(group BOM has no entry for plant)

Usage:

1 (Production)

Alternative:

No entry

Valid from:

Today’s date

Which system message do you get, and why? Ensure no error messages appear. Continued on next page

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3.

PLM110

Enter the following items for BOM T-F##: Item no.

Item cat.

Component

Quantity

Sort string

10

L

T-B##

1

A5

20

L

100-200

2

A1

30

L

100-300

1

A3

Save the BOM and display the material item overview in the transaction: Change material BOM. Go to the BOM header and make a note of the internal BOM number: _______________ Enter a BOM long text 4 lines long. 4.

You are not sure if the fly wheel component of your pump is the right material. Branch off to the material master record to check the material group. Do not exit the current transaction and do not create another session. What is the name of the material group? _________

Task 3: 1.

Assign the group BOM to plants 1000 and 1100.

2.

Why can you not assign it to plant 1100?

3.

Go to the BOM header for plant 1000. What is the internal BOM number? _______________ Why? _______________

4.

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. Continued on next page

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Lesson: Basics of Bills of Material

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.

Task 4: 1.

2.

Create assembly T-B## in plant 1000 as follows: Item no.

Item cat.

Component

Quantity

10

L

100-110

1

20

L

100-200

1

30

L

100-300

1

What status does the BOM have? _______________ Does this status allow the BOM to be used in costing? _______________

3.

In the appropriate field, enter Construction Office KB1 as being responsible for the BOM (header: further data). Save your BOM.

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Solution 3: Basics of Bills of Material Task 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

use

Item category L,

Document Item

use

Item Category D

are suggested. a)

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: Settings → Current settings → User-specific settings: Icon: Execute → New entries User: User ID that you log on to system with. (usually PLM-##) Item increment:

0010

Material item category:

L

Document item category:

D

Task 2: 1.

Create a group BOM for material T-F## (## = group number). Note the following when you create a group BOM:

Continued on next page

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Lesson: Basics of Bills of Material

Plant:

(group BOM has no entry for plant)

Usage:

1 (Production)

Alternative:

No entry

Valid from:

Today’s date

a)

Create material BOM Logistics → Production → Master data → Bills of material → Bill of material → Material BOM → Create (menu paths: see solution 1)

2.

Material:

T-F##

Plant:



Usage:

1

(Default)

Valid from:

Today’s date

(Default)

Which system message do you get, and why? Ensure no error messages appear. a)

“W: Group BOM” and because of the assigned material/production planning and control status, you may also see a warning message: Material T-F## has status ZS (locked for BOM items). The warning message regarding group BOMs can be deactivated from Release 4.7 onwards. If the error message Material status ... does not allow BOM maintenance appears, you will have to cancel the transaction. Change the material master record and delete the material status for basic data 1.

3.

Enter the following items for BOM T-F##: Item no.

Item cat.

Component

Quantity

Sort string

10

L

T-B##

1

A5

20

L

100-200

2

A1

30

L

100-300

1

A3

Save the BOM and display the material item overview in the transaction: Change material BOM.

Continued on next page

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Go to the BOM header and make a note of the internal BOM number: _______________ Enter a BOM long text 4 lines long. a)

Enter the following components in the general item overview: Item no.

Item cat.

Component

Quantity

Sort string

10

L

T-B##

1

A5

20

L

100-200

2

A1

30

L

100-300

1

A3

Save your BOM. Material BOM → Change Item overview → Material tab page Header pushbutton → Quantities / Long text tab page Enter a “BOM text” 4 lines long. 4.

You are not sure if the fly wheel component of your pump is the right material. Branch off to the material master record to check the material group. Do not exit the current transaction and do not create another session. What is the name of the material group? _________ a)

Pushbutton Items Select component T-B## and choose: Environment -> Material -> Display -> Basic data or double-click on the material number. Material master view: Basic Data 1 → Material group 001 (Metal processing)

Task 3: 1.

Assign the group BOM to plants 1000 and 1100. a)

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Plant assignment → Create Assign to plant 1000 and save. Continued on next page

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2.

Why can you not assign it to plant 1100? Answer: Assignment to plant 1100 → “Material T-F## is not maintained in plant 1100” .

3.

Go to the BOM header for plant 1000. What is the internal BOM number? _______________ Why? _______________ a)

The internal BOM number in plant 1000 is the same as the number from 1-2. 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

4.

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)

Continued on next page

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Sort bill of material T-F## (plant 1000) according to the sort string. a)

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 (Push button: Delete allocation). Go back to the “Current assignments” and save. Create a plant-specific BOM as follows: Material:

T-F##

Plant:

1000

(Default)

Usage:

1

(Default)

Valid from:

Today’s date

(Default)

On the create screen, use the Copy from function. Pushbutton: Copy from Material:

T-F##

Plant:

(empty)

Usage:

1

(Default)

Valid from:

Today’s date

(Default)

Select the items you want to copy, and choose the pushbutton: Copy. Change items 10 and 20 as described. • • •

Item overview → Material tab page Materials 100-200 and 100-300 are assemblies ( Asm). Select Item 20 Pushbutton: Item or double-click on Item (Value: 20) Status/lng text tab → Spare part ID. : A (Spare part customer A)

•

Go back to the item overview: Icon: Arrow (green on the left) Edit → Sort → Sort by sort string

Save your BOM.

Continued on next page

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Task 4: 1.

Create assembly T-B## in plant 1000 as follows: Item no.

Item cat.

Component

Quantity

10

L

100-110

1

20

L

100-200

1

30

L

100-300

1

a)

Create BOM Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create:

2.

Material:

T-B##

Plant:

1000

(Default)

Usage:

1

(Default)

Valid from:

Today’s date

(Default)

Item no.

Item cat.

Component

Quantity

10

L

100-110

1

20

L

100-120

1

30

L

100-130

1

What status does the BOM have? _______________ Does this status allow the BOM to be used in costing? _______________ a)

BOM status 1 (in header → bottom right) Relased for costing (see copy from BOM status F4)

3.

In the appropriate field, enter Construction Office KB1 as being responsible for the BOM (header: further data). Save your BOM. a)

Header pushbutton Tab page Further data Lab / Office: save KB1 (using copy) sichern.

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Lesson Summary You should now 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

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Lesson: 75

Lesson: BOM Maintenance

BOM Maintenance Lesson Duration: 120 Minutes

Lesson Overview Participants create bills of material and test the effects of the various item categories and their control functions (statuses). They learn the effects of the BOM status.

Lesson Objectives After completing this lesson, you will be able to: • •

Name and use the different item categories in a bill of material Distinguish between BOM status and item status

Item types Explain the different item categories and when they are used. Point out that since the item category governs control functions, this cannot be changed. In such cases the item has to be deleted and then recreated. Explain what the item category controls: 1. Is it necessary to enter a material? 2. Is the stock quantity recorded? 3. How are the quantities recorded (plus/minus sign)? 4. Are subitems supported? 5. Which fields and screens appear for an item and is it possible/necessary to make an entry in the fields? Non-Stock Item / Item Category: N Variable-Size Item / Item Category: V Variable-Size Item with Formula for a Cylinder Document Item: Item Category: D Class Item / Item Category: C Demonstration for Item Categories 20 minutes Carry out the corresponding exercise for this lesson. Alternatively you can carry out the relevant exercise step for each slide. The class item can be demonstrated in the chapter entitled "Variants and Alternatives". Display the original application file from the document item.

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Business Example Your company has a central engineering design department. You create group BOMs and assign these to different plants. You add various item categories to the BOMs. You use classification for the material search.

Figure 41: Item Categories

Each BOM item must have an item category assigned to it. The item category defines the features and functions of an item. The item category identifies whether special data must be processed, and controls further system activities. The item category provides answers the following questions, for example: • • • • •

Is it necessary to enter a material? 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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Figure 42: Non-Stock Item / Item Category: N

You can create non-stock items both with and without a material master record. If you create a non-stock 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.

Figure 43: Variable-Size Item / Item Category: V

Enter this item category to represent parts of a material of different sizes under one material number.

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On the detail screen: The system calculates the variable-size item quantity from the sizes specified and the formula specified, if any. Advantages: • • •

MRP can be executed by exploding the BOM without any additional work steps. You do not have to create a separate material master record for each size you cut. All calculations use the variable-size item quantity.

Figure 44: Variable-Size Item with Formula for a Cylinder

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 calculates Size 1 * Size 2 * Size 3.

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Figure 45: Document Item / Item Category: D

If you want to document the product or a component, choose item category D. Prerequisite: A document info record must exist for the document, maintained in 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 document management in course PLM120.

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Figure 46: Class Item / Item Category: C

A class item has characteristics and is used in a configurable BOM. 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.

Figure 47: Recursion

Recursion Explain the problem of recursion. Demonstrate recursion by including the header material as an item in a BOM.

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Note: Responsibility for the termination criteria lies with the user who created the recursive BOM. See also SAP note: 161742 Demonstration for Recursion 5 minutes In the BOM for assembly T-B00, create an item 40 with the part number of the finished product T-F00. Show that recursion is allowed. Explain that the structure is not exploded endlessly because the system has been programed with termination criteria (max. low-level code) 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 in some cases it may 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 Recursiveness allowed indicator in the BOM item.

Figure 48: Item Control Indicators

Item control indicators Show the item control indicators on the appropriate views and give a brief explanation of these. The various item categories can be combined with various indicators. Thus special procedures can be controlled.

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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: Do not explode phantom assembly Individual requirements indicator Direct production (special procurement key SOBSL 52) Long-term planning

Figure 49: Discontinuation Control (Simple Discontinuation)

Discontinuation Control (Simple Discontinuation) Discontinuation control (Parallel Discontinuation) Show only the places relevant for maintenance in material master and BOM. Explain the effects of the maintenance.

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The engineering/design department may specify that a material is to be replaced by another at a particular point in time. These changes may be necessary for instance for the following reasons: •

•

New safety regulations may apply after a certain point in time. As a result, a certain component may have to be replaced, as it no longer meets the safety requirements. A cost-intensive part may be replaced by a less expensive one.

Discontinuation control works in the same way for long-term, master production and requirements planning. Simple Discontinuation: A component that is to be discontinued is replaced by a follow-up material as of a certain date, as soon as the stock available for MRP of the discontinued component is zero. This means that when the stock available for MRP of the discontinued material is zero, the dependent requirements are diverted from the discontinued material to the follow-up material. If the follow-up material is not available for MRP, the follow-up material is then acquired (in place of the discontinued material). The safety stock of the discontinued material is not affected by requirements planning. If the stock available for MRP for the discontinued material becomes greater than zero again, due to a later order for instance, the material is used again. An exception message for goods deliveries subsequent to the discontinued date is also produced. Prerequisites: In the material master record of the discontinued component, the discontinued indicator is set to “1”, a follow-up material is entered and a discontinued date set. For information purposes, the follow-up material can be maintained in the BOM as a follow-up material.

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Figure 50: Discontinuation Control (Parallel Discontinuation)

Parallel discontinuation: One group of materials is replaced by another group of materials, for instance, where one (main) component is discontinued and its available stock is zero, and another (dependent) component must also be discontinued. A certain nut may be discontinued, for example, meaning the corresponding screw is also discontinued. Prerequisites: •

•

•

92

Material master record: In the material master record of the main discontinued component, the discontinued indicator is set to “1” and the follow-up indicator “3” appears in the material master record of the dependent discontinued component. Bill of Material: In the extras for the BOM item, you define a discontinuation group under “follow-up/discontinued dates”; this freely-definable character string contains a summary of the associated, discontinued items of a BOM. The main component to be discontinued and its dependent component are identified using the same discontinuation group. You can also define the follow-up component(s) using the follow-up item indicator. The succeeding group contains a summary of the associated follow-up items in a BOM; it determines which follow-up items the discontinued items are to be replaced by. The character string of the succeeding group must correspond with the character string of the discontinued group.

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Lesson: BOM Maintenance

Figure 51: Alternative Items

Alternative Items Alternative Item Data Detail Screen If there is sufficient time, demonstrate this using the relevant optional exercise. It is unlikely that there will be time for this however. Alternative Item: Grouping This serves to summarize alternative items within an item list. All assembly materials can be entered into the alternative item group. Usage: As soon as you create an alternative item group, you will receive an additional dialog window containing the following data: Ranking Order, Strategy, Probability of Usage. You can maintain alternative items for the following situations: •

•

07-01-2005

Alternative items with specified usage probability These alternative items incorporate a certain usage probability. Create a usage probability for each alternative item in a group, so that in requirements planning a dependent requirement is created and this is changed to a reservation in the production order. Alternative Items as Information: You can also create an alternative item for information purposes - for instance that is only referenced in missing part situations. As neither a dependent requirement nor a reservation will occur for this item, you do not produce a usage probability.

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Figure 52: Alternative Item Data Detail Screen

•

•

•

94

Backflush according to usage probability For all items that are to be reserved, maintain the - Strategy (value 1 or no entry) - Ranking order (only affects the sorting of materials) - Usage probability Backflush at 100% availability For all items that are to be reserved, maintain the - ranking order If no ranking order is entered, the system checks the items in the order in which they are transferred for availability check (Value 1 or no entry) - Strategy (Value 2) - Usage probability Backflush at 100% availability (strategy 2) With this strategy, the availability check is executed in the specified ranking order according to ATP logic. Gross requirements: 100 pieces

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Lesson: BOM Maintenance

• •

•

Material

Usage Probability

Ranking Planned Requirement Amount

ATP Quantity:

Backflush quantity

A

20

1

20

30

0

B

30

2

30

150

100

C

50

3

50

180

0

The first material in the ranking order that meets the requirement date 100% is reserved in the required quantity (material B). Once a part backflush has occurred for a production order, no further check takes place for further part flushes with this production order. Any future part backflushes take place from the alternative item from which the first backflush occured. If with Strategy 2 none of the alternative items meet the requirements 100%, the availability check confirms each available quantity. A reservation is then made for the available quantity.

Deleting a Bill of Material Deleting a Bill of Material Explain only.

•

You can delete bills of material 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

Using the delete function, the BOM is removed from the system 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.

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Deletion at header level removes the entire BOM, whereas deletion at item level removes only the specified item. 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 for the same material, plant, and where-used list. If you delete a BOM with history (and so 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.

Figure 53: Why Use Engineering Change Management?

Why Use Engineering Change Management? Engineering Change Management Structure of Change Master Record Material Master Record - Immediate Change Material Master Record - Planned Change

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BOM - Validity Period - Explain everything briefly - Maybe demonstrate on system with minor example - Refer to PLM150 Engineering change management 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 SAP objects (for example, BOMs and routings) more than once. This means that the objects can be stored in all relevant change states. 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 SAP objects that are affected by one change. You can change all 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.

Figure 54: Engineering Change Management

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You can make object changes (for example, BOM changes and routing changes) in the system either with or without history. Note 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 the 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 documents created for changes without history. Engineering change management in the SAP system enables you to document changes completely, to cover product liability requirements, for example.

Figure 55: Structure of Change Master Record

General details about the change are contained in the Change header for the change number. This includes a brief description of the change, as well as validity or status indicator. You determine which objects can be changed with the change master record by selecting the object types.

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The object management records specify the objects to be changed. These contain exact details such as which BOM is changed in which where-used list. These object management records can either be created by the user or generated automatically by the system. Alternative dates allow you to control the “valid-from date” for individual objects more exactly.

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Figure 56: BOM - validity period of elements

•

•

•

•

100

If you process a BOM with reference to a change number, the system produces the valid BOM header and the valid items on the “valid-from” date. In this example, two valid items (items A and C) exist for the date of change number N-2. Item B may have been created - Without engineering change management by a change valid from 1.3. - With a change number such as N4 and a corresponding date - With one of the above change numbers and date element. Make the settings for processing in engineering change management in Customizing for the BOM. Basic settings are made in the modification parameters. These include activating engineering change management for BOM processing, which results in a history requirement for BOMs. You can also specify whether a change number is assigned when a BOM is created. In the history requirement you can make settings for BOM usage (e.g. production), so that a change number has to be allocated for a certain status, even if it has not previously been processed with a change number. In exceptional cases you can allow a BOM change without a change number using the authorization object C_STUE_NOH for BOMs with history requirements. Remember that, in this case, the changes will not be documented fully.

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Lesson: BOM Maintenance

Figure 57: Material Master Record - Immediate Changes

•

•

•

•

07-01-2005

If you would like to change materials with the transaction “Change -> Immediately”, this will only function with a change number whereby the “valid from”- date is either the current date or lies in the past. Material changes with a change number do not produce any new data records. The system saves the changes in the change documents. The last-saved data are always reproduced as the current status independent of “valid-from” date of change master record. In this example, the current status is the data from the second change action (MRP controller 055). There is no history requirement for material changes, meaning that after being processed with a change number, this can also be changed again without a change number. Documentation is still complete however, as change documents are updated for all material changes. For changes with change numbers, material master records require object management records. The appropriate indicator is placed automatically in the object categories overview for the change number. You must ensure that a corresponding object management record exists or is created automatically however.

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Figure 58: Material Master Record - Planned Changes

•

•

• •

102

If you would like to change materials with the transaction “Change -> Plan”, this will only function with a change number whereby the “valid from”date lies in the future. In order for the planned changes to become effective, they must be activated on the planned date. When activated, the system only takes notice of the changes due to become effective on the date in question. A change planned for the future is stored in the form of a change document. The key date is saved in the document header of the change document. For technical reasons, current status is always shown for the following data when displayed on key date: - All types of long text (such as purchasing order texts) - Document data - Joint production - Average plant stock - Revision status - Sales conditions, customs preferences, export licenses - Assignment to configurable material and configuration evaluation - QM testing data - Production versions - Consumption and forecast values and forecast process - Classification

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Exercise 4: BOM Maintenance Exercise Duration: 30 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Process further BOM items according to item category

Business Example The plant-specific BOM is extended by adding different items according to requirements.

Task 1: 1.

Extend your plant-specific BOM T-F## in plant 1000 from the previous exercise by adding the following data:

2. Item no.

Item cat.

Component

Quantity

40

L

100-600

2

The 2 support bases are mounted on the pump. The two support bases should be assembled at the front and the back of the pump. Create subitems for this. 3. Item no.

Item cat.

50

N

Component

Quantity 1

Item text:

“One non-stock item”

Purchasing org.:

1000

Price:

10 EUR

Continued on next page

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Purchasing group:

000

Cost element:

415000

Material group:

Metal processing

4. Item no.

Item cat.

Component

Quantity

60

R

100-700

1 piece

Size 1

200 mm

Size 2

300 mm

Note the calculated variable-size item quantity. Change variable-size 2 to 400mm. Get the system to recalculate the variable-size item quantity. 5. Item no.

Item cat.

Component

Quantity

70

L

100-130

10

Maintain this item as a bulk material. 6. Item no. Item cat.

Document

Typ

DPt

Vs

Quantity

80

T-F1##

DRW

000

00

1

D

Save your BOM. 7.

Display your BOM T-F## with 15 as the required quantity. Who created the BOM? _________________ On what date? ________________

8.

When using the where-used list “ Universal ”, which fields are set as required fields?

Continued on next page

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Lesson: BOM Maintenance

Task 2: Optional exercise: Create alternative items in the BOM T-F1##. 1.

First create a new material master record T-Z## as semi-finished product in the plant with basic data, MRP and accountancy views as a minimum. Use material T-B1## as reference material in plant 1000 also.

2.

b. Next use the requirements/stock list to display the current stock available for the following materials. T-B1## T-B2## T-B3## T-B4## T-F3## T-Z## Change the stock for the above materials in plant 1000 at storage location 0001 to the following status: T-B1##

100 pieces (exact)

T-B2##

200 pieces (minimum)

T-B3##

200 pieces (minimum)

T-B4##

200 pieces (minimum)

T-F3##

1800 pieces (minimum)

T-Z##

100 pieces (exact)

3.

Change the BOM of material T-F1## by creating the new component T-Z## as an alternative item to T-B1##. For item T-B1## enter Alt.item group 01, Ranking 1, Strategy 2 and Usage probability 100. For item T-Z## enter Alt.item group 01, Ranking 2, Strategy 2 and Usage probability 1.

4.

In the steps that follow, test the effects of the alternative item group on production planning and material backflush. Create a production order for the material T-F1## in plant 1000 for more than 100 pieces. Use the order category PP01. Select one month from today’s date as the order finish date. After confirming the data entries with Enter, go to the component overview in order to find the answers to the following questions:

Continued on next page

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How high is the quantity requirement of T-B1##?

____________

How high is the confirmed quantity of T-B1##?

____________

How high is the quantity requirement of T-Z##?

____________

How high is the confirmed quantity of T-Z##?

____________

Caution: Do not save the order yet. 5.

Carry out an availability check for all components. How high is the quantity requirement of T-B1##?

____________

How high is the confirmed quantity of T-B1##?

____________

How high is the quantity requirement of T-Z##?

____________

How high is the confirmed quantity of T-Z##?

____________

Save the order. 6.

Repeat the last two steps to test the effect of the alternative item groups in the case of insufficient stock. Create a production order again for the material T-F1## in plant 1000 for more than 100 pieces. Use the order category PP01. Select one month from today’s date as the order finish date. After confirming your data entries with Enter, go to the Component overview in order to find the answers to the following questions: How high is the quantity requirement of T-B1##?

____________

How high is the confirmed quantity of T-B1##?

____________

How high is the quantity requirement of T-Z##?

____________

How high is the confirmed quantity of T-Z##?

____________

Caution: Do not save the order at this point. 7.

Carry out an availability check for all components. How high is the quantity requirement of T-B1##?

____________

How high is the confirmed quantity of T-B1##?

____________

How high is the quantity requirement of T-Z##?

____________

How high is the confirmed quantity of T-Z##?

____________

Save the order.

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Lesson: BOM Maintenance

Solution 4: BOM Maintenance Task 1: 1.

Extend your plant-specific BOM T-F## in plant 1000 from the previous exercise by adding the following data: a)

Change material BOM T-F##. Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change Pushbutton: New entries

2. Item no.

Item cat.

Component

Quantity

40

L

100-600

2

The 2 support bases are mounted on the pump. The two support bases should be assembled at the front and the back of the pump. Create subitems for this. a) Item no.

Item cat.

Component

Quantity

40

L

100-600

2

Select item 40 and choose pushbutton: Sub-items SubI

Installation point

Sub-item qty Sub-item text

0001

Front of pump

2

0002

Back of pump

1

=> Note: “Item quantity is changed from 2 PCS to 3 PCS.” back with F3 => Quantity is 3 and grayed out. 3.

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Item no.

Item cat.

50

N

Component

Quantity 1

Item text:

“One non-stock item”

Purchasing org.:

1000

Price:

10 EUR

Purchasing group:

000

Cost element:

415000

Material group:

Metal processing

a) Item no.

Item cat.

Component

50

N

1

Quantity

(Enter) => Basic data Item text:

“One non-stock item” (Enter)

=> Purchasing data Purchasing organization:

1000

Price:

10 EUR

Purchasing group:

000 (Superior)

Cost element:

415000

Material group:

001 (Metal processing)

4. Item no.

Item cat.

Component

Quantity

60

R

100-700

1 piece

Size 1

200 mm

Size 2

300 mm

Note the calculated variable-size item quantity. Change variable-size 2 to 400mm. Continued on next page

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Lesson: BOM Maintenance

Get the system to recalculate the variable-size item quantity. a) Item no.

Item cat.

Component

Quantity

60

R

100-700

1 piece

Size 1:

200 mm

Size 2:

300 mm (Enter)

=> Variable size item quantity:

0.060 m2

Size 2:

400 (Enter)

=> Warning messageDelete variable size item quantity! Variable size item quantity:

0.080 m2

5. Item no.

Item cat.

Component

Quantity

70

L

100-130

10

Maintain this item as a bulk material. a) Item no.

Item cat.

Component

Quantity

70

L

100-130

10

Select item and choose pushbutton: Item or double-click on Item. 70, tab page: Long text Bulk material (bottom right) CostingRelevancy back with F3 6.

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Item no. Item cat.

Document

Typ

DPt

Vs

Quantity

80

T-F1##

DRW

000

00

1

D

Save your BOM. a)

Edit → New entries → Document tab page or Item category D in the entry field PTp

7.

Item no.

Item cat.

Component

Quantity

80

D

T-F1## DRW 000

00 1

Display your BOM T-F## with 15 as the required quantity. Who created the BOM? _________________ On what date? ________________ a)

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 Administrative data 8.

When using the where-used list “ Universal ”, which fields are set as required fields? a)

With the “ Universal ” where-used list, there are no requiredfields set. such as: –> Material BOM –> Create –> for where-used list => List of all usages incl. Control indicator of item status.

Continued on next page

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Lesson: BOM Maintenance

Task 2: Optional exercise: Create alternative items in the BOM T-F1##. 1.

First create a new material master record T-Z## as semi-finished product in the plant with basic data, MRP and accountancy views as a minimum. Use material T-B1## as reference material in plant 1000 also. a)

Logistics –> Production –> Master Data –> Material Master –> Material –> Create (General) –> Immediately (= MM01) Copy T-B1## and change the description by adding “Alt##”

2.

b. Next use the requirements/stock list to display the current stock available for the following materials. T-B1## T-B2## T-B3## T-B4## T-F3## T-Z## Change the stock for the above materials in plant 1000 at storage location 0001 to the following status: T-B1##

100 pieces (exact)

T-B2##

200 pieces (minimum)

T-B3##

200 pieces (minimum)

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T-B4##

200 pieces (minimum)

T-F3##

1800 pieces (minimum)

T-Z##

100 pieces (exact)

a)

For analysis of current requirements/stock situation, use: Logistics –> Production –> MRP –> Evaluations –> Stock/Requirements List (= MD04) For any necessary deliveries of goods, use: Logistics –> Materials Management –> Inventory Management –> Goods Movement –> Other (= MB1C) Transaction type: 561, plant 1000, storage location 0001, today’s date as document and booking date, leave other fields empty or enter default differences according to task. For any necessary issues of goods, use: Logistics –> Materials Management –> Inventory Management –> Goods Movement –> Goods Issue (= MB1AC) Use the movement catogory: 201 and the cost center 1000.

3.

Change the BOM of material T-F1## by creating the new component T-Z## as an alternative item to T-B1##. For item T-B1## enter Alt.item group 01, Ranking 1, Strategy 2 and Usage probability 100. For item T-Z## enter Alt.item group 01, Ranking 2, Strategy 2 and Usage probability 1. a)

Changing of item list and addition of alternative item T-Z##: Logistics -> Production -> Master Data -> Bills of Material -> Bill of Material -> Material BOM -> Change (=CS02) In row 70, enter item T-Z## with the quantity 1 piece. To create alternative item group, select both items (T-B1## and T-Z##) and use the goto push button to go to the Item Overview screen, then the “Basic data” tab page. Enter 01 for “Alt Item Group”, press Enter and enter the remaining data. Now go to the second marked item using “Next Item”, and repeat the entries for the corresponding data.

4.

In the steps that follow, test the effects of the alternative item group on production planning and material backflush. Create a production order for the material T-F1## in plant 1000 for more than 100 pieces. Use the order category PP01. Select one month from today’s date as the order finish date. After confirming the data entries with Enter, go to the component overview in order to find the answers to the following questions: Continued on next page

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How high is the quantity requirement of T-B1##?

____________

How high is the confirmed quantity of T-B1##?

____________

How high is the quantity requirement of T-Z##?

____________

How high is the confirmed quantity of T-Z##?

____________

Caution: Do not save the order yet. a)

To create a production order, use: Logistics –> Production –> Production Control –> Order –> Create –> With Material (= CO01) Enter the material number, plant and order type on the initial screen and press Enter. On the next screen enter the total quantity and the order finish date of today + 1 month and press Enter. Go to the Components overview using the appropriate pushbutton: Quantity requirement of T-B1##

100

Confirmed quantity of T-B1##

0

Quantity requirement of T-Z##

1

Confirmed quantity of T-Z##

0

Caution: Do not save the order at this point. 5.

Carry out an availability check for all components. How high is the quantity requirement of T-B1##?

____________

How high is the confirmed quantity of T-B1##?

____________

How high is the quantity requirement of T-Z##?

____________

How high is the confirmed quantity of T-Z##?

____________

Save the order. a)

Pushbutton: Availability check, Material: Quantity requirement of T-B1##

100

Confirmed quantity of T-B1##

100

Quantity requirement of T-Z##

0

Confirmed quantity of T-Z##

0 Continued on next page

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6.

PLM110

Repeat the last two steps to test the effect of the alternative item groups in the case of insufficient stock. Create a production order again for the material T-F1## in plant 1000 for more than 100 pieces. Use the order category PP01. Select one month from today’s date as the order finish date. After confirming your data entries with Enter, go to the Component overview in order to find the answers to the following questions: How high is the quantity requirement of T-B1##?

____________

How high is the confirmed quantity of T-B1##?

____________

How high is the quantity requirement of T-Z##?

____________

How high is the confirmed quantity of T-Z##?

____________

Caution: Do not save the order at this point. a) Quantity requirement of T-B1##

100

Confirmed quantity of T-B1##

0

Quantity requirement of T-Z##

1

Confirmed quantity of T-Z##

0

Caution: Do not save the order at this point. 7.

Carry out an availability check for all components. How high is the quantity requirement of T-B1##?

____________

How high is the confirmed quantity of T-B1##?

____________

How high is the quantity requirement of T-Z##?

____________

How high is the confirmed quantity of T-Z##?

____________

Continued on next page

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Save the order. a) Quantity requirement of T-B1##

0

Confirmed quantity of T-B1##

0

Quantity requirement of T-Z##

100

Confirmed quantity of T-Z##

100

Save the order.

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Lesson Summary You should now be able to: • Name and use the different item categories in a bill of material • Distinguish between BOM status and item status

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Unit Summary

Unit Summary You should now 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

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Unit Summary

118

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Unit 3 BOM Reporting

109

The previous chapter explained how to create BOMs. Course participants will now learn to analyze complex structures. In this unit, additional functions for BOM maintenance are shown.

Unit Overview This unit analyzes the BOM structures according to various reporting functions and describes additional functions for BOM management. With the help of the BOM reporting functions, participants analyze • •

The BOM structure and learn how to adapt the print output. How to work with the product structure browser as well as how to use the mass processing functions.

Unit Objectives After completing this unit, you will be able to: • •

BOM explosion, where-used list and BOM comparison Mass changes and the product structure browser

Unit Contents Lesson: BOM explosion, where-used list, BOM comparison .............120 Exercise 5: BOM explosion, where-used list, BOM comparison .....125 Lesson: Mass Changes and the Product Structure Browser..............133 Exercise 6: Mass Changes and the Product Structure Browser .....137

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Lesson: 110

PLM110

BOM explosion, where-used list, BOM comparison Lesson Duration: 30 Minutes

Lesson Overview BOM explosion, where-used list and BOM comparison

Lesson Objectives After completing this lesson, you will be able to: •

BOM explosion, where-used list and BOM comparison

For reports, you can carry out the relevant exercise steps from the exercises for this lesson. Alternatively you can analyze the BOM T-F00, plant 1000, Where-used list 1 with application PP01. You carry out the BOM comparison for structure P-100 . Note: An application always has to be entered. Show the where-used list using the hexagon head screw 100-130 with different required quantities or resulting quantities. Explain the options under View-Settings for all reports. Note: For the application, you can define a user parameter (SET/GET-Parameter): Parameter CSA. BOM explosion Explain and demonstrate the 3 options for top-down explosion: 1. BOM level by level, 2. Structure level by level, 3. Summarized BOM Where-Used Lists Materia Where-Used Lists Explain the single-level and/or multilevel material where-used list. BOM comparison Explain the function and show the possible comparison statuses using for one example: 1. Same material and quantity 2. Similar material, different quantity 3. Different or not assigned. No similarities

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Lesson: BOM explosion, where-used list, BOM comparison

Business Example The structure of a BOM needs to be checked.

Figure 59: BOM Explosion

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 the requirements for a product The engineering design 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 where-used list 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 field. This value is the SET- / GET-parameter CSA.

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Figure 60: Where-Used Lists

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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Lesson: BOM explosion, where-used list, BOM comparison

Figure 61: Single-Level and Multi-Level Material Where-Used Lists

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: • • • •

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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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Figure 62: BOM Comparison

The BOM comparison is useful if: • • •

Several BOMs exist for a material These have different uses There are different change statuses

The comparison can be single-level or multi-level. You can select which fields you want to compare.

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Exercise 5: BOM explosion, where-used list, BOM comparison Exercise Duration: 15 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Use BOM explosion functions to analyze your plant-specific BOM

Business Example The engineering design department checks the BOMs that have been created.

Task 1:

1.

For reporting, use BOM application “Production – general” = PP01.

2.

Which items in multilevel BOM T-F## (plant 1000) have spare part indicator A?

3.

Which items in multilevel BOM T-F## are spare parts?

Continued on next page

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4.

Which items are non-stock items?

5.

Which item is handled as bulk material?

6.

How many hexagon head screws M10 (100-130) are required for 10 pumps (T-F##) ? Which report are you using for this?

7.

In which materials and in what quantities is the hexagon head screw 100-130 used?

Task 2:

1.

Compare your BOM T-F## in plant 1000 with the group BOM for T-F## single-level and differentiated with Where-used list 1.

Continued on next page

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Lesson: BOM explosion, where-used list, BOM comparison

2.

Which items are similar, the same and different?

3.

Select only the object description as a field to compare. Repeat the comparison. Which items are now similar, the same and different? Reset the fields to compare

4.

Compare your BOM T-F## (plant 1000) with BOM P-100 (plant 1000) – multi-level and summarized with application PP01. Compare stock items only.

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Solution 5: BOM explosion, where-used list, BOM comparison Task 1: 1.

For reporting, use BOM application “Production – general” = PP01. Answer: BOM Explosion Logistics → Production → Master Data → Bills of Material: or Logistics → Central Functions → Engineering → Bill of Material ... Reporting → BOM Explosion → Material BOM → BOM Level by Level: Material: T-F## (Default) Plant: 1000 (Default) Application: PP01 (Production – general)

2.

Which items in multilevel BOM T-F## (plant 1000) have spare part indicator A? Answer: Icon: View Spare part: A (Spare part customer A) Icon: Execute Fly wheel: 100-200

3.

Which items in multilevel BOM T-F## are spare parts? Answer: Back with F3 Icon: View Spare part sel. X(All spare parts) Caution: (Spare part: A delete) Icon: Execute Fly wheel: 100-200

4.

Which items are non-stock items? Answer: Back with F3 Icon: View Item category N (non-stock item) Caution: (Spare part sel. X delete) Icon: Execute A non-stock item. Continued on next page

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Lesson: BOM explosion, where-used list, BOM comparison

5.

Which item is handled as bulk material? Answer: Back with F3 Icon View Select Bulk material Caution: (Delete item category N) Icon: Execute Hexagon head screw M10: 100-130.

6.

How many hexagon head screws M10 (100-130) are required for 10 pumps (T-F##) ? Which report are you using for this? Answer: Summarized BOM Logistics → Production → Master Data → Bills of Material: or Logistics → Central Functions → Engineering → Bill of Material ... Reporting → BOM Explosion → Material BOM → Summarized BOM Material, plant, applicaton as above unter 1, Required quantity 10 Icon: Execute Read number: 110 including totals indicator.

7.

In which materials and in what quantities is the hexagon head screw 100-130 used? Answer: Where-used list Logistics → Production → Master Data → Bills of Material: or Logistics → Central Functions → Engineering → Bill of Material ... Reporting → Where-Used List → Material: Material: 100-130 Type of where-used list: Direct Icon: Next screen Hit list: 1 Plant: 1000 or *

Continued on next page

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Task 2: 1.

Compare your BOM T-F## in plant 1000 with the group BOM for T-F## single-level and differentiated with Where-used list 1. Answer: BOM Comparison Logistics → Production → Master Data → Bills of Material: or Logistics → Central Functions → Engineering → Bill of Material ... Reporting → BOM Comparison:

2.

Which items are similar, the same and different? Answer: Primary and secondary BOM: Material BOM (if necessary): –> Goto –> Primary and Secondary BOM type) Single-level comparison button 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 Items 20 are similar. Items 10 and 30 are the same. The remaining items are different. Go to –> Extras –> Layout to incorporate the item numbers of the two bills of material.

3.

Select only the object description as a field to compare. Repeat the comparison. Which items are now similar, the same and different? Reset the fields to compare Answer: Back with F3 (on the initial screen: Goto → Fields to compare: Select only the object description as a comparison criterion, copy, and repeat the comparison. Items 20 are now the same because the quantities are no longer being compared. All other details are the same as above. Back with F3 Goto → Fields to compare: Pushbutton: Reset

Continued on next page

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Lesson: BOM explosion, where-used list, BOM comparison

4.

Compare your BOM T-F## (plant 1000) with BOM P-100 (plant 1000) – multi-level and summarized with application PP01. Compare stock items only. Answer: BOM Comparison → Multi-level comparison: (or use pushbutton) Icon: Further settings Item category: L (Continue). Application: PP01 (Production – general) Pushbutton: Summarized comparison

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Lesson Summary You should now be able to: • BOM explosion, where-used list and BOM comparison

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Lesson: 123

Lesson: Mass Changes and the Product Structure Browser

Mass Changes and the Product Structure Browser Lesson Duration: 30 Minutes

Lesson Overview Mass changes and the product structure browser

Lesson Objectives After completing this lesson, you will be able to: •

Mass changes and the product structure browser

Mass changes with BOMs Explain and show the mass function options: 1. Mass replacement, for example, assembly T-B00 replaced by 100-100, 2. Mass insertion of new item and so on. Product Structure Browser Explain the function of the product structure browser. Show examples: Changing a BOM, item, material. Demonstration for Product Structure slide 10 minutes Show the functionality using examples T-F00 or P-100.

Business Example A material (item) has to be replaced. All the objects in a structure have to be displayed, processed, or created.

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Figure 63: Mass Change in BOMs

You can use the mass change function to make changes to items in several BOMs using 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 of items Replacing an item

•

– In all selected BOMs – With assignment of a new item quantity if necessary – Using engineering change management if necessary – With restrictive selection criteria such as plant and / or usage Deleting an item – – –

134

In all selected BOMs Using engineering change management if necessary With restrictive selection criteria, such as plant and/or usage

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PLM110

Lesson: Mass Changes and the Product Structure Browser

Figure 64: Product structure

The product structure enables you to display and process all functionally related objects (such as material, BOM, document, and routing). The product data is displayed in a tree structure. You can restrict the display to only the detail data 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: • • • • •

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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 Jump to the engineering workbench.

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Lesson: Mass Changes and the Product Structure Browser

Exercise 6: Mass Changes and the Product Structure Browser Exercise Duration: 10 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Analyze and correct your product structure

Business Example The design engineer wants an overview of all existing objects for his pump in order to be able to process them as and when required.

Task: 1.

Take a look at the product structure for material T-F##. Display the BOM and open a document info record. Display the BOM for the assembly.

2.

Change items 10 / 30 for BOM T-F## in plant 1000: Make item 10 a spare part for customer A too. The explosion type for phantom assembly for item 30 must be switched off. You should therefore check first whether the material in question has the special procurement key 50. Create a new document item with document P-100, DRW, 000, 00 and display its original.

3.

Go to the classification and display the characteristics for your pump. Pump height: ____________ Pump capacity: ____________ Usage: ____________

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Solution 6: Mass Changes and the Product Structure Browser Task: 1.

Take a look at the product structure for material T-F##. Display the BOM and open a document info record. Display the BOM for the assembly. a)

Open up the product structure browser Logistics → Cross-Application Components → Engineering Change Management → Environment → Product Structure: or Logistics → Central Functions → Engineering → Environment → Product Structure: Enter the material: T-F## on the tab page Material and press Enter. Expand the tree structures for bills of material and documents by clicking on the hierarchy node. Double-click on the symbols for bill of material or document to display the corresponding master record. Select the individual objects then right click to display a context menu. From the context menu, you can display or change objects or go to the Engineering Workbench. To recognize which T-F## components are also assemblies, we recommend placing the assemblies indicator in the layout Click pushbutton: Change Layout right-hand side: Pushbutton: Filter here: Select BOM itemhere: Copy the Assembly field onto left using the pushbutton and then click Enter. To display the BOM of an assembly, open the corresponding item and then select: –> Material usage –> Material master of assembly –> BOM usage –> BOM header and double-click to display the BOM.

2.

Change items 10 / 30 for BOM T-F## in plant 1000: Make item 10 a spare part for customer A too.

Continued on next page

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Lesson: Mass Changes and the Product Structure Browser

The explosion type for phantom assembly for item 30 must be switched off. You should therefore check first whether the material in question has the special procurement key 50. Create a new document item with document P-100, DRW, 000, 00 and display its original. a)

Open the tree structure of BOM T-F## in plant 1000 at item level. Select the header of the BOM and right-click. Select Change. Select the item you want to change, and click the Detail icon or double-click the item number (items.: 10 / 30In the Status / Long text tab page, maintain the spare part indicator. In the tab page Basic Data, maintain the explosion type (here: 02). The special procurement key is maintained in the material master record in the MRP 2 view. You can also jump straight to the material number by double-clicking here in the material master record. Assign the required document immediately in Change material BOM. Save your BOM. Refresh the product structure in the browser with the appopriate pushbutton. Select the BOM item with the newly-assigned document and select Display Original in the context menu (right-click). When you reach the appropriate setting for the layout, double-click the glasses symbol. Close the viewer by clicking the left pushbutton .

3.

Go to the classification and display the characteristics for your pump. Pump height: ____________ Pump capacity: ____________ Usage: ____________ a)

Expand the hierarchy node Classification and select the Class. Click the right mouse button and select Characteristic Value Assignment: or double-click the Material symbol and display the classification: Pump height: 5 m Pump capacity: 15 m3 Usage: House technology

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Lesson Summary You should now be able to: • Mass changes and the product structure browser

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Unit Summary

Unit Summary You should now be able to: • BOM explosion, where-used list and BOM comparison • Mass changes and the product structure browser

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Unit Summary

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Unit 4 Variants and Alternatives

133

Once BOM maintenance and reporting have been explained, you then explain two additional technical types for bills of material, and how they differ from variant configuration.

Unit Overview This unit presents the difference between variant configuration and variant BOMs and explains when each technical BOM type is used. The unit also explains the use and purpose of multiple BOMs (alternative BOMs). Participants maintain: •

Variant and multiple BOMs and learn to understand how they differ from variant configuration.

Unit Objectives After completing this unit, you will be able to: • • •

Variant BOMs BOMs in Variant Configuration Multiple BOMs and Alternatives

Unit Contents Lesson: Variant BOM...........................................................144 Exercise 7: Variant BOMs .................................................147 Lesson: BOMs in Variant Configuration .....................................153 Lesson: Multiple BOMs and Alternatives ....................................158 Exercise 8: Multiple BOMs and Alternatives (optional) ................161

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Lesson: 134

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Variant BOM Lesson Duration: 30 Minutes

Lesson Overview Variant BOMs

Lesson Objectives After completing this lesson, you will be able to: •

Variant BOMs

Variant BOM: Several Products Point out that the different products should only differ slightly from each other. Variant BOM Variant BOM “V” Present the variant BOM and its purpose. Demonstration for Variant BOM 10 minutes Create a variant T-F88 for BOM T-F00. Point out the BOM number and the technical type. Enter the additional value "PLM110" for the BOM in the BOM header for the BOM group, and change item 10 to material 100-100. In the alternative text field, enter "Variant Material Number". Show the BOM headers / alternative texts and material items. Alternatively you can use the exercise from the topic "Variant BOM" as an example. Note: A maximum of 99 variants are possible for each internal BOM.

Business Example For additional BOMs, you should use variant BOMs or multiple BOMs

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Lesson: Variant BOM

Figure 65: Variant BOM: Several Products

If several similar products are manufactured whose parts only differ in minor ways then you can represent these various products using a variant BOM. Variants can also differ in component quantity alone. Only a simple (basic) material BOM can be extended to become a variant BOM. You cannot convert a multiple BOM into a variant BOM.

Figure 66: Variant BOM

You can create a variant only if: • •

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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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Figure 67: Variant BOM “V”

The field BOM group 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: • •

146

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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Lesson: Variant BOM

Exercise 7: Variant BOMs Exercise Duration: 15 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Process variant BOMs and recognize the difference between variant BOMs and variant configuration

Business Example The engineering department requires BOMs for simple but similar materials

Task: 1.

You now want to create two additional variants of the pump T-F## in plant 1000 with where-used list 1. These are pumps T-FY## and T-FZ##. Please use the following data when you create variants of T-F## (Icon: Create variant of): BOM text:

“Standard pump”

Alternative Text

Y variant and Z variant

BOM group:

VA##

In variant pump T-FY## replace item 10: T-B## with item 10 assembly T-B1##. 2.

In variant pump T-FZ## replace item 30: 100-300 by item 30 with materialT-BZ##.

3.

Display all variants of T-F##. (BOM group VA##) Check your entries are correct. Check in particular:

4.

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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.

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Solution 7: Variant BOMs Task: 1.

You now want to create two additional variants of the pump T-F## in plant 1000 with where-used list 1. These are pumps T-FY## and T-FZ##. Please use the following data when you create variants of T-F## (Icon: Create variant of): BOM text:

“Standard pump”

Alternative Text

Y variant and Z variant

BOM group:

VA##

Continued on next page

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Lesson: Variant BOM

In variant pump T-FY## replace item 10: T-B## with item 10 assembly T-B1##. a)

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 → Material → Material BOM → Create: Material:

T-FY##

Plant:

1000

(Default)

Where-used list:

1

(Default)

Valid from:

Today’s date

(Default) do not press

→ Material BOM → Create variant of (F9) or Create variant of pushbutton Create variant of Material:

T-F##

Icon:

Select all

Icon:

Copy From

Icon:

Header

BOM group

VA##

BOM text:

Standard pump

Alt text:

Y variant

Confirm with Enter. Item Overview icon: Item no.

Item cat.

Component

Quantity

10

L

T-B1##

1

Save BOM

Continued on next page

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2.

PLM110

In variant pump T-FZ## replace item 30: 100-300 by item 30 with materialT-BZ##. a)

For menu paths see 1..Create material BOM: Material:

T-FZ##

Plant:

1000

(Default)

Where-used list:

1

(Default)

Valid from:

Today’s date

(Default) do not press

→ Material BOM → Create variant of (F9) or pushbutton: Create variant of Material:

T-F##

Icon:

Select all

Icon:

Copy From

Icon:

Header

BOM group

VA##

BOM text:

Standard pump

Alt text:

Z variant

Confirm with Enter. Item Overview icon: Item no.

Item cat.

Component

Quantity

30

L

T-BZ##

1

Save BOM 3.

Display all variants of T-F##. (BOM group VA##) Check your entries are correct. Check in particular:

Continued on next page

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Lesson: Variant BOM

BOM group

_______________

Internal BOM number

_______________

Technical type

_______________

a)

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:

VA##

Plant:

1000

(Default)

Valid From:

Today’s date

(Default)

Pushbutton:

Variants

Select all variants Goto:

Header

BOM number, usage “1”, and technical type “V” exist only once. Hint: In header, click pushbutton: Item You can then move between the individual variants using the pushbuttons: Previous Variants and Next Variants . In the summarized BOM, go to pushbutton: Variant items for selected items. 4.

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. a)

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 02 and 03 for variants T-FY## and T-FZ##.

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Lesson Summary You should now be able to: • Variant BOMs

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Lesson: 143

Lesson: BOMs in Variant Configuration

BOMs in Variant Configuration Lesson Duration: 10 Minutes

Lesson Overview BOMs in Variant Configuration

Lesson Objectives After completing this lesson, you will be able to: •

BOMs in Variant Configuration

Variant Configuration Configuration of a Pump Explain what variant configuration means and when this should be used. Explain how this differs to variant BOMs. If there is time, you can show the configuration of pump P-500 for example.

Business Example You would like to use the variant configuration as you have multivariant products. You are therefore very interested in how to maintain the BOM.

Figure 68: Variant Configuration

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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. A company that sells or produces products with variants must perform these configuration tasks quickly and accurately. However, this is not easy, as product development cycles and life cycles of products are becoming 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 the SAP system as characteristics.

Figure 69: Configuration of a Pump

There are often inter-dependencies between the individual forms of a product. It is frequently the case that not all combinations that are theoretically possible are allowed. There are two reasons for this: • •

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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 colours of paint and seats if you are ordering an expensive model.

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Lesson: BOMs in Variant Configuration

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 parts that appear in all variants of the product, and others that can be chosen 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: • • • •

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PLM130 Classification PLM140 Variant Configuration 1 – Modeling PLM143 Variant Configuration 2 – Integration PLM146 Variant Configuration 3 – Scenarios

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Facilitated Discussion

Discussion Questions Use the following questions to engage the participants in the discussion.Feel free to use your own additional questions. What are the special features of BOMs in variant configuration? • • • •

Not a separate technical type, therefore mostly simple BOMs Viewed in terms of contents, these are super BOMs These are the only BOM items to which relational knowledge can be assigned This is the only case where classes can exist as BOM items

Refer to the courses → PLM140, PLM 143 and PLM 146

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Lesson: BOMs in Variant Configuration

Lesson Summary You should now be able to: • BOMs in Variant Configuration

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Lesson: 147

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Multiple BOMs and Alternatives Lesson Duration: 25 Minutes

Lesson Overview Multiple BOMs and Alternatives

Lesson Objectives After completing this lesson, you will be able to: •

Multiple BOMs and Alternatives

Multiple BOM - One Product Multiple BOM “M” Explain the meaning of multiple BOM. Explain when the multiple (alternative) BOM is used. Note: A maximum of 1000 alternatives are possible. Demonstration for multiple BOMs 10 minutes Use the exercise for the multiple BOM for your demonstration. Assign a name to the alternatives in the alternative text. For example: "Alternative + Material number + Maximum lot size" . Enter a description for the BOM group, for instance: Alternatives or Paints Show the differences and similarities when compared to variant BOMs. Comparison of Different Types of BOM Summarize the features of and differences between the individual technical BOM types. Optional exercise on multiple BOMs only 15 minutes

Business Example For the planning of complex products that can exist in several variants, you should use variant configuration.

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Lesson: Multiple BOMs and Alternatives

Figure 70: Multiple BOM: One Product

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.

Figure 71: Multiple BOM

The field BOM group can also be used as an external BOM number.

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All 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 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

Figure 72: Comparison of Different Types of BOM

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Lesson: Multiple BOMs and Alternatives

Exercise 8: Multiple BOMs and Alternatives (optional) Exercise Duration: 15 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Maintain a multiple BOM

Business Example Recipes for “blue paint” are grouped together in a multiple BOM.

Task: Optional 1.

The recipe for “blue paint” (material number T-F77## (## = group number) has different components or component quantities for different lot sizes. Create a finished product T-F77## in plant 1000 by copying from reference material T-F77.

2.

Create a BOM for the recipe and two alternatives with the following data: Material T-F77##, BOM group: “Color-##” , BOM text “‘multiple BOM group ##’”

3.

Item

Item cat.

Component

Quantity

Un

10

L

T-B71

0,5

kg

20

L

T-B74

1

kg

30

L

T-B75

1

kg

Create an alternative (by copying alternative 1). In this alternative, replace item 10, component T-B71 with Item

Item cat.

Component

Quantity

Un

10

L

T-B72

0,3

kg

Change the quantity of component T-B74 in item 20 to 1.4 l. 4.

In another alternative (copy with reference material alternative 1) item 10, component T-B71 is replaced with: Continued on next page

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5.

6.

PLM110

Item no.

Item cat.

Component

Quantity

Un

10

L

T-B73

0,3

kg

Add the following data to the BOM headers of the alternatives: Alternative

Alt text

Lot size from

to

1

“Paint Color 1”

1

100

2

“Paint Color 2”

101

200

3

“Paint Color 3”

201

500

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 ____________

7.

Change Alternative 1 using the product structure browser. Change the quantity of item 30 as required. Save the data and refresh the product structure in the browser. Display your BOM group PAINT-## to check the change here too.

8.

Create a production order with the material T-F77## and test the effects of the different BOM alternatives with your lot sizes. The production order should be for plant 1000, order type PP01, for more than 125 pieces and for 2 months today. Since there is no working schedule, let the system create an operation. Without changing the production order, check which BOM alternative has been associated. Why was this used? Alternative ____ because ______________________________ Change the order quantity to 225 pieces and update the PP master data. Why this alternative? Alternative ____ because ______________________________

9.

Maintain a multiple BOM for the different alternatives. Selection of alternatives according to date. Example:

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Lesson: Multiple BOMs and Alternatives

Material

Plant

BOM usage

Valid from

BOMAlt

T-F77##

1000

1

01/01/xxxx

1

T-F77##

1000

1

01/07/xxxx

2

T-F77##

1000

1

01/12/xxxx

3

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Solution 8: Multiple BOMs and Alternatives (optional) Task: Optional 1.

The recipe for “blue paint” (material number T-F77## (## = group number) has different components or component quantities for different lot sizes. Create a finished product T-F77## in plant 1000 by copying from reference material T-F77. a)

Create alternative BOMs for the recipe for “blue paint” (T-F77## in plant 1000). Create material T-F77## (##=group number) with the reference material T-F77 (compare with unit: Material master, topic: Maintaining material masters). Logistics → Production → Master data → Material master → Create (special) → Finished product: You must create the MRP views and work scheduling at least.

2.

Create a BOM for the recipe and two alternatives with the following data: Material T-F77##, BOM group: “Color-##” , BOM text “‘multiple BOM group ##’”

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Lesson: Multiple BOMs and Alternatives

Item

Item cat.

Component

Quantity

Un

10

L

T-B71

0,5

kg

20

L

T-B74

1

kg

30

L

T-B75

1

kg

a)

Create a recipe Logistics → Production → Master Data → Bills of Material → Bill of Material: or Logistics → Central functions → Engineering → Bill of Material → Material → Material BOM → Create: Material:

T-F77##

Plant:

1000

(Default)

Usage:

1

(Default)

Valid from:

Today’s date

(Default)

Item overview Item

Item cat.

Component

Quantity

10

L

T-B71

0,5

20

L

T-B74

1

30

L

T-B75

1

Icon:

Header

BOM group:

“PAINT-##”

Tab page:

Quantities / Long text

BOM Text:

“ Multiple BOM group ## ”

Save BOM 3.

Create an alternative (by copying alternative 1). In this alternative, replace item 10, component T-B71 with

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PLM110

Item

Item cat.

Component

Quantity

Un

10

L

T-B72

0,3

kg

Change the quantity of component T-B74 in item 20 to 1.4 l. a)

Create alternative 2 Material:

T-F77##

Plant:

1000

(Default)

Usage:

1

(Default)

Valid from:

Today’s date

(Default) do not

→ Copy from (F7) Confirm warning: BOM is already available, is extended by Alternative 2 Alternative 1 dialog box Icon: “Select all” Icon: “Copy” Change the following two rows in item overview: Item no.

Item cat.

Component

Quantity

10

L

T-B72

0.3 kg

20

L

T-B74

1.41

Save BOM 4.

In another alternative (copy with reference material alternative 1) item 10, component T-B71 is replaced with:

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Lesson: Multiple BOMs and Alternatives

Item no.

Item cat.

Component

Quantity

Un

10

L

T-B73

0,3

kg

a)

Create alternative 3 Material:

T-F77##

Plant:

1000

(Default)

Usage:

1

(Default)

Valid from:

Today’s date

(Default) do not

→ Copy from (F7) Confirm warning message Dialog box Alternative 1 Icon: “Select all” Icon: “Copy” Change the following rows in item overview: Item no.

Item cat.

Component

Quantity

10

L

T-B73

0.3 kg

Save BOM 5.

Add the following data to the BOM headers of the alternatives:

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Alternative

Alt text

Lot size from

to

1

“Paint Color 1”

1

100

2

“Paint Color 2”

101

200

3

“Paint Color 3”

201

500

a)

Complete header data Change material BOM Material:

T-F77##

Plant:

1000

(Default)

Usage:

1

(Default)

Valid from:

Today’s date

(Default)

Select alternative 1 Tab page: Quantities/Long text (F6) Alt text. “Paint Color 1” Lot size from 1 to 100 Repeat these steps for alternatives 2 and 3. 6.

Display all alternatives of T-F77##. (BOM group Paint-##) Check your entries. Pay particular attention to the following: BOM group ____________ Internal BOM number ____________

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PLM110

Lesson: Multiple BOMs and Alternatives

Technical type ____________ a)

View all alternatives Material BOM → Display BOM group: BOM group:

Paint-##

Plant:

1000

(Default)

Usage:

1

(Default)

Valid from:

Today’s date

(Default)

Pushbutton:

Alternative overview

Select all alternatives Icon Header BOM number, 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). 7.

Change Alternative 1 using the product structure browser. Change the quantity of item 30 as required. Save the data and refresh the product structure in the browser. Display your BOM group PAINT-## to check the change here too. a)

Logistics → Cross-application components → Engin. change mgmt → Environment → Product structure: Enter T-F77## on initial screen and press . Open up the BOMs. BOM of alternative 1 is T-F77##, 1000, 1.01. Select Change in the context menu (right mouse button) . Enter Alternative 1 on the BOMs initial screen. Carry out the change. Save. Go back to the product structure in the browser, refresh the BOM and check the change. At this point you can also: - display the BOMs (using right mouse button) or- display the component quantities in the layout or- proceed through transaction of BOM group.

8.

Create a production order with the material T-F77## and test the effects of the different BOM alternatives with your lot sizes. Continued on next page

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The production order should be for plant 1000, order type PP01, for more than 125 pieces and for 2 months today. Since there is no working schedule, let the system create an operation. Without changing the production order, check which BOM alternative has been associated. Why was this used? Alternative ____ because ______________________________ Change the order quantity to 225 pieces and update the PP master data. Why this alternative? Alternative ____ because ______________________________ a)

Logistics → Production → Production control → Order → Create → with material: Material:

T-F77##

Production plant:

1000

Order type:

PP01

Total quantity:

125

Order finish date

2 months today



=> no working schedule found => generate process (ignore protocol.) →Tab page: master data => BOM Alt. 2 (because of quantity) b)

Now change quantity to 225 pieces. → Functions → Read PP master data → Read BOM only => BOM Alt. 3 (because of quantity) Exit order without saving.

9.

Maintain a multiple BOM for the different alternatives. Selection of alternatives according to date. Example:

Continued on next page

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Lesson: Multiple BOMs and Alternatives

Material

Plant

BOM usage

Valid from

BOMAlt

T-F77##

1000

1

01/01/xxxx

1

T-F77##

1000

1

01/07/xxxx

2

T-F77##

1000

1

01/12/xxxx

3

a)

Maintenance of multipleBOM. Selection of alternatives according to date. Logistics → Production → Master Data → Bills of Material → Bill of Material: or Logistics → Central functions → Engineering → Bill of Material → Material → ... Material BOM → BOM group → Create or change: (= CS05) (on the initial screen: Settings: Current settings Double-click on icon: Execute multiple BOM. Selection of alternatives according to date. Maintain data as described in exercise and Save.

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Lesson Summary You should now be able to: • Multiple BOMs and Alternatives

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Unit Summary

Unit Summary You should now be able to: • Variant BOMs • BOMs in Variant Configuration • Multiple BOMs and Alternatives

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Unit Summary

174

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Unit 5 Engineering Workbench (EWB) (Optional)

165

BOM maintenance and reporting are presented in a new maintenance environment, the engineering workbench. • •

Navigation in the engineering workbench Using the browser in the engineering workbench Course participants learn how the engineering workbench differs from the classic transactions for maintaining and managing master data, and what its benefits are.

Unit Overview Engineering Workbench Unit (optional) The optional unit Engineering Workbench unit introduces the engineering workbench and compares it to the more traditional transactions for processing bills of material and routings.

Unit Objectives After completing this unit, you will be able to: • •

EWB - Introduction BOM creation and change in the EWB

Unit Contents Lesson: EWB - Introduction ...................................................176 Lesson: BOM creation and change in the EWB ............................183

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Lesson: 166

PLM110

EWB - Introduction Lesson Duration: 30 Minutes

Lesson Overview EWB - Introduction

Lesson Objectives After completing this lesson, you will be able to: •

EWB - Introduction

Simultaneous Processing of Objects Point out that in comparison to the old (pre Release 4.0) transactions, the system no longer locks all SAP R/3 objects (BOMs, routings) but only their subobjects (item, operations and so on) Structure of the Engineering Workbench Show which objects the Engineering Workbench recognizes and that these have to be selected. Screen Layout Explain the 3 components of the Engineering Workbench screen layout: 1. Toolbar (available functions) 2. Cockpit (controls the engineering workbench) 3. Overview screen (objects relevant to the worklist and so on) Select Worklist Explain the functionality and task of the worklist. Note: Updated information is only available once the worklist has been saved. Demonstrate parts from the next lesson.

Business Example You require an optimum maintenance environment for changes you have to make over and over again. You want to create new master data and create links for this hierarchically.

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Lesson: EWB - Introduction

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 For several change states (change numbers) in one session To save intermediate statuses without quitting For hierarchical copying

Figure 73: Simultaneous Processing of Objects

Any number of items from any BOMs can be processed at the same time by different people. The same is true for 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 you can communicate 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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Figure 74: Structure of the Engineering Workbench

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 Item and subitem in the bill of material Task list header of a routing Operation and suboperation Production resource/tool, trigger point and inspection characteristic

An object can also take the form of an assignment between individual objects. Examples of assignment objects are a material-routing assignment, material-BOM assignment and a component-operation assignment.

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Lesson: EWB - Introduction

Figure 75: Screen Layout

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: •

• •

•

07-01-2005

Process Using, for entering the key date or change number for processing the objects in the worklist. The entry of a key 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 hierarchical relationships between objects on the overview screen. In this slide there is an input line for each material, BOM and item. The Overview Screen lists objects 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 status of a particular object type.

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Figure 76: Select Working Area

The working areas are created in Customizing of the Engineering Workbench. Using the Select working area pushbutton, you can specify a default working area or select a different working area. You can also get to the Working area details screen from the Select Working Area dialog box. Information about the predefined focus and the object types contained in the working area can be found on the detail screen.

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Lesson: EWB - Introduction

Facilitated Discussion This discussion is optional

Discussion Questions Use the following questions to engage the participants in the discussion.Feel free to use your own additional questions. As this is an optional chapter, a discussion is not required and not feasible for reasons of time.

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Lesson Summary You should now be able to: • EWB - Introduction

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Lesson: 171

Lesson: BOM creation and change in the EWB

BOM creation and change in the EWB Lesson Duration: 30 Minutes

Lesson Overview BOM creation and change in the EWB

Lesson Objectives After completing this lesson, you will be able to: •

BOM creation and change in the EWB

Selection Criteria Different Focuses - Bill of Material Different Working Area - Bill of Material Validity Demonstration of Engineering Workbench 30 minutes for both lessons. Show the navigation and functionality of the Engineering Workbench using the Work Area S_ALLES Please note that for changes where master record is changed, all changes that then follow must be carried out with a change number, when changing BOMs dependent on the history requirement defined in Customizing for instance. It is important to demonstrate the simultaneous processing of objects by several work schedulers or production schedulers. Work with a second session and explain the locking strategy. Show that the changes are automatically read in the second session. Point out the additional selection criteria and demonstrate that these are saved for each user. Switch the validity window to demonstrate how it works. Show the multi-level copying of a material and explain the setting options. Point out that these settings are only activated once.

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183

Unit 5: Engineering Workbench (EWB) - (Optional)

PLM110

Demonstrate and discuss the settings in the Extras menu for the selection criteria and work area. Show the differences in the functionality when working with the Engineering Workbench and the Engineering Workbench browser.

Business Example Simultaneous changes need to be made.

Figure 77: Selection Criteria

You use the selection range to restrict the time period for the data. Only data that lies entirely or partially in the validity period is copied into the worklist. The system automatically offers the tab page for the object on which the focus is placed. When entering the selection criteria you can switch the tab page. 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.

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Lesson: BOM creation and change in the EWB

Figure 78: Different Focuses - Bill of Material

These examples illustrate the expected results for different focuses. The prerequisite for these results is that the working area always contains the same object types. You can view the working area (with focus) and selection criteria by choosing Extras from the menu: • •

Working Area Selection Criteria

Figure 79: Different Working Areas - Bill of Material

These examples illustrate the expected results with different working areas.

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To achieve these results it is essential that the focus is always on the same focus object. You can view the working area (with focus) and selection criteria by choosing Extras from the menu: • •

Working Area Selection Criteria

In the example, the focus is set to the BOM header.

Figure 80: Validity

The validity window filters the objects displayed on the overview screen. In 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.

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PLM110

Lesson: BOM creation and change in the EWB

Facilitated Discussion This discussion is optional

Discussion Questions Use the following questions to engage the participants in the discussion.Feel free to use your own additional questions. As this is an optional chapter, a discussion is not necessary and may not be feasible for reasons of time. → PLM111

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Unit 5: Engineering Workbench (EWB) - (Optional)

PLM110

Lesson Summary You should now be able to: • BOM creation and change in the EWB

Related Information Recommended Follow-Up Courses: • • • • • • • • •

SCM200 Overview of Supply Chain Planning SCM310 Production Orders SCM320 Repetitive Manufacturing PLM111 Basic Data Part 2 PLM112 Customizing for Basic Data PLM130 Classification PLM140 Variant Configuration 1 - Modeling PLM143 Variant Configuration 2 - Integration PLM146 Variant Configuration 3 – Integration

Recommended Follow-up Activities • • • •

188

Go through the exercises and read the release notes. When doing so, use the IDES data or your own data. Read the online documentation. Read the IMG documentation.

© 2004 SAP AG. All rights reserved.

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PLM110

Unit Summary

Unit Summary You should now be able to: • EWB - Introduction • BOM creation and change in the EWB

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189

Course Summary

PLM110

Course Summary You should now be able to: • • • • •

190

Create, change, and delete material master records Manage material BOMs Use reporting for material BOMs Maintain variant BOMs and multiple BOMs Use the engineering workbench

© 2004 SAP AG. All rights reserved.

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Appendix 1 Technical Details and Tables: Material Master

Figure 81: Technical Details - Material Master

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191

Appendix 1: Technical Details and Tables: Material Master

PLM110

Figure 82: Table Structure of Material Master

The individual tables contain the following data:

192

MARA

General data

MAKT

Descriptions/short texts

MARM

Conversion factors

MVKE

Sales data per sales organization

MLAN

Sales data per country

MEAN

EAN (European Article Number) data

MBEW

Valuation data

MARC

Material data per plant

MLGN

Material data per WM warehouse

MLGT

Material data per WM storage type

MARD

Material data per storage location

MVER

Consumption data

MAPR

Forecast data (pointer)

© 2004 SAP AG. All rights reserved.

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Appendix 2 Technical Details and Tables: BOMs

Figure 83: Technical Details - BOM Management

BOM numbers are recorded internally - for the system’s use only. You do not need to define any settings.

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193

Appendix 2: Technical Details and Tables: BOMs

PLM110

Figure 84: Table Structure for BOM Management

The individual tables contain the following data:

194

MAST

Assignment of BOM to material

EQST

Assignment of BOM to equipment

DOST

Assignment of document structure to document

TPST

Assignment of BOM to functional location

KDST

Assignment of BOM to sales order

STST

Standard BOM assignment

STKO

BOM header data

STZU

Permanent STL data

STAS

BOM item selection

STPO

BOM item data

STPU

BOM sub-item data

© 2004 SAP AG. All rights reserved.

07-01-2005

Appendix 3 User exits and BAPIs

SAP R/3 Enhancements • •

User exits BAPI’s

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) Completes checks for customer-specific fields. Extends checks for existing fields. Can Change material data. (restricted) For example: enter basic material, material group and consecutive number → as material description

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Appendix 3: User exits and BAPIs

PLM110

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: –

External number changed by customer program. Example: program adds check digit to external material number.

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: All materials starting with MAT- M Result 2: All materials starting with MAT- M

BAPIs for the Material Master • •

196

BAPI_MATERIAL_GET_ALL BAPI_MATERIAL_SAVEREPLICA

© 2004 SAP AG. All rights reserved.

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Appendix 4 Menu paths

Menu Paths (1) •

Material Master Logistics → Materials Management → Material Master Logistics → Production → Master Data → Material Master Logistics → Central Functions → Engineering → Material

•

Displaying, changing, creating material Material

•

Extending material Material Master or Material → Other

•

Archiving a Material Material Master or Material → Other→ Archiving

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Appendix 4: Menu paths

PLM110

Menu Paths (2) •

Bill of material Logistics → Production → Master Data → Logistics → Central Functions → Engineering

•

Displaying, changing, creating material BOM Bill of Material → Material BOM

•

Assigning plant Bill of Material → Material BOM → Plant Assignment

•

BOM explosion, where-used list, BOM comparison Bill of Material → Reporting

•

Mass changes Bills of Material → Extras

Menu Paths (3) •

Engineering Workbench (SAP Easy Access) Logistics → Production → Master Data: Engineering Workbench → Logistics → Central Functions → Engineering: → Engineering Workbench

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Appendix 5 Data Transfer and ALE

Figure 85: Data Transfer Programs

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.

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Appendix 5: Data Transfer and ALE

PLM110

Figure 86: Enterprisewide View of Product Data

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

Advantages: • • •

Independent upgrades Distributed load on the system Heterogeneous infrastructure possible

New in Release 4.7 (Enterprise): Distribution of material masters possible with single-level value assignment. Benefits: Configured material is visible in all systems and/or clients.

200

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Appendix 5: Data Transfer and ALE

Figure 87: List Profile

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

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SAP =

Standard,

CS =

BOM,

LBL =

level by level

→ BOM level by level

MLV =

muli-level

→ Multilevel BOM

WSD =

where used

→ Where-used list

SMX =

summarized explosion

→ Summarized BOM

M=

Material

© 2004 SAP AG. All rights reserved.

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Appendix 5: Data Transfer and ALE

D=

Document

P01 =

initial profile

P02 =

Corresponds to formatting in R/2

PLM110

Standard Profiles • • • •

202

BOM level by level: SAPCSLBLMP01 Multilevel BOM: SAPCSMLVMP01 Summarized BOM: SAPCSSMXMP01 Material where-used list: SAPCSWSDMP01

© 2004 SAP AG. All rights reserved.

07-01-2005

Appendix 6 Product Designer and iPPE

• •

Product designer Integrated product and process engineering (iPPE)

Figure 88: Product Designer

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Appendix 6: Product Designer and iPPE

PLM110

Figure 89: Integrated Product and Process Engineering (iPPE)

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Feedback SAP AG has made every effort in the preparation of this course to ensure the accuracy and completeness of the materials. If you have any corrections or suggestions for improvement, please record them in the appropriate place in the course evaluation.

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